Multi-Layered Resin Structure for Stress-Dispersed Bonding
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Solution Overview
Problem
Existing methods for shaping multi-layered structures using different resin materials face challenges in achieving strong mechanical bonding, especially when resin compatibility is low, leading to potential separation and stress concentration.
Innovation Solution
A multi-layered structure is formed by laminating layers of first and second resin portions with a bonding region where the first resin has protruding portions fitting into recessed portions of the second resin, featuring orthogonal rod-shaped structures or lump portions to enhance mechanical bonding, and optionally varying resin ratios and thicknesses to disperse stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different resin materials are used to form multi-layered structures, then material versatility and functional properties are improved, but mechanical bonding strength deteriorates due to low resin compatibility
Solution Approach 1:
The bonding region is segmented into multiple layers with alternating resin materials (first resin and second resin in different layers). This segmentation allows each layer to contribute its own material properties while the layered structure collectively provides strong mechanical bonding through the cumulative effect of multiple bonding interfaces.
Solution Approach 2:
The bonding region forms a composite structure where first resin and second resin materials are combined in alternating layers. This composite material approach leverages the complementary properties of different resins while creating a bonded structure that is stronger than individual materials alone, resolving the contradiction between material versatility and bonding strength.
2Ease of manufacture
If simple laminating is used to form multi-layered structures, then manufacturing simplicity is improved, but bonding reliability deteriorates due to local separation
Solution Approach 1:
The bonding region is divided into multiple alternating layers of first resin and second resin materials. This segmentation creates multiple bonding interfaces distributed throughout the structure, preventing local separation by ensuring that stress is distributed across many small bonding zones rather than concentrated at a single interface.
Solution Approach 2:
The bonding structure transitions from a simple two-layer interface to a multi-layered three-dimensional structure with alternating resin materials. This dimensional complexity adds multiple bonding planes in the thickness direction, significantly improving bonding reliability while maintaining manufacturing feasibility through automated layering processes.
3Stability of the object's composition
If homogeneous resin distribution is used in bonding region, then material consistency is improved, but stress distribution deteriorates leading to stress concentration
Solution Approach 1:
Different resin materials are assigned to different layers within the bonding region, creating local variations in material properties. The first resin and second resin alternate in a pattern that ensures stress is distributed locally across multiple material interfaces, preventing stress concentration while maintaining overall composition stability.
Solution Approach 2:
The bonding region utilizes composite material construction with alternating layers of different resins. This composite structure inherently distributes stress more evenly compared to homogeneous materials, as the interface between dissimilar materials creates stress relief zones that prevent concentration points while maintaining consistent overall material composition.
Data Source
AI summary
A structure includes a first resin portion shaped of a first resin and a second resin portion shaped of a second resin, and is shaped by laminating a plurality of layers in a bonding direction. A bonding region in which both resin materials of the first resin portion and the second resin portion are mixed is provided between the first resin portion and the second resin portion, and in the bonding region, the first resin portion is provided with a protruding portion, the second resin portion is provided with a recessed portion having the same shape as the protruding portion, and the protruding portion is fitted into the recessed portion so that the first resin portion and the second resin portion are bonded to each other.