Metal-Polymer Resin Bonding via Composite Electrolyte Surface Treatment
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Solution Overview
Problem
Existing methods for manufacturing metal-polymer resin bonded bodies often fail to ensure sufficient adhesion between metals and polymer resins, leading to a need for improved bonding techniques.
Innovation Solution
A method involving degreasing, etching, electrolyzing, and polymer resin injection using specific solutions and processes, including a degreasing solution with sodium hydrogen carbonate and sodium hexameta phosphate, first and second etching solutions with oxalic acid and other acids, and an electrolyte solution containing oxalic acid, sulfuric acid, and carboxylic acids, to enhance surface preparation and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bonding methods (adhesive bonding or insert injection molding) are used to manufacture metal-polymer resin bonded bodies, then the manufacturing process is simple, but the adhesion force between metal and polymer resin is insufficient
Solution Approach 1:
The patent applies preliminary action by performing surface treatment (degreasing, etching, and electrolysis) on the metal surface before bonding with polymer resin. These preparatory steps create a roughened and chemically activated surface that enhances adhesion force, directly resolving the contradiction between simple manufacturing and sufficient bonding strength.
Solution Approach 2:
The patent changes physical and chemical parameters of the metal surface through controlled etching and electrolysis processes. By adjusting etching solution composition, electrolysis conditions, and surface morphology parameters, the patent achieves optimal adhesion force while maintaining manufacturing feasibility, thus resolving the technical contradiction.
2Strength
If the electrolyte solution contains only conventional acids (oxalic acid and sulfuric acid), then the manufacturing process is simple, but the adhesion strength between metal and polymer resin is insufficient
Solution Approach 1:
The patent uses a composite electrolyte solution containing oxalic acid, sulfuric acid, and carboxylic acid components. This composite chemical system creates synergistic effects during electrolysis, producing superior surface activation and adhesion strength compared to conventional single-acid solutions, while maintaining reasonable process complexity.
Solution Approach 2:
The patent modifies the chemical composition parameters of the electrolyte solution by introducing carboxylic acid components with specific functional groups. This parameter change enhances the chemical reactivity and surface activation capability, directly improving adhesion strength without excessive complexity increase.
3Strength
If extensive surface treatment processes are applied to improve adhesion, then the adhesion strength increases, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent merges multiple surface treatment functions (degreasing, etching, and electrolysis) into a integrated sequential process. By combining these treatments in one workflow with optimized transition times, the patent achieves high adhesion strength while minimizing total processing time, thus resolving the contradiction between adhesion improvement and manufacturing efficiency.
Solution Approach 2:
The patent optimizes process parameters including treatment durations, temperatures, and solution concentrations to achieve maximum adhesion strength within efficient time frames. By carefully controlling these parameters, the patent balances quality requirements with productivity demands.
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 significantly improves the adhesion strength between metals and polymer resins, as demonstrated by increased tensile strength and reduced helium leakage, indicating superior bonding quality.
Implementation Method 1
degreasing metal using a degreasing solution
Implementation Method 2
etching the metal using an etching solution
Implementation Method 3
electrolyzing the metal using an electrolyte solution
Data Source
Figure 1
AI summary
In one general aspect, there is provided a method of manufacturing a metal-polymer resin bonded body, including: degreasing metal using a degreasing solution; etching the metal using an etching solution; electrolyzing the metal using an electrolyte solution; and performing a polymer resin injection to bond a polymer resin to the metal, wherein the electrolyte solution includes a compound containing distilled water, oxalic acid, sulfuric acid, and carboxylic acid.