Composite Member Bonding via Controlled Surface Asperities
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Solution Overview
Problem
Existing methods for producing composite members do not adequately address the influence of the bonding surface form on bonding strength between metal and resin components, leading to a need for improved techniques to achieve excellent bonding strength.
Innovation Solution
A method involving surface treatment to form micro-order or nano-order asperities on the base material, followed by direct injection molding with a resin, which enhances bonding strength through a strong anchor effect by controlling the arithmetic average and root-mean-square inclinations of the surface asperities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bonding surface of the metal member is roughened by physical or chemical treatment, then the bonding strength between the metal member and the resin member is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention changes the surface roughness parameters by controlling the arithmetic average inclination (RΔa) to be 0.17 to 0.50 and root-mean-square inclination (RΔq) to be 0.27 to 0.60. This specific parameter control creates optimal asperities that enhance bonding strength while avoiding excessive manufacturing complexity
Solution Approach 2:
The invention replaces complex multi-step surface treatment processes (chemical etching, multiple mechanical treatments) with a single blast machining process that directly creates the desired asperity structure, simplifying the manufacturing system
2Strength
If laser beam machining is used to roughen the bonding surface, then bonding strength is improved, but the production time and cost increase
Solution Approach 1:
The invention replaces laser beam machining with blast machining, which is a more efficient mechanical process that creates the required asperity structure faster and at lower cost, thereby improving productivity while maintaining bonding strength
Solution Approach 2:
By controlling the blast machining parameters (abrasive particle size, blast pressure, treatment time) to achieve specific RΔa and RΔq values, the process creates optimal asperities with reduced production time compared to laser machining
3Strength
If milli-order asperities are formed on the surface, then the surface structure is modified, but the anchor effect is insufficient compared to micro-order or nano-order asperities
Solution Approach 1:
The invention precisely controls the asperity dimensions by targeting specific ranges for arithmetic average inclination (0.17 to 0.50) and root-mean-square inclination (0.27 to 0.60), which corresponds to micro-order or nano-order asperities that provide superior anchor effect
Solution Approach 2:
The invention uses blast machining with specifically sized abrasive particles (30 to 300 μm) to create the desired micro-order or nano-order asperities, replacing surface treatments that produce only milli-order asperities with insufficient anchor effect
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
This method produces composite members with significantly improved bonding strength by creating micro-order or nano-order asperities on the base material surface, allowing for quantitative control of the surface structure and reducing costs and time, while being applicable to various materials like metal, glass, and ceramic.
Implementation Method 1
a surface treatment step of forming micro-order or nano-order asperities on a surface of the base material
Implementation Method 2
The surface treatment step may be a step for forming the asperities using blast machining
Implementation Method 3
The resin member penetrates the micro-order or nano-order asperities, and is cured in the asperities, and thereby a strong anchor effect occurs
Data Source
AI summary
Provided is a method for producing a composite member formed by bonding a base material and a resin member. The method includes: a surface treatment step of forming micro-order or nano-order asperities on a surface of a base material; and a bonding step of directly bonding, by injection molding, a resin member to the surface of the base material that has the asperities formed in the surface treatment step. In addition, the composite member includes: a base material having micro-order or nano-order asperities on a surface thereof; and a resin member that is in direct contact with the surface of the base material.