Resin-Metal Joining Structure With Adhesive Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The direct contact between resin and metal components in conventional joining structures leads to concerns of galvanic corrosion, which existing technologies have not effectively addressed.

Innovation Solution

A component joining structure is developed where metal tips are inserted into a resin component through molding, with protruding portions that are spot welded to a metal component, and an adhesive agent is interposed between the components to prevent galvanic corrosion, while detent portions on the metal tips prevent rotation and enhance join strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a resin component and metal component are joined by direct contact, then the joining structure is simple, but galvanic corrosion occurs between the resin and metal components

Engineering Contradiction:

Improvejoining structure complexityVSAvoidcorrosion resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

An adhesive agent is introduced as an intermediary substance between the resin component and metal component. The adhesive agent includes a primer layer and a topcoat layer, where the primer layer adheres to the metal component and the topcoat layer adheres to the resin component, preventing direct contact between dissimilar metals and thus inhibiting galvanic corrosion while maintaining joining strength

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If metal tips are inserted into resin component by insert molding, then the join strength is improved, but the complexity of manufacturing process increases

Engineering Contradiction:

Improvejoin strengthVSAvoidmanufacturing process simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Metal tips with protruding portions are pre-formed and inserted into the resin component during the insert molding process. The protruding portions extend beyond the resin component surface, allowing subsequent spot welding operations to be performed easily. This preliminary preparation of metal tips with specific geometries enables simplified downstream manufacturing steps while achieving strong mechanical and metallurgical bonds

Inventive Principle:

Principle #10Preliminary action

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 structure effectively inhibits galvanic corrosion and improves the strength of the join between resin and metal components, ensuring a stable and durable bond without compromising rigidity.

Implementation Method 1

a metal component that is spot welded to the protruding portions, and that is joined to the resin component by an adhesive agent that is provided in gaps formed, by the protruding portions between the resin component and the metal component

Methodology Applied

Scientific EffectGalvanic corrosion prevention: Adhesive

Implementation Method 2

a metal component that is spot welded to the protruding portions

Methodology Applied

Scientific EffectSpot welding: Welding

Data Source

PatentUS11460060B2Component joining structure

Publication Date: 2022.10.04 TOYOTA JIDOSHA KK

AI summary

There is provided a component joining structure that includes: a resin component; a metal tip that is provided in the resin component by insert molding, and that includes protruding portions that protrude from the resin component; and a metal component that is spot welded to the protruding portions, and that is joined to the resin component by an adhesive agent that is provided in gaps formed, by the protruding portions, between the resin component and the metal component.