Methods and processes for producing polymer-metal hybrid components via COM bonds

Abstract

A method for producing polymer-metal hybrid components, wherein at least one of hot pressing, rolling, and injection molding methods is used to create chemical bonding conditions at the polymer-metal interface, thereby achieving bonding at the interface via C-O-M bonds. When the thermal cycling and compressive stresses described herein are combined at the polymer-metal interface, strong C-O-M bonds are formed at the interface, and the metal and polymer are strongly bonded together through the reaction of carbonyl groups (C=O) in the polymer with the metal surface. For polymers lacking sufficient carbonyl groups, new functional groups can be generated in situ at the polymer-metal interface by introducing distributed cavitation for the formation of three-dimensional distributed C-O-M bonds at the interface.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Patent Application No. 17 / 323,647, filed May 18, 2021, and the benefit of U.S. Provisional Application No. 63 / 027,456, filed May 20, 2020. The entire disclosure of the above applications is incorporated herein by reference. Technical Field

[0003] This disclosure relates to achieving direct polymer / metal bonding by using hot pressing, rolling, or injection molding to create bond-forming conditions to form COM bonds at the bonding interface.

[0004] Background Art and Invention Content

[0005] This section provides background information relating to this disclosure, which is not necessarily prior art. This section provides a general overview of this disclosure and is not a complete disclosure of the entire scope or all features of this disclosure.

[0006] High-quality polymer-metal hybrid structures urgently require weight minimization for airframes, automotive bodies, and marine structures. Previously, polymer-metal bonding relied on mechanical interlocking, adhesives, or a combination of both. However, mechanical interlocking alone cannot guarantee a hermetic seal and often leads to interfacial contamination. While adhesive bonding can achieve a hermetic seal, it requires a long curing time.

[0007] However, this teaching provides a method for producing polymer-metal hybrid components bonded at the interface via COM bonds. The hybrid structures produced by the teachings of this invention are characterized by a combination of low cost and high performance.

[0008] Further applications will become apparent from the description provided herein. The descriptions and specific embodiments in this invention are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0009] The accompanying drawings described herein are for illustrative purposes only, and not for all possible implementations, and are not intended to limit the scope of this disclosure.

[0010] Figure 1 This illustrates the schematic principle of how COM bonds are formed between carbonyl groups in a polymer and atoms in a metal.

[0011] Figure 2 This illustrates the schematic principle of forming three-dimensional (3D) COM bonds between polymers and metals by means of distributed cavitation.

[0012] Figure 3 The hot pressing process for producing two-layer polymer-metal hybrid components bonded by COM bonds is shown.

[0013] Figure 4 The hot pressing process for producing multilayer polymer-metal hybrid components bonded by COM bonds is shown.

[0014] Figure 5 The hot pressing process for producing two-layer polymer-metal hybrid components bonded by 3D COM bonds is shown.

[0015] Figure 6 The hot pressing process for producing multilayer polymer-metal hybrid components bonded by 3D COM bonds is shown.

[0016] Figure 7 The hot rolling process for producing two-layer polymer-metal hybrid components bonded by COM bonds is shown.

[0017] Figure 8 The hot rolling process for producing multilayer polymer-metal hybrid components bonded by COM bonds is shown.

[0018] Figure 9 The hot rolling process for producing two-layer polymer-metal hybrid components bonded by 3D COM bonds is shown.

[0019] Figure 10 The hot rolling process for producing multilayer polymer-metal hybrid components bonded by 3D COM bonds is shown.

[0020] Figure 11 The hot rolling process for producing polymer-metal hybrid components bonded via COM bonds using multiple rolling mills is illustrated.

[0021] Figure 12 The hot rolling process for producing polymer-metal hybrid components bonded via COM bonds is shown with the aid of an additional preheating system.

[0022] Figure 13 The hot rolling process for producing polymer-metal hybrid components bonded via COM bonds is illustrated by means of an additional preheating system and an additional cooling system.

[0023] Figure 14 An injection molding process for producing polymer-metal hybrid components bonded via COM bonds is shown.

[0024] Figure 15An injection molding process for producing two-layer polymer-metal hybrid components bonded by 3D COM bonds is shown.

[0025] Figure 16 This illustrates welding a porous metal or compressed distributed metal wire to a metal plate.

