Material-Plastic Composite Covalent Bonding
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Solution Overview
Problem
Existing methods for producing metal-plastic composites face challenges in achieving strong, durable bonds due to differences in thermal expansion coefficients and material properties, often resulting in insufficient bond strength and potential delamination.
Innovation Solution
The development of material-plastic composites that form covalent bonds between a material component and a plastic component using a partially crosslinked paint layer with reactive groups, which react with the plastic component's functional groups to create stable urethane, allophanate, or ester bonds, without melting the paint layer during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive technology is used to bond material and plastic components, then bond strength is improved, but thermal expansion differences cause material stress and delamination
Solution Approach 1:
The patent changes the chemical parameters of the paint layer by incorporating reactive groups (isocyanate, epoxy, hydroxyl, carboxylic acid) that can form covalent bonds with the plastic component. This chemical modification transforms the paint from a simple adhesive layer to an actively bonding interface that creates durable chemical connections, resolving the reliability issue caused by thermal expansion differences.
Solution Approach 2:
The patent creates a composite structure where the paint layer acts as an intermediate material combining properties of both the material component and the plastic component. This intermediate layer with reactive groups forms a transition zone that accommodates thermal expansion differences while maintaining strong bonds, effectively solving the delamination problem.
2Strength
If thermal post-treatment is applied to strengthen the bond, then adhesion is improved, but the paint layer may be damaged or weakened
Solution Approach 1:
The patent applies preliminary action by incorporating reactive groups into the paint layer formulation before application. These pre-built reactive groups are designed to activate during the normal curing process rather than requiring aggressive post-treatment, thus achieving strong adhesion without compromising paint layer integrity through excessive thermal or chemical processing.
Solution Approach 2:
The patent replaces mechanical/physical bonding mechanisms with chemical bonding mechanisms. Instead of relying on thermal post-treatment to create physical interlocking or mechanical anchoring, the reactive groups form covalent bonds chemically during controlled curing, achieving equivalent or superior bond strength without the need for damaging thermal processing.
3Ease of manufacture
If conventional painting is used, then surface coating is achieved, but covalent bonding with plastic component cannot be formed
Solution Approach 1:
The patent merges two previously separate processes into one: the surface coating function and the chemical bonding function are combined in a single paint layer application. The paint layer simultaneously provides surface protection/appearance and creates covalent bonds with the plastic component, eliminating the need for separate bonding operations while maintaining manufacturing simplicity.
Solution Approach 2:
The patent makes the paint layer multi-functional by incorporating reactive groups that enable it to perform both protective coating and chemical bonding functions. This universal paint layer can adhere to material components while simultaneously forming covalent bonds with plastic components, replacing the need for specialized bonding agents or procedures.
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 bond strength significantly by forming both adhesive and covalent bonds, improving the durability and stability of the composite, while avoiding thermal post-treatment that could weaken the paint layer.
Implementation Method 1
a covalent bond via urethane groups and/or allophanate groups and/or urea groups and/or biuret groups and/or ester groups and/or ether groups and/or amide groups and/or amine groups between the (partially) crosslinked paint and the elastic plastic component is formed
Implementation Method 2
the (re)active free isocyanate groups and/or epoxy groups and/or the isocyanate groups deblocked with thermal cleavage and/or the (thermally and/or catalytically) activatable uretdione groups and/or allophanate groups and/or biuret groups of the (partially) crosslinked paint have reacted with the functional groups of the elastic plastic component
Implementation Method 3
The elastic plastic component is at least partially applied to the paint layer by a thermal application process
Data Source
AI summary
The invention refers to the area of materials science and relates to a material-plastic composite as can be applied as composites in functional parts, for example. The object of the present invention is to provide material-plastic composites that provide an integral direct composite by way of adhesive and above all covalent bonds. The object is accomplished through material-plastic composites comprised of at least one material component and at least one elastic plastic composite, wherein the material component is coated with at least one (partially) cross-linked enamel, the re(active) and/or activatable groups thereof that have functional groups or the functional groups thereof that have re(active) and/or activatable groups of elastic plastic components having covalent bonds. The object is further accomplished by a method for manufacturing material-plastic composites in which a coating of a (partially) cross-linkable enamel is applied to at least one material component, followed by at least one elastic plastic component being at least partially applied to the enamel coating layer by way of a thermal application method.