PAS Resin Shielding Member with Chemical Etching Adhesion

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Solution Overview

Problem

The challenge is to create an electromagnetic wave-shielding member with a plating layer on a polyarylene sulfide resin molded product that offers high adhesive strength and excellent electric and magnetic field shielding properties, while being simple to manufacture and maintaining surface smoothness.

Innovation Solution

A method involving chemical etching to roughen the surface of a molded product made from a PAS resin composition, followed by a plating treatment, using a mixture of PAS resin, thermoplastic resin, carbonate, and polyolefin wax to enhance adhesive strength and shielding properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a metal film is formed on the surface of PAS resin molded product, then electromagnetic wave shielding performance is improved, but adhesion of the metal film deteriorates due to low adhesion of PAS resin

Engineering Contradiction:
Improveelectromagnetic wave shielding performanceVSAvoidadhesion of metal film
Core Design Contradiction:
Object-affected harmful factorsVSReliability

Solution Approach 1:

The surface of the PAS resin molded product is subjected to etching treatment before metal film formation to create a rough surface structure. This preliminary surface modification increases the surface area and creates mechanical interlocking sites that enhance adhesion of the subsequent metal coating layer.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The surface roughness parameter is changed through etching treatment to improve adhesion. By controlling the etching depth and surface roughness within specific ranges, the patent achieves optimal balance between adhesion enhancement and surface smoothness requirements.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the surface of PAS resin molded product is etched with etchant, then adhesion of metal film is improved, but surface strength deteriorates making the surface fragile

Engineering Contradiction:
Improveadhesion of metal filmVSAvoidsurface strength
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The etching treatment parameters (etchant concentration, temperature, time) are precisely controlled to achieve optimal surface roughness without excessive erosion. This parameter optimization ensures the surface becomes rough enough for adhesion while maintaining sufficient surface strength and integrity.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The etching treatment is applied partially and controllably to create sufficient surface roughness for adhesion while avoiding complete surface degradation. The treatment depth is optimized to balance adhesion enhancement with surface strength preservation.

Inventive Principle:
Principle #16Partial or excessive action

3Reliability

If the surface of PAS resin molded product is roughened by sand blasting or shot blasting, then adhesion of coating film is improved, but surface smoothness deteriorates

Engineering Contradiction:
Improveadhesion of coating filmVSAvoidsurface smoothness
Core Design Contradiction:
ReliabilityVSShape

Solution Approach 1:

The patent replaces mechanical surface roughening methods (sand blasting, shot blasting) with chemical etching treatment. This substitution achieves surface roughness and adhesion enhancement through chemical reaction rather than mechanical impact, preserving surface smoothness while improving coating adhesion.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The surface roughness parameter is precisely controlled through chemical etching to achieve optimal adhesion without the excessive roughness caused by mechanical blasting methods. The chemical etching process allows fine control over surface morphology.

Inventive Principle:
Principle #35Parameter changes

4Reliability

If multiple layers (primer resin layer, metal layer, plating layer) are formed successively, then adhesive strength and shielding properties are improved, but manufacturing complexity increases

Engineering Contradiction:
Improveadhesive strength and shielding propertiesVSAvoidnumber of manufacturing steps
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated process. The etching treatment and metal film formation are performed in sequence as a unified surface treatment process, eliminating the need for separate primer coating and multiple plating steps. This merging reduces manufacturing complexity while maintaining performance.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The etching treatment serves multiple functions: surface roughening for adhesion, surface cleaning, and surface activation. The subsequent metal film formation provides both electromagnetic shielding and corrosion protection. This multi-functionality reduces the number of separate processes needed.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 laminated body with improved adhesive strength and enhanced electric and magnetic field shielding properties, achieving high shielding effectiveness with reduced material usage and processing time.

Implementation Method 1

roughening a surface of a molded product obtained by molding a PAS resin composition by a chemical etching treatment

Methodology Applied
Scientific EffectChemical etching:

Implementation Method 2

subjecting the roughened surface of the molded product to a plating treatment

Methodology Applied
Scientific EffectPlating treatment: Electroplating

Data Source

PatentUS20240198634A1Electromagnetic wave-shielding member and method for manufacturing same
Publication Date: 2024.06.20 DIC CORP
  • US20240198634A1 patent drawing
  • US20240198634A1 patent drawing
  • US20240198634A1 patent drawing

AI summary

Provided is a method for manufacturing an electromagnetic wave-shielding member that is a laminated body having a plating layer formed on a surface of a polyarylene sulfide (PAS) molded product. Provided are an electromagnetic wave-shielding member and a method for manufacturing the electromagnetic wave-shielding member including a step of roughening a surface of a molded product obtained by molding a PAS resin composition by a chemical etching treatment, and a step of subjecting the roughened surface of the molded product to a plating treatment, wherein the laminated body has a plating layer on at least two surfaces that are paired, and the PAS resin composition is obtained by mixing a PAS resin (A), a thermoplastic resin (B) other than the polyarylene sulfide resin selected from the group consisting of a thermoplastic elastomer (b1) and a hydrolyzable thermoplastic resin (b2), a carbonate (C), and a polyolefin wax (D).