Metal-Polymer Resin Composite Bonding via Electrolysis
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Solution Overview
Problem
Existing methods for preparing metal-polymer resin composites, particularly with copper or copper alloys, face challenges in achieving high bonding strength and uniformity while maintaining surface smoothness to minimize transmission loss in electronic circuit boards, as surface roughening for adhesion compromises electrical conductivity.
Innovation Solution
A method involving pretreatment etching, electrolysis in a sulfur-containing and metal chelate compound solution to form an adhesive coating, followed by drying and direct injection-molding of polymer resin onto the metal surface, ensuring strong and uniform bonding without compromising surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the surface of copper foil is roughened to improve adhesion and bonding strength with resin material, then bonding strength is improved, but transmission loss increases due to skin effect
Solution Approach 1:
The invention applies different surface treatments to different regions or aspects of the copper foil surface. The electrolysis process creates localized adhesive coating layers and micropores that provide bonding strength only where needed for resin attachment, while preserving the overall smoothness of the copper surface required for low transmission loss. This local differentiation resolves the contradiction between adhesion needs and electrical performance.
Solution Approach 2:
The invention introduces an intermediary adhesive coating layer formed through electrolysis in a sulfur-containing compound solution. This coating layer acts as a mediator between the copper foil and resin material, providing the necessary adhesion properties without requiring roughening of the underlying copper surface. The coating layer transfers the bonding function while preserving the electrical conductivity and smoothness of the copper substrate.
2Strength
If existing electrolysis methods are used with aluminum alloys, then bonding strength is achieved, but the method cannot be applied to copper or copper alloys
Solution Approach 1:
The invention changes the chemical parameters of the electrolysis process by using a sulfur-containing compound solution instead of traditional electrolytes. This parameter change makes the electrolysis process compatible with copper and copper alloys, which have different electrochemical properties compared to aluminum alloys. The sulfur-containing compound enables effective adhesive coating formation on copper surfaces, expanding the method's material applicability.
Solution Approach 2:
The invention creates a universal electrolysis method that can be applied to multiple metal types including aluminum alloys, copper, and copper alloys. By using a sulfur-containing compound solution as the electrolyte, the process achieves consistent results across different metal substrates, making the method universally applicable to various metal-polymer resin composite applications.
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 method achieves bonding strengths greater than 30 MPa and excellent airtightness, significantly improving the bonding quality and reducing transmission loss in copper-based electronic components.
Implementation Method 1
an electrolysis process step (S2) of forming an adhesive coating layer on a surface of the pretreated metal member
Implementation Method 2
a pretreatment step (S1) of etching a metal member
Data Source
AI summary
The present disclosure relates to a method for preparing a metal-polymer resin composite with excellent bonding strength and bonding uniformity. The method includes a pretreatment step (S1) of etching a metal member, an electrolysis process step (S2) of forming an adhesive coating layer on a surface of the pretreated metal member, a drying step (S3) of drying the metal member with the adhesive coating layer formed on the surface, and an injection-molding process step (S4) of bonding a polymer resin to the dried metal member, and the electrolysis process is performed in an electrolyte solution containing a sulfur-containing compound and a metal chelate compound.