Resin Molded Body Sealing Interface Exfoliation
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Solution Overview
Problem
Conventional resin molded bodies experience exfoliation at the bonding interface between thermosetting and thermoplastic resin members due to uneven stress distribution, particularly at the boundary between roughened and non-roughened surfaces, leading to reduced adhesion and potential delamination.
Innovation Solution
The resin molded body features a thermosetting resin member with a non-roughened and roughened surface, where the roughened surface is chemically bonded with a thermoplastic resin containing functional groups, and multiple closed-circular roughened surfaces are aligned in a direction that aligns with the stress-induced exfoliation, creating steps that inhibit exfoliation progression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a roughened surface is formed at a part of the sealed surface to improve adhesion with the thermoplastic resin member, then adhesion is improved, but exfoliation may progress at the boundary between the roughened surface and the non-roughened surface
Solution Approach 1:
The sealed surface is segmented into multiple distinct regions: a non-roughened surface region, one or more intermediate roughened surface regions, and a fully roughened surface region. This segmentation creates a gradient structure that distributes stress more evenly and prevents exfoliation from propagating across the entire interface, while still providing sufficient adhesion through the roughened regions.
Solution Approach 2:
Different regions of the sealed surface are given different surface qualities (roughness levels) according to their functional requirements. The non-roughened region provides stress relief, the intermediate regions provide gradual transition, and the fully roughened region provides maximum adhesion. This local differentiation optimizes both adhesion and exfoliation resistance.
2Strength
If chemical bonding is applied between the roughened surface and the thermoplastic resin member to enhance adhesion, then adhesion is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The roughening treatment and chemical bonding are merged into a unified process sequence where the roughening treatment is performed first to create the surface morphology, followed by application of the thermoplastic resin member that contains reactive groups. This combination achieves both mechanical interlocking through roughness and chemical bonding, while streamlining the manufacturing process by integrating multiple functions into a coordinated sequence.
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 configuration effectively inhibits exfoliation at the bonding interface by distributing stress and enhancing adhesion, ensuring the integrity of the resin molded body.
Implementation Method 1
adhesiveness is attempted to improve by mechanically bonding both the resin members at the roughened surface
Implementation Method 2
chemically bonding a functional group existing at a roughened surface and the functional group existing in the additive
Data Source
AI summary
A part of the sealed surface of the thermosetting resin member is a non-roughened surface that is not subjected to a roughening treatment. The other part of the sealed surface is a roughened surface recessed from the non-roughened surface to form a step and more roughened than the non-roughened surface. The thermoplastic resin member includes an additive added thereto, and the additive contains a functional group. A functional group existing in the roughened surface and the functional group existing in the additive are chemically bonded together. The roughened surface has a closed-circular shape that is formed over an entire circumference of the sealed surface around an axis parallel to the first direction. The three or more roughened surfaces each having a closed-circular shape on the sealed surface are arranged along the first direction with the non-roughened surface interposed as a distance between each adjacent two of the roughened surfaces.