Metal Resin Composite Bonding via Dual-Scale Surface Roughness
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Solution Overview
Problem
Current methods for bonding metal and resin components, particularly using non-polar polyolefin resins, result in low bonding strength and limited shape flexibility, with existing technologies requiring high pressure and melted resin states, leading to inefficient and imperfect bonding.
Innovation Solution
A metal/resin composite structure is achieved by forming specific concavo-convex shapes on the metal surface with defined roughness characteristics, combined with ultrafine pores, using blast treatment and chemical etching, to enhance bonding with non-polar polyolefin resins, allowing for direct and strong bonding without resin denaturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If non-polar polyolefin resin is used for bonding to metal surface, then resin stability and chemical inertness are improved, but bonding strength deteriorates due to lack of affinity with metal
Solution Approach 1:
The invention applies local quality by creating a dual-scale surface structure on the metal: macroscopic concave portions (1-100 μm) for mechanical interlocking and microscopic roughness (Ra 0.3-3 μm) for increased surface area. This localized structural modification enables non-polar polyolefin resin to bond strongly to metal surfaces without changing the resin's inherent stability and chemical inertness.
Solution Approach 2:
The invention employs preliminary action by pre-forming the dual-scale concave-convex structure on the metal surface before resin application. The blast treatment and chemical etching are performed in advance to create the optimal surface morphology, ensuring that when the non-polar polyolefin resin is applied, it immediately achieves strong bonding through mechanical interlocking and increased surface contact area.
2Strength
If traditional bonding methods (laminating or pressing) are used with acid-modified polyolefin resin, then bonding strength is improved, but manufacturing complexity and pressure requirements increase
Solution Approach 1:
The invention extracts and eliminates the need for complex bonding equipment and high-pressure laminating processes. By creating the dual-scale surface structure on the metal, the invention enables direct bonding of non-polar polyolefin resin without requiring the specialized equipment needed for traditional acid-modified resin bonding methods.
Solution Approach 2:
The invention applies self-service by enabling the non-polar polyolefin resin to bond to the metal surface through its own inherent adhesive properties and the pre-prepared surface structure. The resin does not require external assistance from complex bonding equipment or high-pressure processes, as the surface morphology itself provides the bonding mechanism.
3Area of stationary object
If metal surface is roughened to enhance bonding, then bonding area is improved, but surface flatness and precision deteriorate
Solution Approach 1:
The invention applies segmentation by dividing the surface roughness into two distinct scales: macroscopic concave portions (1-100 μm depth) that increase bonding area, and microscopic surface roughness (Ra 0.3-3 μm) that provides fine interlocking. This segmented approach allows the surface to provide adequate bonding area while maintaining sufficient flatness for precision applications.
Solution Approach 2:
The invention employs parameter changes by precisely controlling the depth and dimensions of the concave portions (1-100 μm) and the surface roughness (Ra 0.3-3 μm). By optimizing these parameters, the surface provides enhanced bonding area while maintaining the flatness required for precision manufacturing and assembly.
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 approach results in a metal/resin composite with high bonding strength, enabling flexible shaping and improved performance by ensuring the resin enters the concave portions effectively, overcoming limitations of previous methods.
Implementation Method 1
forming concavo-convex shapes on a surface of the metal member by performing blast treatment
Implementation Method 2
forming concavo-convex shapes on a surface of the metal member by performing chemical etching
Data Source
AI summary
A metal/resin composite structure (106) of the invention is formed by bonding a metal member (103) and a resin member (105) to each other.A concavo-convex shape satisfying the following characteristics (i) and (ii) is formed on a bonding surface (104) of the metal member (103) to be bonded to the resin member (105).(i) A mean width of the profile elements (RSm) is equal to or greater than 150 μm and equal to or smaller than 1500 μm and a maximum height roughness (Rz) is equal to or greater than 170 μm and equal to or smaller than 800 μm(ii) A mean width of the profile elements (RSm) is equal to or greater than 100 nm and equal to or smaller than 10000 nm and a maximum height roughness (Rz) is equal to or greater than 100 nm and equal to or smaller than 10000 nm.