Metal-CFRP Composite Resin Layer for Corrosion and Heat Transfer
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Solution Overview
Problem
The challenge is to create a composite of metal and carbon-fiber-reinforced plastic that maintains adhesion and heat transfer while preventing electrolytic corrosion at the interface between metal and carbon fiber reinforced plastic, which is not adequately addressed by existing methods that use nonwoven fabrics, leading to reduced heat transfer and inferior flexural strength.
Innovation Solution
A composite is developed with a resin layer containing an inorganic filler of high thermal conductivity and low electrical conductivity, positioned between the metal and carbon fiber reinforced plastic, along with a two-stage hot pressing process to control the number density of the inorganic filler, ensuring effective heat transfer and improved flexural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nonwoven fabric is placed at the interface of metal and CFRP to prevent electrolytic corrosion, then corrosion prevention is improved, but heat transfer ability deteriorates
Solution Approach 1:
An insulating resin layer is introduced as an intermediary substance between the metal and CFRP. This resin layer contains inorganic filler particles that provide electrical insulation to prevent electrolytic corrosion while maintaining thermal conductivity through the filler material, thus mediating between the conflicting requirements of corrosion protection and heat transfer.
Solution Approach 2:
The electrical and thermal properties of the resin layer are controlled by adjusting the type, content, and distribution of inorganic filler particles. By changing the filler parameters (such as using materials with high thermal conductivity but low electrical conductivity), the resin layer achieves the dual function of electrical insulation and thermal conduction.
2Reliability
If a nonwoven fabric is placed at the interface of metal and CFRP to prevent electrolytic corrosion, then corrosion prevention is improved, but adhesion deteriorates
Solution Approach 1:
The insulating resin layer serves as a chemical intermediary that bonds to both the metal substrate and the CFRP. The resin formulation includes adhesion promoters and coupling agents that enable strong interfacial bonding, replacing the mechanical bonding of nonwoven fabrics with chemical bonding that maintains both corrosion protection and adhesion.
3Temperature
If pitch CFRP is used as a heat transfer member, then weight is reduced and thermal conductivity is improved, but flexural strength deteriorates
Solution Approach 1:
A multi-layer composite structure is created combining metal, insulating resin with inorganic filler, and CFRP. This composite structure leverages the high thermal conductivity of pitch CFRP and metal while the metal layer provides structural strength, compensating for the low flexural strength of pitch CFRP alone.
Solution Approach 2:
Different layers of the composite structure have different functional qualities: the pitch CFRP layer is optimized for thermal conductivity, the metal layer for structural strength, and the insulating resin layer for electrical insulation. Each layer performs its specific function, and the combination achieves overall performance that no single material could provide.
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 effectively prevents electrolytic corrosion and enhances the adhesion and heat transfer between metal and carbon fiber reinforced plastic, resulting in improved flexural strength and thermal conductivity of the composite.
Implementation Method 1
providing a resin layer mainly comprised of a predetermined resin between the metal and CFRP and making it function as a bonding layer... and by including in such a resin layer an inorganic filler having a predetermined thermal conductivity and extremely low in electrical conductivity
Implementation Method 2
an inorganic filler having a predetermined thermal conductivity and extremely low in electrical conductivity (high in electrical resistivity)
Implementation Method 3
by performing a two-stage hot pressing process at a predetermined temperature, pressure, and time, it becomes possible to raise the number density of the inorganic filler near the interface with the CFRP layer in the resin layer
Data Source
AI summary
A composite of metal and carbon-fiber-reinforced plastic according to the present invention comprising a predetermined metal member, a resin layer positioned at a surface of at least part of the metal member and containing an inorganic filler having a thermal conductivity of 20 W/(m·K) or more, and carbon fiber reinforced plastic positioned on the resin layer and containing a predetermined matrix resin and carbon reinforcing fiber present in the matrix resin, the carbon reinforcing fiber being at least one of pitch-based carbon reinforcing fiber having a thermal conductivity of 180 to 900 W/(m·K) in range or PAN-based carbon reinforcing fiber having a thermal conductivity of 100 to 200 W/(m·K) in range, a content of the inorganic filler in the resin layer being 10 to 45 vol % in range with respect to a total volume of the resin layer, a number density of the inorganic filler present in a region of a width X μm from an interface of the resin layer and the carbon fiber reinforced plastic in a direction of the resin layer being 300/mm2 or more, where X μm is an average particle size of the inorganic filler.