Hydrogenated Block Copolymer Adhesive Layer for Metal Resin Bonding
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Solution Overview
Problem
Conventional styrene-based thermoplastic elastomers face challenges in achieving sufficient adhesion to ceramics and metals, requiring separate adhesive application or primer treatments, and exhibit poor melt-bonding capabilities.
Innovation Solution
A multilayer body is created with an adhesive layer containing a hydrogenated block copolymer, specifically formulated to have a storage modulus within a specific range (1.20×105 to 4.00×105 Pa at 100° C.), enabling strong bonding between metal, resin, and ceramic materials without the need for primer treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional styrene-based thermoplastic elastomers are used as adhesive layers, then flexibility and mechanical properties are improved, but adhesion to ceramics and metals is insufficient and separate primer treatment is required
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive layer by using a hydrogenated block copolymer with specific characteristics (hydrogenation rate of 5-50%, specific molecular weight range, specific viscoelastic properties). This parameter optimization enables the adhesive to achieve sufficient adhesion to ceramics and metals without requiring separate primer treatments, thus resolving the contradiction between adhesion strength and process complexity
Solution Approach 2:
The patent employs a hydrogenated block copolymer that combines polystyrene blocks (for adhesion and structural integrity) with hydrogenated polybutadiene blocks (for flexibility and bonding). This composite polymer structure integrates multiple functions within a single material, eliminating the need for separate primer layers while maintaining strong adhesion to both metals and ceramics
2Ease of manufacture
If conventional styrene-based thermoplastic elastomers are used, then molding processability is improved, but melt-bonding capability is insufficient
Solution Approach 1:
The patent optimizes the molecular weight and molecular weight distribution parameters of the hydrogenated block copolymer to achieve a balance between melt flow characteristics (for good molding processability) and melt-bonding strength. The specific viscosity range (0.3-3.0 dL/g) ensures adequate melt-bonding capability while maintaining ease of molding
3Strength
If separate adhesive application and primer treatment are applied, then adhesion to metals and ceramics is improved, but the bonding process becomes complicated
Solution Approach 1:
The patent merges the functions of the adhesive layer and primer layer into a single hydrogenated block copolymer adhesive layer. This material simultaneously provides the adhesion promotion properties of a primer and the bonding properties of an adhesive, eliminating the need for separate application steps and improving bonding efficiency
Solution Approach 2:
The hydrogenated block copolymer exhibits multi-functionality by simultaneously acting as both adhesive and primer. It can directly bond to metals, ceramics, and synthetic resins without requiring separate surface treatment, making it a universal bonding solution that simplifies the overall bonding process
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 provides a robust and efficient bonding method that enhances adhesion between base materials, improving mechanical properties and simplifying the bonding process by eliminating the need for separate adhesive application or primer treatments.
Implementation Method 1
the adhesive layer (Y) has a storage modulus G′ at 100° C. of 1.20×105 to 4.00×105 Pa
Data Source
AI summary
Provided are a multilayer body in which base materials composed of a metal, a resin or the like are firmly bonded to each other even when not subjected to primer treatment or the like, and a method for producing the multilayer body. The multilayer body has a base material (X), an adhesive layer (Y), and a base material (Z) in this order, wherein the adhesive layer (Y) contains a hydrogenated block copolymer (A) obtained by hydrogenating a block copolymer (P) containing a polymer block (a) composed of a structural unit derived from an aromatic vinyl compound and a polymer block (b) composed of a structural unit derived from a conjugated diene, the mass ratio [(a)/(b)] of the polymer block (a) to the polymer block (b) is 1/99 to 50/50, and the adhesive layer (Y) has a storage modulus G′ at 100° C. of 1.2×105 to 4.0×105 Pa.