Composite Laminate with In Situ Polymerizable Phenoxy Resin
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Solution Overview
Problem
Existing surface treatment methods for aluminum materials face challenges in maintaining sufficient bonding strength over time, particularly during storage and transportation, and often require complex and costly waste liquid treatment processes.
Innovation Solution
A composite laminate is developed with a metal base material coated with one or more layers of a resin composition containing an in situ polymerizable phenoxy resin, optionally combined with thermosetting resins and a functional group adherent layer, enhancing adhesiveness through surface treatments like etching and boehmite treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical surface treatment methods (etching, anodizing) are used to form porous films on aluminum material, then bonding strength with resin is improved, but the treatment process becomes complex and requires waste liquid treatment
Solution Approach 1:
The invention extracts and eliminates the complex waste liquid treatment process from the surface treatment system. By using plasma treatment instead of chemical etching and anodizing, the process generates no liquid waste requiring treatment, thus removing this complex step while maintaining bonding strength through plasma-induced surface activation and roughening.
Solution Approach 2:
The invention replaces chemical treatment methods (etching solutions, anodizing baths) with a physical plasma treatment method. This substitution eliminates the need for chemical waste liquid treatment while achieving similar or superior surface activation and bonding performance through plasma-induced surface modifications.
2Strength
If physical surface treatment (shotblasting) is used on aluminum material, then surface roughness is improved for bonding, but productivity decreases and it is unsuitable for thin or complicated shaped articles
Solution Approach 1:
The invention replaces mechanical shotblasting with plasma treatment. Plasma can uniformly treat complex and thin-shaped articles without the limitations of mechanical access, maintaining surface activation and roughening effects while significantly improving productivity and applicability to various geometries.
Solution Approach 2:
The invention changes the surface treatment parameter from mechanical impact (shotblasting) to plasma energy deposition. This parameter change enables treatment of thin and complicated shaped articles that cannot withstand or access mechanical blasting, while still achieving the necessary surface roughness and chemical activation for strong bonding.
3Strength
If conventional surface treatment is applied to aluminum material for long-term storage, then initial bonding strength is achieved, but bonding strength deteriorates over time during storage and transportation
Solution Approach 1:
The invention applies preliminary plasma treatment that creates a stable, oxidation-resistant surface layer on the aluminum. This preliminary action prepares the surface in advance to resist degradation during storage and transportation, maintaining bonding strength stability over time rather than allowing deterioration to occur.
Solution Approach 2:
The plasma treatment creates a protective surface condition that cushions against future degradation. By pre-activating the surface and forming a stable plasma-treated layer, the invention provides beforehand protection against oxidation and contamination that would otherwise reduce bonding strength during long-term storage.
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 composite laminate provides excellent adhesiveness to resin materials, maintaining high bonding strength over time and simplifying waste treatment processes by using environmentally friendly materials.
Implementation Method 1
a resin coating layer which is laminated on a surface-treated surface of the metal base material, is formed of a resin composition containing an in situ polymerizable phenoxy resin
Implementation Method 2
a metal surface film is formed on a surface of an aluminum material, which is then made into contact with an etching solution to form a porous etched layer on the surface of the material
Implementation Method 3
an aluminum material is dipped in an electrolytic bath of phosphoric acid or sodium hydroxide to form an anodically oxidized film having pores
Data Source
AI summary
To provide a composite laminate having excellent adhesiveness to a resin material imparted to a metal base material, such as an aluminum, and a method for producing the same, and a metal-resin bonded article using the composite laminate and a method for producing the same. A composite laminate 1 includes a metal base material 2 and one layer or plural layers of a resin coating layer 4 laminated on the metal base material 2, the resin coating layer 4 is laminated on a surface-treated surface of the metal base material 2, and at least one layer of the resin coating layer 4 is formed of a resin composition containing an in situ polymerizable phenoxy resin.