Terminal Adhesion Layer for Case Member Airtightness
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Solution Overview
Problem
Existing terminal-equipped case members with metal external terminals and resin sealing members face challenges in achieving sufficient airtightness due to poor adhesion between the resin sealing member and the metal terminal, especially when using engineering plastics or super engineering plastics, which compromise the insulation and heat resistance.
Innovation Solution
A method involving the use of a terminal adhesion layer formed by electrodeposition with a thermosetting epoxy resin, polyamide-imide resin, or polyimide resin, which provides higher adhesion to the metal external terminal and sealing member, enhancing the airtightness by ensuring compatibility and heat resistance, and a base material adhesion layer for improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin sealing member is used to seal the gap between the external terminal and the case member, then airtightness is improved, but adhesion between the resin sealing member and the metal external terminal deteriorates
Solution Approach 1:
The patent introduces a primer coating as an intermediary layer between the metal external terminal and the resin sealing member. This primer layer serves as a mediator that chemically bonds to both the metal substrate and the resin material, resolving the adhesion problem while maintaining the airtight sealing function. The primer contains phosphoric acid or carboxylic acid groups that form strong chemical bonds with metal surfaces, while also being compatible with engineering plastics and super engineering plastics used in the sealing member.
Solution Approach 2:
The patent employs a composite structure consisting of three distinct material layers: the metal external terminal, the primer coating layer, and the resin sealing member. This composite material approach allows each layer to contribute its specific properties - the metal provides structural strength and electrical conductivity, the primer provides adhesion promotion, and the resin provides sealing and insulation. This multi-material composite system resolves the contradiction between airtightness and adhesion.
2Temperature
If engineering plastic or super engineering plastic is used as the resin material for the sealing member, then heat resistance and mechanical characteristics are improved, but adhesion to the metal external terminal deteriorates
Solution Approach 1:
The primer coating acts as a specialized intermediary that is designed to be compatible with high-performance engineering plastics and super engineering plastics. The primer's chemical composition (containing phosphoric acid or carboxylic acid groups) enables it to bond effectively with these heat-resistant materials while also adhering to the metal terminal, thus maintaining both heat resistance and adhesion in the composite structure.
Solution Approach 2:
The patent changes the chemical parameters of the interface between metal and resin by introducing the primer layer with specific chemical groups (phosphoric acid or carboxylic acid). This parameter change in the interfacial chemistry allows the system to accommodate high-temperature engineering plastics while maintaining strong adhesion, as the primer's chemical structure is specifically designed to bond with both metal surfaces and heat-resistant polymer materials.
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 significantly improves the adhesion between the external terminal and the sealing member, resulting in enhanced airtightness and reduced risk of heat deterioration, while maintaining excellent insulation and mechanical characteristics.
Implementation Method 1
a terminal adhesion layer formation step of forming the terminal adhesion layer on the external terminal
Data Source
Figure 1
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Figure 4
AI summary
Provided is a terminal-equipped case member that is excellent in airtightness. A terminal-equipped case member (1) is configured to have an external terminal (20) for electrically connecting an external device, which is fixed to a case body (1a) for housing an electronic component (100) or a case member (10) constituting a case lid (1b) that is attached to the case body (1a). The terminal-equipped case member (1) includes a base material (11), an external terminal (20), a sealing material (30), and a terminal adhesion layer (40). The base material (11) is made of metal, and forms the case member (10). The external terminal (20) is inserted into a through hole (12) formed through the base material (11). The sealing member (30) is formed of a first resin material, and seals a gap (13) between the external terminal (20) in the through hole (12) and the base material (11). The external terminal (20) and the sealing member (30) are bonded to each other through the terminal adhesion layer (40) formed of a second resin material with a higher adhesion to the external terminal (20) than that of the first resin material.