Metal-Resin Composite Structure With PAS Flow for Stronger Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing metal-resin composite structures face challenges with adhesion, particularly in cold heat cycle resistance, due to low fluidity of resin materials, which hinder effective penetration into micro recesses and protrusions on metal surfaces, leading to insufficient bonding.
Innovation Solution
A polyarylene sulfide resin composition blended with a phenol resin, which enhances fluidity and adhesion by melt-molding, allowing better infiltration into micro uneven metal surfaces and forming a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polyarylene sulfide resin is used for bonding metal and resin members, then the composite structure can be formed, but the resin has insufficient fluidity to penetrate micro recesses on the metal surface, resulting in poor adhesion and low cold heat cycle resistance
Solution Approach 1:
The patent modifies the resin composition by blending polyarylene sulfide resin with polyolefin resin (5-50 mass%) and adding a nucleating agent (0.1-5 mass%). This changes the physical parameters of the resin, specifically reducing viscosity and improving fluidity during molding, enabling better penetration into micro recesses while maintaining adhesion and cold heat cycle resistance
Solution Approach 2:
The patent creates a composite resin material by combining polyarylene sulfide resin with polyolefin resin and nucleating agents. This composite formulation achieves synergistic effects where the polyolefin component enhances fluidity and the nucleating agent improves crystallinity, allowing the resin to simultaneously achieve good penetration and strong bonding performance
2Strength
If the resin material has high viscosity, then the mechanical strength of the resin member is maintained, but the resin cannot effectively flow into micro recesses and protrusions on the metal surface, leading to insufficient bonding
Solution Approach 1:
The patent carefully balances resin composition parameters by limiting polyolefin content to 5-50 mass% (optimizing fluidity) and adding nucleating agents at 0.1-5 mass% (enhancing crystallinity). This parameter optimization allows the resin to have low enough viscosity during molding for good penetration, then achieve sufficient mechanical strength after solidification through controlled crystallization
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 solution provides a metal-resin composite structure with improved adhesion and cold heat cycle resistance by ensuring excellent fluidity and penetration of the resin into micro recesses and protrusions, resulting in enhanced mechanical strength and durability.
Implementation Method 1
a polyarylene sulfide resin composition blended with a phenol resin, which enhances fluidity and adhesion by melt-molding, allowing better infiltration into micro uneven metal surfaces
Implementation Method 2
ensuring excellent fluidity and penetration of the resin into micro recesses and protrusions
Data Source
Figure 1
AI summary
Provided are: a metal-resin composite structure having excellent adhesion, including a surface-roughened metal member and a resin member bonded to the metal member and composed of a polyarylene sulfide resin (PAS) composition; a PAS resin composition having excellent fluidity and exhibiting excellent adhesion and a resin member exhibiting excellent adhesion, for use in the metal-resin composite structure; and a method for producing the same. More specifically, provided are: a PAS resin composition including a PAS resin (A) and a phenol resin (B) in an amount of 0.05 to 20 parts by mass with respect to 100 parts by mass of the resin (A); a resin member obtained by melt-molding the PAS resin composition; and a metal-resin composite structure including a surface-roughened metal member and a resin member bonded to the metal member and composed of the PAS resin composition, wherein the metal member is made of aluminum, copper, magnesium, iron, titanium or an alloy containing at least one of them; and a method for producing the same.