Aluminum Alloy Resin Composite Joining Strength
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Solution Overview
Problem
The existing technologies for joining aluminum alloys with resin compositions by injection molding face a decrease in joining strength over time due to storage delays, especially when amine molecules adsorbed on the surface of aluminum alloys degrade, leading to reduced moisture resistance and heat resistance.
Innovation Solution
A composite of aluminum alloy and resin with a surface configuration featuring threefold irregularities and a resin composition containing polyphenylene sulfide as the main component, along with a modified polyolefin resin and reinforcing fibers, which maintains high joining strength even after extended storage periods and under humid or high-temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If amine molecules are chemically adsorbed onto the surface of aluminum alloy to achieve strong joining strength, then joining strength is improved, but joining strength decreases over time due to degradation of adsorbed amine molecules during storage
Solution Approach 1:
The patent applies preliminary action by forming surface irregularities (roughness) on the aluminum alloy surface before joining. This rough surface treatment creates mechanical interlocking features that remain stable over time, eliminating the need for amine molecule adsorption which degrades during storage. The surface irregularities are created in advance and maintain their effectiveness throughout the storage period and after joining.
Solution Approach 2:
The patent extracts the problematic amine molecule adsorption step from the surface treatment process. By removing the chemical adsorption of amine molecules and replacing it with purely physical surface roughening, the patent eliminates the source of time-dependent degradation while maintaining strong joining performance.
2Strength
If surface treatment with amine molecules is performed to achieve high joining strength, then joining strength is improved, but storage time must be minimized to maintain performance
Solution Approach 1:
The surface irregularities are formed in advance as a preliminary action that remains effective indefinitely. This eliminates the time constraint associated with amine molecule adsorption, allowing parts to be stored for extended periods before joining without performance degradation.
3Strength
If amine molecules are adsorbed on aluminum alloy surface to achieve strong bonding, then joining strength is improved, but moisture resistance and heat resistance decrease over time
Solution Approach 1:
The patent removes the amine molecule adsorption step that causes susceptibility to moisture and heat degradation. By replacing chemical adsorption with physical surface roughening, the joining interface becomes resistant to environmental factors while maintaining strong bonding.
Solution Approach 2:
The patent converts the potential harm of chemical instability into benefit by using purely physical surface roughening. The surface irregularities provide mechanical interlocking that is inherently resistant to moisture and heat, transforming the problem of chemical degradation into a solution based on physical stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures that the joining strength of the composite remains high and resistant to moisture and heat over an extended period, eliminating the need for immediate joining after surface treatment and enhancing the composite's durability for applications in moving machines and outdoor environments.
Implementation Method 1
Water soluble amine compounds should be chemically adsorbed to the surface layer
Implementation Method 2
forming fine surface irregularities suitable for each of various metal materials
Implementation Method 3
a molten engineering resin is injected onto a metal part preliminarily inserted into a metallic mold for injection molding thereby forming a resin portion and at the same time the molded article and the metal part are joined
Data Source
AI summary
An aluminum alloy material is prepared that has surface configuration of threefold irregularities such that rough surface having surface roughness of 10 to 100 μm period is observed with an electron microscope in a magnification of 1000 times, surface having fine irregularities of 1 to 5 μm period based on crystal grain boundary is observed with an electron microscope in a magnification of 10000 times and surface having ultrafine irregularities of 30 to 100 nm period is confirmed with an electron microscope in a magnification of 100000 times. Aluminum alloy material is integrally joined with a resin composition consisting of a total resin part containing polyphenylene sulfide resin by 70 mass % or more of the resin part, modified polyolefin resin by 30 mass % or less of the resin part and a resin of third component having ability for promoting compatibility of polyphenylene sulfide resin and modified polyolefin resin.