[0026] Figure 17 A scratch tool with one or more scribe tips is shown.

[0027] Figure 18 The diagram illustrates the use of rotating and lateral scraping tools to create deep grooves on a metal surface.

[0028] Figure 19 This demonstrates the XPS detection results showing the transformation of carbonyl groups (C=O) into COM bonds at the bonding interface of polymer-metal hybrid components.

[0029] Throughout the several views in the accompanying drawings, corresponding reference numerals denote the corresponding parts. Detailed Implementation

[0030] The embodiments will now be described more fully with reference to the accompanying drawings.

[0031] The provision of embodiments makes this disclosure thorough and will fully communicate the scope to those skilled in the art. Numerous specific details, such as embodiments of specific components, apparatus, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that these specific details are not required, that embodiments may be embodied in many different forms, and none of these should be construed as limiting the scope of this disclosure. In some embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0032] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are open-ended and therefore specifically refer to the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein should not be construed as necessarily requiring them to be performed in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed.

[0033] When an element or layer is referred to as “on another element or layer,” “engaged to,” “connected to,” or “linked to another element or layer,” the element or layer may be directly on, engaged to, connected to, or linked to another element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly engaged to,” “directly connected to,” or “directly linked to,” there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the relevant listed items.

[0034] Although the terms first, second, third, etc., are used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another region, layer, or section. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence. Therefore, without departing from the teachings of the example embodiments, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section.

[0035] For ease of description, spatial relative terms (e.g., "inside," "outside," "below," "below," "down," "above," and "above") may be used herein to describe the relationship between one element or feature shown in the figures and another element or feature. In addition to the orientations depicted in the figures, spatial relative terms may be intended to cover different orientations of the device in use or operation. For example, if the device in the figures is flipped, an element described as "below" or "below" of other elements or features would be oriented as "above" of other elements or features. Thus, the embodiment term "below" can cover both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein are interpreted accordingly.

[0036] As used in this article, “metal” includes pure metals, alloys, and metal-based composites.

[0037] As used in this article, “polymer” includes polymers and polymer composites.

[0038] Recent scientific breakthroughs based on the principles of this teaching have provided evidence for the formation of chemical bonds "COM" (where "M" represents an element in the metal to be bonded) at the polymer-metal interface under certain conditions. For example... Figure 1 As shown, metal 12 and polymer 14 can be bonded along bonding interface 16 via chemical bonds “COM”. It should be understood that in order to form COM bonds, the polymer surface should contain sufficient carbonyl groups (C=O), because when these C=O groups encounter M atoms on the metal surface under bonding conditions, they will transform into COM groups.

[0039] For many polymers that do not contain sufficient C=O groups, additional functional groups can be added between polymer 14 and metal 12. In some embodiments, additional functional groups can be added by adding a functionalized polymer between polymer 14 and metal 12. Under applied temperature and compressive pressure, the functionalized polymer can bond to metal 12 by forming COM bonds at their interface, while also bonding to polymer 14. In some embodiments, the functionalized polymer includes polymers containing C=O groups. In some embodiments, such as... Figure 2 As shown, distributed cavitation 18 can be added between polymer 14 and metal 12, thereby forming new functional groups in situ through the reaction of the surface 20 of polymer 14 with air 22 trapped within the distributed cavitation 18. The intermediate state of the new functional groups on the polymer surface will be transferred to COM bonds. These distributed cavitation 18 can include three-dimensional shapes, and therefore the resulting bonds are referred to herein as three-dimensional (3D) chemical bonds or 3DC-OM bonds. In some embodiments, polymer 14 containing C=O groups can be added at the polymer-metal interface 16.

[0040] According to some embodiments of this teaching, a method for producing polymer-metal hybrid components bonded at the interface via COM bonds includes the following steps:

[0041] Step 1: Optionally overlap at least one metal with a polymer containing a carbonyl group (C=O);

[0042] Step 2: Apply compression pressure to the interface between the metal and the polymer by means of the compression pressure application system 110 that applies compression force F, the applied compression pressure being higher than the flow resistance of the softened polymer at the interface;

[0043] Step 3: Maintain the temperature at the bonding interface above the glass transition temperature of the polymer and maintain the compressive pressure to create close atomic contact between the metal and the polymer, thereby generating substantial COM chemical bonds along the bonding interface, which are formed by carbonyl groups (C=O) within the polymer.

