Thermoplastic Polymer Adhesion to Ceramics and Metals
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Solution Overview
Problem
Thermoplastic polymer compositions with styrene-based thermoplastic elastomers face challenges in adhering to ceramics and metals at low temperatures without primer treatment, as existing solutions require high-temperature heat treatment, which can damage synthetic resin components and are costly due to complex processes.
Innovation Solution
A thermoplastic polymer composition comprising a styrene-based thermoplastic elastomer, polyvinyl acetal resin, polar group-containing olefin-based copolymer, and softener, specifically formulated to adhere to ceramics, metals, and synthetic resins at 190°C or lower without primer treatment, using specific blending ratios and properties to ensure adhesion and maintain mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature heat treatment (200°C or higher) is used to achieve adhesion to ceramics and metals, then adhesion strength is improved, but synthetic resin components are damaged and production costs increase
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature treatment (200°C or higher) to low-temperature treatment (100°C or higher, preferably 100-180°C). This is achieved by incorporating a polyvinyl acetal component into the thermoplastic polymer composition, which enables sufficient adhesion to ceramics, metals, and synthetic resins at lower temperatures, thereby preventing damage to synthetic resin components while maintaining strong adhesion
Solution Approach 2:
The patent creates a composite material system by combining thermoplastic polymer granules (50-95 parts by mass) with polyvinyl acetal granules (5-50 parts by mass). This composite composition leverages the adhesion properties of polyvinyl acetal to enable low-temperature bonding to diverse substrates including ceramics, metals, and synthetic resins, eliminating the need for high-temperature treatment that would damage temperature-sensitive components
2Strength
If primer treatment or adhesive coating is applied to achieve adhesion to ceramics and metals, then adhesion strength is improved, but process complexity increases and productivity decreases
Solution Approach 1:
The patent merges the adhesion function into the thermoplastic polymer composition itself by incorporating polyvinyl acetal granules. This eliminates the need for separate primer treatment or adhesive coating steps, as the composition directly provides sufficient adhesion to ceramics, metals, and synthetic resins at low temperatures, thereby simplifying the overall process and improving productivity
Solution Approach 2:
The thermoplastic polymer composition containing polyvinyl acetal granules provides self-adhesion capability without requiring external primer or adhesive treatments. The composition itself performs the adhesion function when heated to 100°C or higher, enabling direct bonding to various substrates and eliminating complex pre-treatment steps
3Strength
If high-temperature heat treatment (200°C or higher) is used to achieve adhesion to ceramics and metals, then adhesion strength is improved, but production costs increase due to additional heating equipment and complex processes
Solution Approach 1:
The patent changes the temperature parameter from 200°C or higher to 100-180°C by incorporating polyvinyl acetal granules into the composition. This parameter change eliminates the need for additional high-temperature heating equipment and complex processing steps, thereby reducing production costs while maintaining strong adhesion to ceramics, metals, and synthetic resins
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 composition achieves strong adhesion to ceramics, metals, and synthetic resins at lower temperatures, eliminating the need for additional heating and reducing production costs by using existing machinery, while maintaining flexibility and mechanical properties, thus producing durable and cost-effective molded products.
Implementation Method 1
a thermoplastic polymer composition which is excellent in flexibility, mechanical properties, and moldability and capable of adhering to ceramics, metals and synthetic resins at low temperatures without treatment with a primer and other treatments
Data Source
AI summary
A thermoplastic polymer composition which is excellent in flexibility, mechanical properties, and moldability and is capable of adhering to ceramics, metals, and synthetic resins even by heat treatment at a low temperature (for example, 190° C. or lower) without the treatment with a primer, and a molded product obtained by using the thermoplastic polymer composition. The thermoplastic polymer composition includes 100 parts by mass of a thermoplastic elastomer (A), 1 to 100 parts by mass of a polyvinyl acetal resin (B), 5 to 100 parts by mass of a polar group-containing olefin-based copolymer (C), and 0.1 to 300 parts by mass of a softener (D). The thermoplastic elastomer (A) is a block copolymer which has a polymer block constituted by aromatic vinyl compound units and a polymer block constituted by conjugated diene units or a hydrogenated product of the block copolymer.