Grooved Resin Composite Bonding via Laser-Exposed Fillers
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Solution Overview
Problem
Current methods for manufacturing composite molded articles lack sufficient strength at the interface between joined molded articles, with existing techniques failing to achieve a high anchor effect or adequate bonding strength, particularly when using resin and metal or fiber-reinforced materials.
Innovation Solution
A composite molded article is created by forming grooves in a resin molded article with fibrous inorganic fillers, exposing their end portions from the groove surfaces, which act as anchors to enhance the bonding strength when integrated with another molded article, using laser irradiation to form the grooves and adjust resin removal for optimal anchor effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bonding methods are used to join molded articles, then the manufacturing process is simple, but the bonding strength at the interface is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves and exposing fibrous inorganic fillers on the surface of the resin molded article before the bonding process. This preparation creates an anchor structure that significantly enhances bonding strength when the article is subsequently joined with another molded article, resolving the contradiction between simple process and strong bonding.
Solution Approach 2:
The patent applies local quality by creating grooves with exposed fibrous inorganic fillers at specific locations on the molded article surface. This localized modification provides enhanced bonding strength precisely at the joining regions without requiring complex modifications to the entire article or bonding process.
2Strength
If surface treatments are applied to enhance bonding, then the bonding strength improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces conventional chemical or plasma surface treatments with a mechanical approach of exposing fibrous inorganic fillers through groove formation. This substitution maintains bonding enhancement effectiveness while simplifying the manufacturing process by eliminating complex chemical treatment steps.
3Strength
If adhesive agents are used to bond surface layer material, then detachment is prevented, but the manufacturing process requires additional bonding steps
Solution Approach 1:
The patent applies self-service by designing the molded article surface to inherently provide bonding capability through exposed fibrous inorganic fillers. The fillers themselves act as anchors that enable direct mechanical interlocking with the joined article, eliminating the need for separate adhesive application steps and improving manufacturing efficiency.
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 exposed fibrous inorganic fillers significantly enhance the strength of the composite molded body by preventing detachment and destruction at the joining region, achieving a higher anchor effect and improved bonding strength compared to traditional methods.
Implementation Method 1
forming grooves in a resin molded article with fibrous inorganic fillers, exposing their end portions from the groove surfaces, which act as anchors to enhance the bonding strength when integrated with another molded article, using laser irradiation to form the grooves
Data Source
AI summary
A composite molded article in which another material is integrated on a face having grooves in a grooved resin molded article having grooves in which end parts of a fibrous inorganic filler protrude and are exposed from lateral faces of the grooves on a surface side in at least the insides of the grooves. Exposure of the end parts of the fibrous inorganic filler and formation of the grooves may be accomplished by laser irradiation, and the depth of the grooves may be at least 200 μm. Another molded article comprising the other material is arranged surrounding the fibrous inorganic filler in the insides of the grooves.