[0044] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds;

[0045] Based on the principles of this teaching, in some embodiments, a method for producing polymer-metal hybrid components bonded at the interface via COM bonds includes the following steps:

[0046] Step 1: Add distributed cavitation or a polymer containing functional groups to the interface between the metal and the polymer to be bonded.

[0047] Step 2: Apply compressive pressure to the interface between the metal and the polymer, the applied compressive pressure being higher than the flow resistance of the softened polymer at the interface;

[0048] Step 3: Maintain the polymer-metal interface temperature above the polymer's glass transition temperature, and maintain the compressive pressure at the polymer-metal interface above the flow resistance of the softened polymer, so as to create close atomic contact between the metal and the polymer, thereby generating COM chemical bonds along the bonding interface.

[0049] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds.

[0050] In some embodiments, the hot-pressing method can be used to produce polymer-metal hybrid components comprising a layer of metal 12 and a layer of polymer 14 bonded by COM bonds 16. Figure 3 ).

[0051] In some embodiments, a hot-pressing method can be used to produce polymer-metal hybrid components comprising layers of a plurality of metals 12, 12' bonded by COM bonds 16 and a polymer 14 ( Figure 4 It should be understood that the layers of metal 12 and 12' can be similar or dissimilar metals.

[0052] In some embodiments, hot pressing can be used to produce polymer-metal hybrid components comprising a metal and a polymer bonded by 3D COM bonds. Figure 5A layer of distributed cavitation 18 (such as porous metal, metal mesh, and enhanced 3D metal surface texture) or a functionalized polymer can be added at the interface 16 between the surfaces of metal 12 and polymer 14 to generate COM bonds.

[0053] In some embodiments, hot pressing can be used to produce polymer-metal hybrid components comprising layers of multiple metals bonded by COM bonds and a polymer. Figure 6 Distributed cavitation 18 (such as porous metal, metal mesh, and enhanced 3D metal surface texture) or functionalized polymers can be added at the interface 16 of the surfaces of metal 12 and polymer 14 to generate COM bonds.

[0054] In some embodiments, the polymer 14 and metal 12 to be bonded by COM bonds have complex shapes.

[0055] In some embodiments, before the metal 12 overlaps with the polymer 14, the metal 12 is heated in a furnace to a temperature higher than the glass transition temperature of the polymer 14 but lower than the metal melting temperature of the metal 12.

[0056] In some embodiments, after the metal 12 overlaps with the polymer 14, the metal 12 is heated by an additional heating system 120 to a temperature above the glass transition temperature of the polymer 14 and below the flash ignition temperature of the polymer 14 and below the metal melting temperature of the metal 12.

[0057] In some embodiments, after applying compressive pressure, the metal 12 is heated by an additional heating system 120 to a temperature higher than the glass transition temperature of the polymer 14, but lower than the flashover temperature of the polymer 14 and lower than the metal melting temperature of the metal 12.

[0058] In some implementations, heating and compression pressure are achieved or applied via an integrated system. The metal is heated to a temperature higher than the polymer's glass transition temperature but lower than the polymer's flash point and lower than the metal's melting temperature.

[0059] In some embodiments, distributed cavitation 18 is formed along at least a portion of the interface 16 between the metal 12 and the polymer 14.

[0060] In some implementations, the distributed cavitation 18 is generated by capturing porous structures on the surface of the metal 12.

[0061] In some implementations, the distributed cavitation 18 is generated by welding a porous structure layer onto the surface of the metal 12.

[0062] In some implementations, the distributed cavitation 18 is generated by welding a metal mesh to the surface of the metal 12.

[0063] In some implementations, distributed cavitation 18 is achieved in situ by creating three-dimensional surface features, grooves, or protrusions on the surface of metal 12.

[0064] In some embodiments, the three-dimensional surface features, grooves, or protrusions on the metal surface can be generated using suitable mechanical engraving, energy beams, chemical agents, and / or discharge systems. In some embodiments, the depth or height of the distributed cavitation 18 can be greater than 10 micrometers.

