Polyurethane Coated Metal for Thermoplastic Resin Adhesion
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Solution Overview
Problem
Existing composites of shaped metal materials and thermoplastic resin compositions exhibit insufficient adhesion and complex, costly production processes due to surface roughening treatments.
Innovation Solution
A coated shaped metal material with a polyurethane resin coating containing a polycarbonate unit, applied with a film thickness of 0.5 µm or larger, which includes oxides, hydroxides, or fluorides of metals like Ti, Zr, V, or W, enhancing adhesion and corrosion resistance, is used in conjunction with insert molding to join the thermoplastic resin composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface roughening treatment is applied to shaped metal material, then adhesion to resin composition is improved, but production steps become complicated and production cost increases
Solution Approach 1:
A coating layer is applied in advance to the shaped metal material surface before insert molding. This preliminary coating action eliminates the need for subsequent surface roughening treatments, simplifying the production process while ensuring adequate adhesion between the metal material and thermoplastic resin composition.
Solution Approach 2:
The invention changes the surface parameters of the shaped metal material by applying a coating layer with specific properties (thickness of 0.5 μm or more, containing metal oxides/hydroxides/fluorides). This parameter change provides both the necessary adhesion and corrosion resistance without requiring complex surface roughening processes.
2Reliability
If surface roughening treatment is applied to shaped metal material, then adhesion to resin composition is improved, but production cost increases
Solution Approach 1:
The coating layer is applied in advance during the manufacturing process, combining multiple functions (adhesion promotion and corrosion resistance) into a single step. This eliminates the need for separate surface roughening treatments, reducing production cost while maintaining reliable adhesion.
Solution Approach 2:
The invention uses a composite coating layer containing metal oxides, hydroxides, or fluorides combined with a binder resin. This composite structure provides both adhesion promotion and corrosion resistance in a single layer, replacing the need for multiple separate treatments and reducing overall production cost.
3Reliability
If coating layer with polycarbonate unit is applied to shaped metal material, then adhesion and corrosion resistance are improved, but coating material complexity increases
Solution Approach 1:
The invention specifies particular parameters for the coating layer (thickness ≥0.5 μm, polycarbonate unit content 15-80 mass%, specific metal oxide/hydroxide/fluoride content 1-50 mass%). By controlling these parameters within defined ranges, the coating achieves optimal adhesion and corrosion resistance without requiring overly complex material compositions.
Solution Approach 2:
The coating layer is designed as a composite material containing polycarbonate units combined with specific metal oxides, hydroxides, or fluorides. This composite structure provides synergistic effects that improve both adhesion and corrosion resistance while maintaining a manageable material composition through defined concentration ranges.
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 coated shaped metal material achieves excellent adhesion and simplified production of composites with improved corrosion resistance and reduced production costs, ensuring strong bonding with thermoplastic resin compositions.
Implementation Method 1
a coating formed on the surface of the shaped metal material, the coating including a polyurethane resin containing a polycarbonate unit... excellent in adhesion to a molded article of a thermoplastic resin composition
Implementation Method 2
the coating includes an oxide, a hydroxide, or a fluoride of a metal selected from the group consisting of Ti, Zr, V, Mo, and W, or a combination thereof... improved corrosion resistance
Data Source
AI summary
The present invention relates to a shaped and coated metallic material which has excellent adhesion to a molded article of a thermoplastic resin composition and can be produced in a simple manner. The shaped and coated metallic material comprises a shaped metallic material and a coating film formed on the surface of the shaped metallic material. The coating film comprises a polyurethane resin containing a polycarbonate unit. The ratio of the mass of the polycarbonate unit relative to the total mass of resins in the coating film is 15 to 80 mass%. The thickness of the coating film is 0.5 µm or more.