PAS Metal-Resin Bonding for Micro-Texture Adhesion
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Solution Overview
Problem
The existing metal-resin composite structures face challenges with low adhesion between metal and resin components due to insufficient fluidity of the resin material, particularly when bonding to micro recesses and protrusions on the metal surface, leading to issues with cold heat cycle resistance.
Innovation Solution
A polyarylene sulfide resin composition is developed by blending polyarylene sulfide resin with phenol resin, which enhances the fluidity and adhesion of the resin to the metal components, allowing for better infiltration into micro recesses and protrusions, thereby improving the bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polyarylene sulfide resin is used for bonding to metal members with micro recesses, then the resin provides high heat resistance, but the resin has insufficient fluidity to penetrate into the micro recesses, resulting in poor adhesion
Solution Approach 1:
The patent uses a composite resin system combining polyarylene sulfide resin with a flexible polymer (polybutadiene, polyisoprene, or polyisobutylene). The flexible polymer acts as a modifier that reduces the viscosity of the polyarylene sulfide resin, enabling it to flow into micro recesses on metal surfaces while maintaining the high heat resistance and adhesion properties of the base resin.
Solution Approach 2:
The patent modifies the physical parameters of the polyarylene sulfide resin by controlling the molecular weight and composition of the flexible polymer additive. By adjusting the weight ratio of flexible polymer (0.1-10 parts by mass per 100 parts of polyarylene sulfide resin) and the molecular weight of the flexible polymer, the resin achieves optimal fluidity for penetrating micro recesses while maintaining structural integrity and bonding strength.
2Strength
If the resin has high viscosity to maintain structural integrity, then the resin maintains its shape and strength, but the resin cannot flow into micro recesses and protrusions on the metal surface, leading to insufficient adhesion
Solution Approach 1:
The patent creates a composite resin system where the flexible polymer (polybutadiene, polyisoprene, or polyisobutylene) serves as a viscosity modifier. This composite structure allows the resin to exhibit dual characteristics: low viscosity for infiltration into micro recesses, and sufficient structural integrity for maintaining bond strength after curing.
Solution Approach 2:
The flexible polymer components are strategically selected to provide localized fluidity enhancement at the bonding interface during the molding process, while the polyarylene sulfide base resin maintains its structural integrity in the bulk material. This local quality differentiation enables simultaneous achievement of good infiltration and structural strength.
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 modified resin composition achieves excellent adhesion and cold heat cycle resistance by increasing the fluidity and wettability of the resin, ensuring strong bonding with metal components even under thermal expansion and contraction.
Implementation Method 1
the resin flows into the recess of the metal member, and a region that becomes stuck after being solidified is formed, whereby excellent adhesion is obtained
Data Source
AI summary
Provided are: a metal-resin composite structure, 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 and a resin member, for use in the metal-resin composite structure; and a method. 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.