[0065] According to some embodiments of this teaching, a hot rolling process for producing polymer-metal hybrid components bonded at the interface via COM bonds includes the following steps:

[0066] Step 1: Optionally, overlap at least one metal with a polymer containing a carbonyl group (C=O);

[0067] Step 2: Roll the overlapping metal and polymer after or during a time when the interface temperature is higher than the glass transition temperature of the polymer and lower than the flash point temperature of the polymer and the melting point of the metal.

[0068] Step 3: A compressive pressure higher than the flow resistance of the softened polymer is generated at the interface to create a close atomic contact between the metal and the polymer, thereby forming substantial COM chemical bonds along the bonding interface. These COM chemical bonds are formed by carbonyl groups (C=O) within the polymer.

[0069] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds.

[0070] According to some embodiments of this teaching, a hot rolling process for producing polymer-metal hybrid components bonded at the interface via COM bonds includes the following steps:

[0071] Step 1: Form distributed cavitation at the interface between the metal and polymer to be bonded or add a polymer containing functional groups.

[0072] Step 2: Roll the overlapping metal and polymer after or during a time when the interface temperature is higher than the glass transition temperature of the polymer and lower than the flash point temperature of the polymer and the melting point of the metal.

[0073] Step 3: A compressive pressure higher than the flow resistance of the softened polymer is generated at the interface to create a close atomic contact between the metal and the polymer, thereby forming substantial COM chemical bonds along the bonding interface; and

[0074] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds.

[0075] In some embodiments, hot rolling can be used to produce polymer-metal hybrid components comprising layers of metal 12 and polymer 14 bonded via COM bonds through a rolling system 130. Figure 7 ).

[0076] In some embodiments, hot rolling can be used to produce polymer-metal hybrid components comprising layers of multiple metals 12, 12' bonded by COM bonds and a polymer 14 ( Figure 8 ).

[0077] In some embodiments, hot rolling can be used to produce polymer-metal hybrid components comprising a metal layer and a polymer layer bonded by COM bonds. Figure 9 Layers of distributed cavitation (such as porous metals, metal meshes, and enhanced 3D metal surface textures) or functionalized polymers can be added at the interface between metal and polymer surfaces to generate COM bonds.

[0078] In some embodiments, hot pressing can be used to produce polymer-metal hybrid components comprising multiple metal layers bonded by 3D COM bonds and a polymer. Figure 10 Distributed cavitation 18 (such as porous metal, metal mesh, and enhanced 3D metal surface texture) can be added at the interface between the surfaces of metal 12 and polymer 14 to generate 3D COM bonds.

[0079] In some embodiments, the rolling system 130 includes a plurality of rolling mills 132. Figure 11 ).

[0080] In some implementations, an additional heating system 120 is applied during the rolling process. Figure 12 The heating system 120 may include a heating gun, a flame, an induction heater, a convection heater, a radiant heater, a furnace, or other heating systems.

[0081] In some implementations, an additional heating system 120 and an additional cooling system 140 are applied during the rolling process. Figure 13 The cooling system 140 may include a cold air system, a cold water system, or other cooling systems.

[0082] In some implementations, the metal is heated in a furnace to a temperature above the glass transition temperature of the polymer but below the melting temperature of the metal before it overlaps with the polymer.

[0083] In some embodiments, prior to rolling, the metal is heated by an additional heating system 120 to a temperature above the glass transition temperature of the polymer, but below the flash point of the polymer and below the melting temperature of the metal.

[0084] In some implementations, heating and compression pressure are achieved together via a rolling system. The metal is heated to a temperature higher than the polymer's glass transition temperature but lower than the polymer's flash point and lower than the metal's melting temperature.

[0085] In some implementations, distributed cavitation is formed along at least a portion of the interface 16 between the metal and the polymer.

[0086] In some implementations, the distributed cavitation 18 is generated by capturing porous structures on a metal surface.

[0087] In some implementations, the distributed cavitation 18 is generated by welding a porous structure layer onto a metal surface.

[0088] In some implementations, the distributed cavitation 18 is generated by welding a metal mesh to a metal surface.

[0089] In some embodiments, the distributed cavitation 18 is achieved in situ by creating three-dimensional surface features, grooves, or protrusions on the surface of the metal. In some embodiments, the three-dimensional surface features, grooves, or protrusions on the metal surface can be created using suitable mechanical engraving, energy beams, chemical agents, and / or discharge systems. In some embodiments, the depth or height of the cavitation can be greater than 10 micrometers.

