Polyacetal-Aliphatic Ester Composite Bonding via Melt State
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Solution Overview
Problem
Conventional composite materials with a polar thermoplastic resin and an aliphatic ester structure face challenges in achieving high adhesion strength at the interface, particularly when combined with polyacetal, which has high crystallinity and low surface reactivity, limiting their mechanical properties and biodegradability.
Innovation Solution
A composite molded article is created by bonding a polar thermoplastic resin, such as polyacetal, with an aliphatic ester-structured resin in a melted state, using a process where one resin is plasticized above its melting point and injected into a mold containing the other resin, forming a two-layer structure with enhanced adhesion strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyacetal resin with high crystallinity is used to improve mechanical properties, then strength and rigidity are improved, but adhesion strength at the interface deteriorates due to low surface reactivity
Solution Approach 1:
The patent changes the physical state parameter of the polar thermoplastic resin from solid to melted state during bonding. By heating the polyacetal resin to its melting point or above, the surface reactivity is dramatically improved, allowing strong adhesion with the aliphatic ester-structured resin. After bonding, the resin solidifies again, maintaining both the mechanical strength from high crystallinity and the adhesion strength from the melted state bonding process.
2Ease of manufacture
If conventional bonding methods are used to join polar thermoplastic resin and aliphatic ester-structured resin, then manufacturing simplicity is maintained, but adhesion strength at the interface deteriorates
Solution Approach 1:
The patent utilizes the phase transition of the polar thermoplastic resin from solid to melted state to achieve strong bonding. By heating the polyacetal resin to melt it, then bringing it into contact with the aliphatic ester-structured resin, strong adhesion occurs at the interface. The subsequent cooling causes the resin to solidify, creating a durable bond. This phase transition approach maintains manufacturing simplicity while dramatically improving adhesion 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
This approach results in a composite material with improved adhesion strength and mechanical properties, maintaining biodegradability while reducing the limitations of high crystallinity and low surface reactivity, suitable for various applications like multilayer films and fibers.
Implementation Method 1
plasticizing an aliphatic ester-structured resin (B) at a temperature higher than a melting point of the thermoplastic resin (A)
Implementation Method 2
a composite molded article having a two-layer structure obtained by locating a molded article (a) comprising a polar thermoplastic resin (A) inside a mold, plasticizing an aliphatic ester-structured resin (B) at a temperature higher than a melting point of the thermoplastic resin (A), injecting the resin (B) to the inside of the mold, and putting the resin (B) into contact with the molded article (a)
Data Source
AI summary
The present invention has an object of providing a molded article of a composite structure obtained by bonding a polar thermoplastic resin, especially polyacetal, with another resin in a simple manner. According to the present invention, a molded article of a composite structure obtained by bonding a polar thermoplastic resin and a resin containing an aliphatic ester structure as a main component to each other in the state where at least a face at which both of the materials contact each other is in a melted state can be provided.