Direct Metal-Coated Polymer Structural Member Without Priming Coat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for structural members in electronic devices are complex and inefficient, requiring priming coats that increase production time and solvent use, leading to pollution and reduced reliability due to poor bonding and thermal expansion mismatches.
Innovation Solution
A structural member comprising a substrate made of a polymer material with a polar group and high heat distortion temperature, allowing direct formation of a metal coating layer without a priming coat, utilizing high-temperature sputtering coating to enhance bonding and reduce thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a priming coat is applied between the metal coating layer and the substrate, then the bonding force is improved, but the manufacturing process becomes more complex and production efficiency decreases
Solution Approach 1:
The patent removes the priming coat layer from the traditional three-layer structure (substrate-priming coat-metal coating), achieving direct bonding between the metal coating layer and the polymer substrate through surface treatment methods such as plasma treatment, corona treatment, or flame treatment, thereby simplifying the manufacturing process while maintaining adequate bonding strength
Solution Approach 2:
The patent changes the surface energy parameters of the polymer substrate through physical or chemical surface treatments, increasing the surface polarity and enabling direct adhesion of the metal coating layer without requiring a priming coat, thus eliminating an entire process step
2Strength
If a priming coat is applied between the metal coating layer and the substrate, then the bonding force is improved, but production efficiency decreases
Solution Approach 1:
The patent eliminates the priming coat application step entirely by using surface treatment methods that directly activate the substrate surface, reducing the number of process steps from three (substrate preparation-priming coat application-metal coating deposition) to two (substrate preparation-metal coating deposition), thereby improving production efficiency
Solution Approach 2:
The patent skips the priming coat application and drying steps by using plasma, corona, or flame treatment that immediately activates the substrate surface, allowing the metal coating to be deposited directly onto the treated surface without intermediate processing time
3Ease of manufacture
If conventional polymer materials are used, then the manufacturing cost is reduced, but thermal deformation occurs during metal coating layer formation
Solution Approach 1:
The patent selects polymer materials with specific thermal parameters (heat distortion temperature ≥175°C and coefficient of thermal expansion ≤60×10^-6/K), changing the material properties to resist thermal deformation during metal coating deposition while maintaining cost-effectiveness
Solution Approach 2:
The patent uses polymer materials containing polar groups (such as polyetherimide, polysulfone, polyacrylonitrile, or polyvinylidene fluoride) that provide both adequate thermal stability and enhanced surface polarity for direct metal coating adhesion, balancing performance and cost
4Adaptability or versatility
If conventional polymer materials with high coefficient of thermal expansion are used, then material selection is easier, but the bonding force between substrate and metal coating layer deteriorates
Solution Approach 1:
The patent specifies a coefficient of thermal expansion ≤60×10^-6/K for the polymer substrate, matching it more closely to the metal coating layer to prevent thermal stress-induced bonding failure, while still maintaining practical material selection flexibility
Solution Approach 2:
The patent employs polymer materials with specific chemical composition (containing polar groups) that provide both appropriate thermal expansion characteristics and enhanced surface chemistry for direct metal adhesion, achieving a balance between material versatility and bonding performance
5Strength
If solvent-based priming coats are used, then the bonding force is improved, but pollution is increased
Solution Approach 1:
The patent removes the solvent-based priming coat from the system entirely, replacing it with solvent-free surface treatment methods (plasma, corona, or flame treatment) that activate the substrate surface without introducing harmful solvents, thereby eliminating pollution while achieving adequate bonding
Solution Approach 2:
The patent replaces the chemical bonding mechanism of solvent-based priming coats with physical surface activation methods (plasma, corona, or flame treatment), eliminating the need for solvents and their associated environmental pollution while achieving direct metal coating adhesion
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
Simplifies manufacturing, reduces pollution, and improves production efficiency while ensuring strong bonding, high-quality metal coating, and enhanced structural stability, with improved reliability and aesthetic appeal.
Implementation Method 1
The polar group of the polymer material may form a strong bonding force with metal atoms in the metal coating layer
Implementation Method 2
utilizing high-temperature sputtering coating to enhance bonding and reduce thermal expansion differences
Data Source
AI summary
This application provides a structural member, and an electronic device. The structural member includes a substrate and a metal coating layer. The substrate includes an outer surface. The metal coating layer is provided on the outer surface. The substrate is made of a polymer material having a polar group. A heat distortion temperature of the polymer material is greater than or equal to 175° C. A coefficient of thermal expansion of the polymer material is less than or equal to 60*10−6/K. In the structural member shown in this application, the substrate is made of the polymer material having a polar group. The polar group of the polymer material helps form a strong bonding force with the metal coating layer. The metal coating layer may be directly formed on the outer surface of the substrate without the need to design a priming coat between the metal coating layer and the outer surface.