[0090] According to some implementations currently taught, an injection molding method for producing polymer-metal hybrid components bonded at the interface via COM bonds includes the following steps ( Figure 14 ).

[0091] Step 1: Place at least one metal component inside the mold;

[0092] Step 2: Inject the liquid polymer containing carbonyl groups (C=O) into a mold containing at least one metal component.

[0093] Step 3: Maintain the polymer-metal interface temperature above the polymer's glass transition temperature and maintain the compressive pressure at the polymer-metal interface above the flow resistance of the softened polymer to create close atomic contact between the metal and the polymer, thereby generating substantial COM chemical bonds along the bonding interface, which are formed by carbonyl groups (C=O) within the polymer.

[0094] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds.

[0095] like Figure 14 As shown, injection molding can be achieved using an injection molding system 150, which has: a mold having a closed volume 152 for receiving metal 12; a nozzle 154 for receiving liquid polymer 14; and a drive system 156 for injecting polymer 14, the drive system being such as a piston 158.

[0096] Based on the principles currently taught, in some implementations, an injection molding method for producing polymer-metal hybrid components bonded at the interface via three-dimensional distributed COM bonds includes the following steps ( Figure 15 ):

[0097] Step 1: Place at least one metal component in the mold, the metal component having distributed cavitation or a surface of a functionalized polymer;

[0098] Step 2: Inject the liquid polymer into a mold containing at least one metal component, the metal component having at least one distributed cavitation or a surface of a polymer containing functional groups;

[0099] Step 3: Maintain the polymer-metal interface temperature above the polymer's glass transition temperature and maintain the compressive pressure at the polymer-metal interface above the flow resistance of the softened polymer to create close atomic contact between the metal and the polymer, thereby generating substantial COM chemical bonds along the bonding interface. These COM chemical bonds are formed by new functional groups generated from the reaction of the polymer surface with gases trapped in the distributed cavities.

[0100] Step 4: Lower the interface temperature below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid severe breakage of COM chemical bonds.

[0101] In some embodiments, before placing the metal in the mold, the metal is heated in a furnace to a temperature above the glass transition temperature of the polymer, but below the flash point of the polymer and below the melting temperature of the metal.

[0102] In some implementations, after the metal is placed in the mold, the metal is heated by an additional heating system to a temperature higher than the glass transition temperature of the polymer, but lower than the flash point of the polymer and lower than the melting temperature of the metal.

[0103] In some embodiments, the metal is directly heated by a hot liquid polymer to a temperature above the polymer's glass transition temperature but below the polymer's flash point and below the metal's melting temperature.

[0104] In some implementations, the metal placed inside the mold can be a metal part with a complex shape.

[0105] In some implementations, the metal placed inside the mold can be a sheet of metal.

[0106] In some implementations, distributed cavitation is formed on the metal surface before the metal is placed in the mold.

[0107] In some implementations, distributed cavitation is formed on the metal surface after the metal is placed in the mold.

[0108] In some implementations, distributed cavitation is formed on at least a portion of the interface between the metal and the polymer.

[0109] In some implementations, the distributed cavitation 18 is generated by capturing porous structures on a metal surface.

[0110] In some implementations, the distributed cavitation 18 is created by welding a porous structure layer to a metal surface.

[0111] In some implementations, the distributed cavitation 18 is generated by welding a metal mesh to a metal surface.

[0112] In some implementations, distributed cavitation 18 is achieved by generating three-dimensional surface features, grooves, or protrusions in situ on the surface of the metal.

[0113] In some embodiments, three-dimensional surface features, grooves, or protrusions on the metal surface can be created using suitable mechanical engraving, energy beams, chemical agents, and / or discharge systems. In some embodiments, the depth or height of the cavitation can be greater than 10 micrometers.

[0114] In some embodiments, the distributed cavitation 18 on the metal surface is created by welding a porous structure layer (e.g., a metal mesh) to the metal surface using resistance welding. Figure 16 ).

