Bonded Body Manufacturing with Solid Thermoplastic Adhesive
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Solution Overview
Problem
Conventional bonding techniques for dissimilar materials face issues such as long bonding process times, short open times, and inadequate adhesive strength, particularly with thermosetting epoxy resin-based adhesives and hot-melt adhesives.
Innovation Solution
A method involving a pre-bonding step with a laminated body of a base material, a solid bonding agent containing amorphous thermoplastic resin (thermoplastic epoxy resin or phenoxy resin), and a fitting member, followed by a bonding step where the laminated body is heated and pressurized to melt and bond the materials, utilizing a phase change without chemical reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermosetting epoxy resin-based adhesive is used, then adhesive strength is improved, but bonding process time becomes long
Solution Approach 1:
The invention changes the physical state parameter of the bonding agent from liquid (thermosetting epoxy resin) to solid (amorphous thermoplastic resin). This parameter change eliminates the need for application and curing steps, reducing bonding process time while maintaining adhesive strength through the solid bonding agent's inherent adhesion properties and phase change mechanism.
Solution Approach 2:
The invention utilizes phase transition of the amorphous thermoplastic resin from solid to molten state during heating, allowing the bonding agent to flow and bond dissimilar materials. This phase change mechanism replaces the chemical curing process, achieving fast bonding without requiring long polymerization times, thus resolving the contradiction between adhesive strength and bonding process time.
2Loss of time
If a hot-melt adhesive is used, then bonding process time is shortened, but adhesive strength becomes insufficient
Solution Approach 1:
The invention changes the chemical composition parameter of the hot-melt adhesive by using amorphous thermoplastic resin with specific properties (epoxy equivalent of 1,600 or more, or no epoxy group with heat of fusion of 15 J/g or less). This parameter change prevents excessive fluidity at high temperatures while maintaining adequate adhesive strength, resolving the contradiction between short bonding process time and sufficient adhesive strength.
3Strength
If a liquid type adhesive is used, then adhesive strength is improved, but open time becomes short
Solution Approach 1:
The invention changes the physical state parameter from liquid to solid, which fundamentally alters the time characteristics. The solid bonding agent does not undergo polymerization reaction, so it remains stable and does not begin to cure immediately upon application. This allows for extended open time while maintaining adhesive strength, as the bonding agent only activates when heated during the bonding process.
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 method achieves a short bonding process time, long open time, and excellent adhesiveness, allowing for stable high adhesive force without fluidity issues, and enables easy recycling and repair.
Implementation Method 1
a bonding step in which the laminated body is heated and pressurized to melt the solid bonding agent and bond the base material A and the base material B
Implementation Method 2
the laminated body is heated and pressurized to melt the solid bonding agent
Data Source
Figure 1~2
AI summary
Provided is a bonding technique that is short in bonding process time, long in open time, and excellent in adhesiveness, with regard to a technique of bonding a member to be fitted having a portion to be fitted and a fitting member having a fitting portion to be fitted to the portion to be fitted of the member to be fitted. A method for producing a bonded body, the method including: a pre-bonding step in which a laminated body is prepared by arranging, in the following order, a base material A that is a member to be fitted having a portion to be fitted, a solid bonding agent containing an amorphous thermoplastic resin that is at least one type selected from a thermoplastic epoxy resin and a phenoxy resin, and a base material B that is a fitting member having a fitting portion to be fitted to the portion to be fitted of the member to be fitted; and a bonding step in which the laminated body is heated and pressurized to melt the solid bonding agent and bond the base material A and the base material B, in which the amorphous thermoplastic resin has an epoxy equivalent of 1,600 or more or does not contain an epoxy group and has a heat of fusion of 15 J/g or less.