Laser Surface Roughening for Porous Metal-Resin Bonding
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Solution Overview
Problem
Existing methods for roughening metal molded body surfaces for composite manufacturing do not effectively create complex porous structures necessary for strong bonding with resins or metals, leading to suboptimal joint strengths.
Innovation Solution
A method involving laser light irradiation at an energy density of 1 MW/cm² or more and an irradiation rate of 2000 mm/sec or more, with alternating laser-irradiated and non-irradiated portions in straight, curved, or combined patterns, to form complex porous structures on the metal surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If laser light is irradiated at conventional energy densities and irradiation rates, then the metal surface is roughened, but complex porous structures are not formed effectively
Solution Approach 1:
The patent applies parameter changes by optimizing the laser energy density to 1 MW/cm² or more and the irradiation rate to 2000 mm/sec or more. These specific parameter adjustments transform the surface treatment outcome from simple roughening to complex porous structure formation, resolving the contradiction between surface shape modification and manufacturing precision.
Solution Approach 2:
The patent employs periodic action through alternating laser-irradiated and non-irradiated portions in straight, curved, or combined patterns. This periodic irradiation approach creates the complex porous structures by cyclically heating and cooling the metal surface, allowing vaporization and recondensation cycles that form the desired porous morphology.
2Strength
If laser irradiation creates complex porous structures, then bonding strength with resins or metals improves, but deformation and spatter issues may occur
Solution Approach 1:
The alternating laser-irradiated and non-irradiated portions create periodic heating and cooling cycles that form porous structures while controlling thermal accumulation. This periodic action allows the material to vaporize and recondense in a controlled manner, forming porous structures that enhance bonding strength while minimizing uncontrolled deformation and spatter.
Solution Approach 2:
The patent applies local quality by creating distinct irradiated and non-irradiated zones with different thermal histories. The irradiated portions develop porous structures for bonding, while the non-irradiated portions remain relatively intact, providing a balance between bonding strength and structural integrity that reduces harmful deformation and spatter.
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 surface roughening of metal molded bodies, enabling the formation of complex porous structures that improve the bonding strength with resins, metals, or rubbers, reducing deformation and spatter issues while maintaining efficiency.
Implementation Method 1
irradiating laser light under laser light irradiation conditions different from laser light irradiation conditions described in JP-B 5774246 and JP-B 5701414
Implementation Method 2
the surface of the metal molded body is partially evaporated while being melted
Implementation Method 3
irradiating laser light at an irradiation rate of 2000 mm/sec or more with an energy density of 1 MW/cm² or more
Implementation Method 4
the surface of the metal molded body is partially evaporated while being melted
Data Source
Figure 1~2(b)
Figure 3(a)~3(b)
Figure 4
AI summary
A method for roughening a surface of a metal molded body which can be used as an intermediate for manufacturing a composite molded body of a metal molded body with a resin, a rubber, a metal, or the like is provided. The method for roughening a metal molded body surface includes a step of irradiating the surface of the metal molded body with laser light at an irradiation rate of 2000 mm/sec or more with an energy density of 1 MW/cm2 or more using a laser apparatus, and the laser light irradiation step is a step of irradiating laser light so that laser light-irradiated portions and non-laser light-irradiated portions are generated alternately when the laser light is irradiated to be in a straight line, a curved line, or a combination of a straight line and a curved line on the surface of the metal molded body to be roughened.