[0115] In some embodiments, a scraping tool 160 with one or more scribing tips 162 is provided to create distributed cavitation by scraping out deep grooves, which can trap sufficient air at the polymer-metal interface. Figure 17 The scraping tool is driven to rotate and travel along the surface of the aluminum sheet. The cutting depth of the scribing tip is 0.2-0.5 mm. This creates dispersed, distributed deep grooves on the metal surface. Figure 18 ).

[0116] In some embodiments, XPS detection is used to characterize the surface of the as-received polymer and the polymer-metal bonding interface of the polymer-metal hybrid structure. This XPS detection reveals the transition from carbonyl (C=O) to COM bonds that occurs during the fabrication of the polymer-metal hybrid structure described in this teaching.

[0117] This instruction is particularly applicable to all thermoplastic polymers or polymer composites.

[0118] The manufacturing process is cost-effective and high-speed.

[0119] Suitable for mass production.

[0120] No adhesive is required.

[0121] Suitable for automation and robotics applications.

[0122] Possible changes include additional metal surface finishing methods, and new temperature and compression application mechanisms could be developed in the future.

[0123] In some embodiments, a method for producing a polymer-metal hybrid component is provided, wherein the polymer-metal hybrid component is bonded at a bonding interface via COM bonds, where M represents an element in the metal to be bonded. The method includes:

[0124] It provides metals and polymers containing carbonyl groups (C=O);

[0125] A compressive pressure is applied to the interface between the metal and the polymer, and the applied compressive pressure is higher than the flow resistance of the softened polymer at the interface.

[0126] Heating the bonding interface to a temperature higher than the polymer's glass transition temperature while maintaining compressive pressure at the interface creates close atomic contact between the metal and polymer, thereby generating substantial COM chemical bonds along the bonding interface; and

[0127] The interface temperature is lowered to below the polymer's melting temperature before 5% of the polymer is pyrolyzed to avoid the breaking of COM chemical bonds.

[0128] In some embodiments, the method further includes forming distributed cavitation on at least one surface of the metal prior to the step of applying compressive pressure to the bonding interface. In some embodiments, the step of forming distributed cavitation includes trapping a porous structure on the metal. In some embodiments, the step of forming distributed cavitation includes forming three-dimensional surface features, grooves, or protrusions on the surface of the metal. In some embodiments, COM chemical bonds are formed by new functional groups resulting from the reaction of the polymer with the gas trapped within the distributed cavities. In some embodiments, the step of providing the metal and polymer includes overlapping the metal and polymer.

[0129] In some embodiments, the method further includes rolling the overlapping metal and polymer during a step of maintaining the interface temperature above the glass transition temperature of the polymer.

[0130] In some embodiments, the step of providing the metal and polymer includes overlapping the metal and polymer. In some embodiments, the method further includes rolling the overlapping metal and polymer while maintaining the interface temperature above the glass transition temperature of the polymer. In some embodiments, a step of heating the bonding interface to the interface temperature is performed prior to the rolling step. In some embodiments, the step of heating the bonding interface to the interface temperature is performed simultaneously with the rolling step.

[0131] In some embodiments, the steps of providing the metal and polymer include: positioning the metal in a mold and injecting the polymer into the mold. In some embodiments, the step of heating the bonding interface is performed by heating the polymer and injecting the polymer into the mold.

[0132] In some embodiments, the metal includes distributed cavitation along at least a portion of its surface. In some embodiments, the COM chemical bonds are formed by the reaction of the polymer with gases trapped within the distributed cavitation, resulting in the formation of new functional groups. In some embodiments, the COM chemical bonds are formed by carbonyl groups (C=O) within the polymer. In some embodiments, the COM chemical bonds are distributed three-dimensionally along the bonding interface.

[0133] In some implementations, the steps of applying compressive pressure and heating the interface to the interface temperature are carried out using a discrete system.

[0134] In some implementations, the steps of applying compressive pressure and heating the interface to the interface temperature are carried out using a unitary system.

[0135] In some embodiments, the step of heating the bonding interface to an interface temperature above the glass transition temperature of the polymer includes heating the bonding interface to an interface temperature above the glass transition temperature of the polymer and below the flash point of the polymer and below the melting point of the metal.

