Porous Metal Plastic Junctions via Resin Penetration
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Solution Overview
Problem
The bonding strength between plastics and metals is typically low without the use of chemical adhesives, making it difficult to achieve a strong bond, especially with injection molded polymers like amorphous polymers, which can lead to issues such as plastic detachment during production or consumer use.
Innovation Solution
A method involving a metal form with a plurality of pores and a flowable resin composition including polybutylene terephthalate and polyethylene terephthalate, where the resin composition is cured to form a solid plastic, providing a strong and aesthetically pleasing metal-plastic junction with improved bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical adhesives are used to bond plastics and metals, then bonding strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the chemical adhesive from the bonding system. Instead of using adhesives to bond plastics and metals, the patent creates direct mechanical interlocking through porous metal structures that allow plastic to penetrate and anchor, thereby achieving strong bonding without the complexity of adhesive application and curing processes
Solution Approach 2:
The porous metal structure acts as an intermediary between the plastic and metal bonding interface. The pores serve as a mediating structure that enables mechanical interlocking, allowing the plastic to physically anchor into the metal surface without requiring chemical adhesives as a intermediary bonding agent
2Productivity
If injection molded polymers are used to form junctions with metal, then production efficiency is improved, but bonding strength deteriorates due to inability to achieve intimate contact
Solution Approach 1:
The invention employs porous metal structures with controlled pore sizes and distributions that enable injection molded polymers to penetrate and anchor effectively. The porous structure provides sufficient surface area and mechanical interlocking features that allow thermosetting plastics to achieve strong bonding while maintaining the efficiency of injection molding processes
Solution Approach 2:
The patent applies local quality by creating porous structures specifically at the bonding interface regions where plastic-metal contact is needed, while maintaining solid metal structure in other areas. This localized porosity enables intimate contact and mechanical interlocking precisely where required for bonding, without compromising the overall structural integrity or production efficiency
3Reliability
If polybutylene terephthalate or polyester blends are used for metal-plastic junctions, then chemical resistance and weathering ability are improved, but bonding strength remains limited to about 30 MPa
Solution Approach 1:
The invention creates a composite bonding structure where polybutylene terephthalate or polyester blends are combined with porous metal structures. The composite system leverages the chemical resistance and weathering ability of the polyester materials while the porous metal provides enhanced mechanical interlocking, achieving bonding strengths exceeding 30 MPa through the synergistic combination of material properties and structural design
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 method achieves a bonding strength comparable to chemical adhesive-bonded metal-plastic junctions, with lower failure rates and costs, while allowing for complex shapes and reduced weight, offering design freedom and mechanical properties of both plastics and metals.
Implementation Method 1
The resin composition is integrally bonded to the surface of the metal substrate having the nano-pores and filling the nano-pores
Implementation Method 2
curing the flowable composition to form the solid plastic
Data Source
Figure 1A~3
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AI summary
Various embodiments of the present invention relate to plastic-metal junctions and methods of making the same. In various embodiments, the present invention provides a method of forming a junction between a metal form and a solid plastic. The method can include contacting a metal including a plurality of pores and a flowable resin composition including a polybutylene terephthalate and a polyethylene terephthalate. The method can also include curing the flowable composition to form the solid plastic, to provide the junction between the metal and the solid plastic. In a preferred method the flowable resin composition comprises at least one of: at least two polyethylene terephthalate polymers having different viscosities; and at least two polybutylene terephthalate polymers having different viscosities;