Method for manufacturing layered article, layered article, and heated toilet seat device
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Solution Overview
Problem
Conventional methods for bonding substrates, particularly those containing polymers and metal atoms, often result in reduced long-term reliability and adhesion over time, especially when exposed to water, leading to hydrolysis and dissociation of the bonding interface.
Innovation Solution
A method involving the formation of a bridge layer using a metal carboxylate compound and a cross-linkable polymer, where the metal atoms are irradiated with ultraviolet rays in an alcohol atmosphere, followed by contact to create a strong, reversible bond with excellent water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods are used to bond metal substrate and polymer substrate, then bonding can be achieved, but long-term reliability and adhesion strength deteriorate over time due to hydrolysis
Solution Approach 1:
The patent introduces a bridge layer containing metal carboxylate compounds as an intermediary between the metal substrate and polymer substrate. This bridge layer acts as a mediator that forms strong coordination bonds with metal atoms while also bonding to the polymer, preventing direct hydrolytic attack at the metal-polymer interface and thereby maintaining adhesion strength over time
Solution Approach 2:
The patent creates a composite bonding structure consisting of three distinct layers: metal substrate, bridge layer with metal carboxylate compounds, and polymer substrate. This composite structure combines the advantages of metal-metal coordination bonding (high strength, water resistance) with polymer-metal adhesion, solving the hydrolysis problem through material composition design
2Strength
If high thermal energy is applied to bond substrates, then bonding strength improves, but the structure and function of polymer-containing substrates are damaged
Solution Approach 1:
The patent replaces thermal bonding mechanisms with photochemical bonding mechanisms. By using ultraviolet light to activate the formation of metal carboxylate compounds in the bridge layer, the method achieves strong bonding through chemical coordination rather than thermal fusion, thereby avoiding damage to the polymer substrate's structure and function
Solution Approach 2:
The patent changes the bonding mechanism from thermal (high temperature) to photochemical (ultraviolet light activation). This parameter change allows bonding to occur at lower temperatures that do not degrade the polymer, while still achieving strong adhesion through the formation of stable metal-carboxylate coordination bonds in the bridge layer
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 method produces an integrated body with enhanced long-term reliability and adhesive strength, maintaining stability even when exposed to water, by forming a metal carboxylate structure that can rejoin upon partial dissociation, thus ensuring excellent water resistance.
Implementation Method 1
a step A in which, in an atmosphere that contains at least one alcohol compound selected from the group consisting of primary alcohols and secondary alcohols, the first substrate and the second substrate are each irradiated with an ultraviolet ray
Implementation Method 2
a precursor layer (a) that contains a metal carboxylate compound in which the metal atoms and a carboxylic acid are joined is formed on the first substrate
Data Source
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AI summary
The present invention addresses the problem of providing a layered article having exceptional long-term reliability, and a method for manufacturing the layered article. One aspect of the present invention for solving the aforementioned problem is a method for manufacturing a layered article having, in the stated order, a first substrate that contains metal atoms, a cross-linking layer, and a second substrate that contains a polymer, wherein the method for manufactruing a layered article has: a step A in which, in an atmosphere that contains at least one alcohol compound selected from the group consisting of primary alcohols and secondary alcohols, the first substrate and the second substrate are each irradiated with ultraviolet rays, a precursor layer a that contains a metal carboxylate compound in which the metal atoms and a carboxylic acid are joined is formed on the first substrate, and a precursor layer b that contains a cross-linkable polymer in which a cross-linkable group is joined to the polymer is formed on the second substrate; and a step B in which the precursor layer a and the precursor layer b are brought into contact with each other and the cross-linking layer is formed thereby manufacturing the layered article. The metal atoms may be capable of forming a hydrate.