[0136] Summarize

[0137] The current teachings describe a method for producing polymer-metal hybrid components that creates chemical bonding conditions at the polymer-metal interface using at least one of hot pressing, rolling, and injection molding methods, for bonding at the interface via COM bonds. When the thermal cycling and compressive stresses specified in the teachings are combined at the polymer-metal interface, strong COM bonds form at the interface, and the metal and polymer are strongly bonded together through the reaction of carbonyl groups (C=O) in the polymer with the metal surface. For polymers lacking sufficient carbonyl groups, new functional groups can be generated in situ at the polymer-metal interface by introducing distributed cavitation for the formation of 3D distributed COM bonds at the interface.

[0138] For illustrative and descriptive purposes, the above description of the embodiments has been provided. These embodiments are not exhaustive or limiting of this disclosure. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and may be used in selected embodiments even if not specifically shown or described. Similarly, variations are possible in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A method for producing a polymer-metal hybrid component, wherein the polymer-metal hybrid component is bonded at a polymer-metal interface via a COM bond, wherein M represents an element in the metal to be bonded, the method comprising: Provide the metal and the polymer; A compressive pressure is applied to the polymer-metal interface, the applied compressive pressure being higher than the flow resistance of the softened polymer at the polymer-metal interface; The polymer-metal interface is heated to an interface temperature above the glass transition temperature of the polymer and compressive pressure is maintained at the polymer-metal interface to create close atomic contact between the metal and the polymer, thereby generating substantial COM chemical bonds along the polymer-metal interface. as well as The interface temperature is lowered to below the melting temperature of the polymer before 5% of the polymer is pyrolyzed to avoid the breaking of the COM chemical bonds; The method further includes forming distributed cavitation on at least one surface of the metal prior to the step of applying compressive pressure to the polymer-metal interface; wherein additional COM chemical bonds are formed by new functional groups generated by the reaction of the polymer with the gas trapped within the distributed cavitation.

2. The method according to claim 1, wherein, The step of forming the distributed cavitation includes capturing a porous structure on the metal.

3. The method according to claim 1, wherein, The step of forming the distributed cavitation includes forming a three-dimensional surface feature on the surface of the metal.

4. The method according to claim 3, wherein, The three-dimensional surface features are grooves or protrusions.

5. The method according to claim 1, wherein, The step of forming the distributed cavitation includes scraping grooves into the surface of the metal.

6. The method according to claim 1, wherein, The step of providing the metal and the polymer includes overlapping the metal with the polymer.

7. The method according to claim 6, further comprising: During the step of maintaining the interface temperature above the glass transition temperature of the polymer, the overlapping metal and polymer are rolled.

8. The method according to claim 7, wherein, Prior to the rolling step, a step is performed to heat the polymer-metal interface to the interface temperature.

9. The method according to claim 7, wherein, The step of heating the polymer-metal interface to the interface temperature is performed simultaneously with the rolling step.

10. The method according to claim 1, wherein, The steps of providing the metal and the polymer include positioning the metal in a mold and injecting the polymer into the mold.

11. The method according to claim 10, wherein, The step of heating the polymer-metal interface is performed by heating the polymer and injecting the polymer into the mold.

12. The method according to claim 10, wherein, The metal includes distributed cavitation along at least a portion of its surface.

13. The method according to claim 12, wherein, The COM chemical bonds are formed by new functional groups generated from the reaction of the polymer with air trapped within the distributed cavities.

14. The method according to claim 1, wherein, The polymer contains functional groups and is applied to the surface of the metal prior to the step of applying compressive pressure to the polymer-metal interface.

15. The method according to claim 1, wherein, The COM chemical bond is formed by the carbonyl group C=O within the polymer.

16. The method according to claim 1, wherein, The COM chemical bonds are distributed three-dimensionally along the polymer-metal interface.

17. The method according to claim 1, wherein, The steps of applying compressive pressure and heating the polymer-metal interface to the interface temperature are implemented using a separate system.

18. The method according to claim 1, wherein, The steps of applying compressive pressure and heating the polymer-metal interface to the interface temperature are implemented using an integrated system.

19. The method according to claim 1, wherein, The step of heating the polymer-metal interface to an interface temperature higher than the glass transition temperature of the polymer includes: heating the polymer-metal interface to the interface temperature, which is higher than the glass transition temperature of the polymer, lower than the flashover temperature of the polymer, and lower than the melting temperature of the metal.

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