Metal Resin Composite with Microcrack Interlocking for Strong Bonding
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Solution Overview
Problem
Existing methods for bonding metal and resin materials face limitations in robustness, reliability, and material applicability, particularly in achieving strong bonding strength across various metal types and complex product shapes.
Innovation Solution
A metal resin composite is developed, comprising a metal substrate with a metal layer and a resin layer, where the metal layer features a plurality of microcracks. The composite is prepared by forming a metal layer on a substrate, creating microcracks on the metal layer, and then applying a resin layer. This structure enhances bonding through interlocking and improves applicability to diverse metals and product shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a binder is used for connecting metal and resin, then the bonding process is simple, but the bonding strength and reliability are limited
Solution Approach 1:
The invention removes the binder component entirely from the bonding system. Instead of using a chemical adhesive, the metal layer itself is structured with microcracks that mechanically interlock with the resin, eliminating the need for any binding agent while achieving superior bonding strength.
Solution Approach 2:
The metal layer is designed with a porous structure containing numerous microcracks. This porous configuration allows the resin to penetrate and interlock with the metal layer, creating a strong mechanical bond without requiring any binder material.
2Strength
If T treatment is used to form micropores on aluminum alloy, then bonding strength is strong, but the method can only be applied to aluminum alloy
Solution Approach 1:
The microcrack formation technique is universally applicable to various metal materials including but not limited to aluminum alloy, stainless steel, and copper alloy. The method does not depend on material-specific chemical properties, allowing the same bonding approach to be used across different metal types while maintaining strong bonding strength.
Data Source
AI summary
A metal resin composite includes a metal substrate, a metal layer formed on a surface of the metal substrate, and a resin layer formed on the metal layer. A plurality of microcracks are formed at a surface of the metal layer.