The
epoxy monolith with a highly porous structure is fabricated
by the thermal curing of 2,2-bis(4-glycidyloxyphenyl)propane and 4,4′-methylenebis(cyclohexylamine)
in the presence of poly(ethylene glycol) as the porogen via polymerization-induced
phase separation. In this study, we demonstrated a new type of dissimilar
material bonding method for various polymers and metals coated with
the epoxy monolith. On the basis of scanning electron microscopy (SEM)
observations, the pore size and number of epoxy monoliths were evaluated
to be 1.1–114 μm and 8.7–48 200 mm
–2
, respectively, depending on the ratio of the epoxy
resin and cross-linking agent used for the monolith fabrication. Various
kinds of thermoplastics, such as polyethylene, polypropylene, polyoxymethylene,
acrylonitrile–butadiene–styrene copolymer, polycarbonate
bisphenol-A, and poly(ethylene terephthalate), were bonded to the
monolith-modified metal plates by thermal welding. The bond strength
for the single lap-shear tensile test of stainless steel and copper
plates with the thermoplastics was in the range of 1.2–7.5
MPa, which was greater than the bond strength value for each bonding
system without monolith modification. The SEM observation of fractured
test pieces directly confirmed an anchor effect on this bonding system.
The elongated deformation of the plastics that filled in the pores
of the epoxy monolith, was observed. It was concluded that the bond
strength significantly depended on the intrinsic strength of the used
thermoplastics. The epoxy monolith bonding of hard plastics, such
as polystyrene and poly(methyl methacrylate), was performed by the
additional use of adhesives, solvents, and a reactive monomer. The
epoxy monolith sheets were also successfully fabricated and applied
to dissimilar material bonding.