Metal Insert-Molded Article Adhesion via Inorganic Filler
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Solution Overview
Problem
Conventional insert-molded electronic components face issues with airtightness due to peeling at coupled portions, leading to water or moisture ingress, and existing surface treatment methods can corrode the metal or cause electrical failures.
Innovation Solution
A metal insert-molded article is created using a crystalline thermoplastic resin with 0-15% inorganic filler and a metal material with an aspect ratio of 1-10, eliminating the need for surface treatment, thereby enhancing adhesion and maintaining airtightness without chemical bonds or etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface treatment methods (triazine thiol-based agent or chemical etching) are applied to metal material to enhance adhesion, then adhesion between molding material and metal material is improved, but the metal surface is corroded causing electrical characteristic failure
Solution Approach 1:
The invention changes the chemical composition parameters of the molding material by specifying precise ranges of inorganic filler (20-40 wt%), glass fiber (10-30 wt%), and lubricant (3-15 wt%). This compositional parameter change enables adequate adhesion without requiring corrosive surface treatments, thus preserving the metal's electrical characteristics while achieving sufficient bonding strength.
Solution Approach 2:
The invention uses a composite molding material containing inorganic filler, glass fiber, and lubricant combined with crystalline thermoplastic resin. This composite structure provides both adhesion enhancement through inorganic filler and mechanical reinforcement through glass fiber, while the lubricant ensures proper flow and filling, achieving adequate bonding without metal surface corrosion.
2Strength
If surface treatment processes are applied to metal material before insert molding, then adhesion is improved, but the process complexity increases due to washing and drying requirements
Solution Approach 1:
The invention extracts and eliminates the surface treatment step from the manufacturing process. By formulating a molding material with specific inorganic filler content (20-40 wt%) that provides inherent adhesion capability, the complex surface treatment process including application, washing, and drying is completely removed, simplifying the overall manufacturing process while maintaining adequate adhesion.
Solution Approach 2:
The molding material itself provides the adhesion enhancement function through its inorganic filler content, eliminating the need for separate surface treatment services. The inorganic filler within the molding material directly interacts with the metal surface during injection molding to achieve adequate bonding, making the process self-sufficient and simpler.
3Reliability
If adhesive coating is applied to interface between molding material and metal material, then airtightness is improved, but the component thickness and size increase due to adhesive layer requirements
Solution Approach 1:
The invention merges the adhesion function and airtightness function into a single integrated molding material formulation. The inorganic filler (20-40 wt%) provides both bonding strength and sealing capability at the interface, eliminating the need for separate adhesive layers and achieving both adhesion and airtightness within the base material thickness itself.
Solution Approach 2:
The inorganic filler acts as an intermediary between the crystalline thermoplastic resin and the metal material surface. It enhances the interaction at the interface, providing both adhesion and airtightness without requiring additional adhesive materials or increasing component thickness, as the filler is incorporated within the existing material 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 achieves excellent airtightness and mechanical strength, preventing corrosion and electrical failures, while simplifying the production process and reducing costs by eliminating the need for surface treatments.
Implementation Method 1
a molding material is melted by heating for improving fluidity of the molding material
Implementation Method 2
a molding material is melted by heating for improving fluidity of the molding material, poured in a mold, and cooled/solidified
Implementation Method 3
a molding material is melted by heating for improving fluidity of the molding material, poured in a mold, and cooled/solidified
Implementation Method 4
the molding material comprises a crystalline thermoplastic resin as a main component, and comprises an inorganic filler in an amount of 20% by weight to 40% by weight, and a glass fiber in an amount of 10% by weight to 30% by weight
Data Source
AI summary
A metal insert-molded article having sealing ability, a method for producing the same, and an electronic component having the metal insert-molded article, the metal insert-molded article comprising: a molding material and a metal material integrally molded together by insert molding, wherein the molding material comprises a crystalline thermoplastic resin as a main component, and comprises an inorganic filler in an amount inclusive of 0% by weight to 15% by weight, and the metal material has an aspect ratio inclusive of 1 to 10 in a cross section perpendicular to a lengthwise dimension of the metal insert-molded article, and is not surface treated for adhesion with the molding material.