Abstract
An epoxy monolith layer with porous structure is fabricated on the surface of a stainless steel (SUS) plate by polymerization induced phase separation process as the mediator for the bonding of SUS and various thermoplastic resin plates. Bonding strength is evaluated in the presence and absence of the epoxy monolith layer by a tensile lap shear test. The morphology of fracture surfaces is observed by scanning electron microscopy (SEM) in order to clarify the anchor effect of molten resins into the pores of the epoxy monoliths. The bonding strength values are calculated to be 1.2‒2.7 MPa based on an apparent adhesion area for the bonding of SUS with polyethylene, polypropylene, polyoxymethylene and acrylonitrile–butadiene–styrene copolymer in the presence of the epoxy monolith mediator. These values are 2‒30 times higher than those for direct metal-resin bonding. By the SEM observation, stretched needle-like structures were detected on the both fracture surfaces of the resins and the epoxy monoliths. The direct observation of the stretched debris out of the holes located at the monolith surfaces indicates the significant anchor effect for the present metal-resin bonding system. The bonding system mediated by the epoxy monolith layer is conveniently used for the bonding of dissimilar materials such as metals and resins without any special process and apparatus.
Highlights
Tough and reliable bonding between dissimilar materials is one of the most important and challenging topics in the fields of adhesion and adhesives because metal components used for automobiles, aircrafts, and mechanical parts have increasingly been replaced by lightweight plastics and polymer composites during recent years [1, 2]
It was revealed that the number and size of pores depended on the reaction conditions for the epoxy monolith fabrication, such as the ratio of the numbers of amino hydrogens and epoxy groups, the amount of the porogen, and the curing temperature
The anchor effect for the robust bonding of dissimilar materials was directly confirmed by the scanning electron microscopy (SEM) observation of the epoxy monolith and resin fracture surfaces
Summary
Tough and reliable bonding between dissimilar materials is one of the most important and challenging topics in the fields of adhesion and adhesives because metal components used for automobiles, aircrafts, and mechanical parts have increasingly been replaced by lightweight plastics and polymer composites during recent years [1, 2]. Monolithic porous materials consisting of polymers or inorganic compounds have been prepared by thermally induced phase separation [11], non-solvent induced phase separation [12], and polymerization induced phase separation [13]. They are mainly used as separation filters, column packing materials for ion exchange and chromatography, catalyst supports, and electrical or thermal insulators due to their high strength and porosity [14,15,16,17,18]. The morphology of fracture surfaces was investigated in order to discuss an anchor effect on this bonding system
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