Insert Molded Product Layered Structure Bonding
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Solution Overview
Problem
Conventional insert molding methods fail to achieve sufficient bonding between metal core members and resin materials, resulting in insufficient bonding force and difficulty in creating watertight characteristics in molded products.
Innovation Solution
The implementation of a layered structure on the metal base member, including a nickel layer, a noble metal layer, a compound layer containing silicon and oxygen, and a mixture layer where the compound and resin are mixed, with nickel included in both the compound and mixture layers, using a process that involves forming these layers through metallizing plating and chemical vapor deposition, and injecting resin at high temperatures to promote bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional insert molding methods are used with only close contact between core member and resin, then the manufacturing process is simple, but the bonding force between core member and resin is insufficient
Solution Approach 1:
The surface treatment layer is divided into multiple functional sub-layers: a ground layer (nickel plating) for adhesion, a noble metal layer for corrosion resistance, and a compound layer (silicon oxide) for chemical bonding with resin. This segmentation allows each layer to perform its specific function, collectively achieving strong bonding force while maintaining manageable complexity through systematic structure design.
Solution Approach 2:
The surface treatment layer combines multiple materials (nickel, noble metal, silicon oxide compound) into a composite structure. Each material contributes different properties: nickel provides mechanical adhesion, noble metal provides corrosion resistance, and silicon oxide provides chemical bonding capability with the resin. This composite approach resolves the contradiction by achieving superior bonding force through material synergy rather than simple mechanical contact.
2Reliability
If conventional insert molding methods are used without chemical bonding layers, then the manufacturing process is simple, but watertight characteristics cannot be achieved
Solution Approach 1:
The surface treatment layers are formed on the core member before the resin injection molding process. The ground layer, noble metal layer, and compound layer are prepared in advance through plating and chemical vapor deposition, creating a pre-conditioned surface that ensures watertight bonding when the resin is injected. This preliminary action resolves the contradiction by establishing the bonding interface beforehand, making the subsequent molding process straightforward while achieving reliable watertight characteristics.
Solution Approach 2:
The compound layer (silicon oxide) acts as an intermediary between the metal core member and the resin. It provides chemical bonding sites that facilitate strong adhesion and create watertight sealing. The noble metal layer serves as an intermediary protecting the ground layer while allowing the compound layer to form the bonding interface. This intermediary approach achieves watertight characteristics without requiring complex direct bonding between dissimilar materials.
3Strength
If high temperature resin injection is used to promote bonding, then the bonding force is improved, but the risk of material degradation increases
Solution Approach 1:
The multi-layer surface treatment structure serves as a protective cushion between the high-temperature resin and the metal core member. The compound layer (silicon oxide) has high thermal stability and acts as a thermal barrier, protecting the underlying noble metal and ground layers from thermal degradation during high-temperature resin injection. This beforehand cushioning allows high temperature processing to achieve strong bonding while preventing material degradation through the protective layering structure.
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 approach enhances the bonding force and maintains high watertight characteristics, even under conditions such as autoclave sterilization, improving chemical and heat resistance, and allowing for easier manufacturing with better quality and lower costs.
Implementation Method 1
a compound layer formed of a compound containing silicon (Si) and oxygen (O)... formed in this order on the metal base member
Implementation Method 2
a ground layer, a noble metal layer formed of a noble metal... in this order on the metal base member, and wherein nickel (Ni) is included in both the compound layer and the mixture layer
Implementation Method 3
injecting resin at high temperatures to promote bonding
Data Source
AI summary
An insert molded product in which a metal base member and a resin are bonded together includes a ground layer; a noble metal layer formed of a noble metal; a compound layer formed of a compound containing silicon (Si) and oxygen (O); and a mixture layer where the compound and the resin are mixed together, wherein the ground layer, the noble metal layer, the compound layer, and the mixture layer are formed in this order on the metal base member, and wherein nickel (Ni) is included in both the compound layer and the mixture layer.