Sliding Material Bonding Resin to Metal via Porous Intermediate Layer
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Solution Overview
Problem
Existing methods for joining resin and metallic materials in bearing assemblies face challenges such as insufficient bonding strength, high manufacturing costs, and equipment capacity limitations, particularly when producing sliding materials for high-load bearings.
Innovation Solution
A sliding material comprising a sliding plane member, a base member made of a different material, and an intermediate member with spaces impregnated with the sliding plane member and a joining member, which enhances bonding strength and reduces manufacturing costs by eliminating the need for vacuum equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molten metal solidification technique is used to join resin material and metallic material, then bonding is achieved through mechanical bonding, but bonding strength is insufficient
Solution Approach 1:
The patent introduces an intermediate layer with porous structure between the resin material and metallic material. This intermediate layer acts as a mediator that enables both chemical bonding (through diffusion reaction in the porous structure) and mechanical bonding (through anchoring effect), thereby achieving sufficient bonding strength and reliability that cannot be obtained by direct joining methods.
Solution Approach 2:
The patent utilizes a porous intermediate layer with controlled pore structure. The porous structure allows molten metal to penetrate and solidify within the pores, creating strong mechanical interlocking and diffusion bonding. This porous structure is key to achieving adequate bonding strength between dissimilar materials without requiring excessive heat or pressure that would damage the resin.
2Strength
If high-temperature and high-pressure conditions are applied to join resin material and metallic material, then bonding strength may be improved, but resin material is deteriorated and manufacturing cost increases
Solution Approach 1:
The porous intermediate layer enables bonding at reduced temperatures and pressures compared to direct joining methods. The porous structure provides a large surface area and capillary action that facilitates metal penetration and bonding at lower temperatures, preventing resin deterioration while achieving adequate bonding strength.
Solution Approach 2:
The patent changes the physical state and structure of the intermediate layer by creating a porous configuration. This structural parameter change allows the joining process to occur at milder conditions (lower temperature and pressure) while still achieving strong bonding, thereby reducing manufacturing cost and preventing resin degradation.
3Strength
If adhesive is used to join resin material and metallic material, then bonding is achieved, but junction interface certainly exists and bonding strength is not essentially improved
Solution Approach 1:
The porous intermediate layer serves as a functional intermediary that eliminates the need for separate adhesive layers. The layer itself provides bonding through a combination of diffusion reaction and mechanical interlocking, creating a more reliable junction without the inherent weakness of adhesive interfaces.
Solution Approach 2:
The patent creates a composite structure consisting of resin material, porous intermediate layer, and metallic material. This composite construction integrates multiple bonding mechanisms (chemical diffusion, mechanical interlocking) within a single structured layer, achieving superior bonding strength and reliability compared to simple adhesive bonding.
4Strength
If surface area is expanded with honing or chemical etching to improve bonding strength, then junction area increases, but resistance against shear peeling is small and bonding strength is not sufficiently improved
Solution Approach 1:
The porous intermediate layer provides a three-dimensional network of pores that extends throughout the layer thickness, creating extensive surface area for bonding without requiring complex surface treatment processes like honing or chemical etching. This internal porous structure offers superior mechanical interlocking and resistance to shear peeling compared to surface-only treatments.
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 solution improves the bonding strength and sliding performance of the material, reducing manufacturing costs and equipment dependency, while maintaining reliability and frictional characteristics.
Implementation Method 1
a joining member for bonding the intermediate member to the base member, wherein a portion of the space of the intermediate member is impregnated with a portion of the sliding plane member so that the sliding plane member is bonded to the intermediate member, and residual portion of the space of the intermediate member is impregnated with a portion of the joining member
Implementation Method 2
when different metallic materials are joined together by a molten metal solidification technique, a diffusion reaction occurs because of both metals are joined such that physical or chemical bonding occurs as well as mechanical bonding
Implementation Method 3
a portion of the space of the intermediate member is impregnated with a portion of the sliding plane member so that the sliding plane member is bonded to the intermediate member
Implementation Method 4
when different metallic materials are joined together by a molten metal solidification technique, a diffusion reaction occurs because of both metals are joined such that physical or chemical bonding occurs
Data Source
AI summary
A sliding material sliding material includes: a sliding plane member; a base member made of a material different from that of the sliding plane member; an intermediate member provided between the sliding plane member and the base member and formed with a plurality of spaces; and a joining member for bonding the intermediate member to the base member, in which a portion of the space formed to the intermediate member is impregnated with a portion of the sliding plane member so that the sliding plane member is bonded to the intermediate member, and a residual portion of the space of the intermediate member is impregnated with a portion of the joining member so that the base member is bonded to the intermediate member with the joining member therebetween.