Coating system with functionalized particles

Abstract

A coating system is disclosed. The coating system includes a coating disposed on a substrate and a plurality of functionalized particles within the coating. The plurality of functionalized particles are configured to dissipate local heat flux from the substrate, where at least a portion of the plurality of functionalized particles are aligned.

Description

Technical Field

[0001] The present disclosure relates to coating systems and methods and, more particularly, to coating systems configured to dissipate heat from a substrate. Background Art

[0002] This introduction generally presents the background of the present disclosure. To the extent that the work performed by the presently named inventors is described in this introduction and in various aspects of the specification, it is not intended to be prior art at the time of filing the application, and it is never expressly or impliedly admitted to be prior art to the present disclosure.

[0003] Coating systems can be used to protect a substrate and give the substrate a desired appearance. In environments with high temperature, high humidity, thermal radiation, and / or UV radiation, such as in a vehicle engine environment, the surface pattern in the coating system may be highly deformed. Due to high temperature and high humidity, it can be challenging to control the surface properties of the patterned coating system.

[0004] While there are prior art methods and systems for minimizing or preventing deformation of coating systems, there remains a need for new and improved coating systems having deformation prevention. Accordingly, a coating system comprising a plurality of aligned functionalized particles is disclosed. Summary of the invention

[0005] According to several aspects of the present disclosure, a coating system is provided. The coating system includes a coating disposed on a substrate and a plurality of functionalized particles within the coating. The plurality of functionalized particles are configured to dissipate a local heat flux from the substrate, wherein at least a portion of the plurality of functionalized particles are aligned.

[0006] According to another aspect of the present disclosure, the coating system further includes a substrate that is at least one of metal or plastic and is integrated with holes for air flow.

[0007] According to another aspect of the present disclosure, the coating system further includes a substrate, which is a vehicle intake manifold.

[0008] According to another aspect of the present disclosure, the coating system further includes a coating including an appearance surface.

[0009] According to another aspect of the present disclosure, the coating system further includes a coating including an appearance surface having a surface roughness of 15 to 35 micrometers average roughness (Ra) / area average roughness (Sa).

[0010] According to another aspect of the present disclosure, the coating system further includes a coating including an appearance surface having a surface roughness, the surface roughness being surface patterned with a matte finish.

[0011] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles having high bonding strength and high heat dissipation capability.

[0012] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles having a stack angle of 30° to 160° and a thermal conductivity greater than 0.3 Watts per meter-Kelvin (W / mK).

[0013] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles, wherein the functionalized particles are at least one of an organic conductive additive or an inorganic conductive additive.

[0014] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles having a size of one nanometer to two micrometers.

[0015] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles, wherein the functionalized particles are graphene.

[0016] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles, wherein the functionalized particles are iron-based functionalized particles.

[0017] According to another aspect of the present disclosure, the coating system further includes a plurality of functionalized particles comprising plates.

[0018] According to another aspect of the present disclosure, the coating system further includes a coating in an alternating curvature configuration.

[0019] According to another aspect of the present disclosure, a vehicle propulsion system includes an engine having a manifold body and a coating system coupled to the manifold body. The coating system includes a coating disposed on the manifold body and a plurality of functionalized particles within the coating, the plurality of functionalized particles configured to dissipate local heat flux from the manifold body. At least a portion of the plurality of functionalized particles are aligned, at least a portion of the plurality of functionalized particles are sheets, and the plurality of functionalized particles have a thermal conductivity greater than 0.3 W / mK.

[0020] According to another aspect of the present disclosure, a method for forming a heat dissipation coating system is disclosed. The method includes applying a coating to a manifold body so that the coating adheres to the manifold body, wherein the coating includes a plurality of functionalized particles configured to dissipate local heat flux from the manifold body. The method also includes aligning at least a portion of the plurality of functionalized particles within the coating so that the portion of the plurality of functionalized particles has a stacking angle of 30° to 160°. In addition, the method includes curing the coating with the aligned plurality of functionalized particles.

[0021] According to yet another aspect of the present disclosure, applying the coating to the substrate includes at least one of painting, casting, injection molding, or additive manufacturing the coating.

[0022] According to yet another aspect of the present disclosure, aligning the plurality of functionalized particles includes applying a magnetic field to the plurality of functionalized particles.

[0023] According to yet another aspect of the present disclosure, a coating system includes a wavy surface pattern having ridges of equal width and height.

[0024] According to yet another aspect of the present disclosure, a coating system is configured to prevent color shift of the coating.

[0025] The above features and advantages and other features and advantages of the systems and methods of the present disclosure are apparent from the following detailed description, including the claims and exemplary embodiments, when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present disclosure can be more fully understood from the detailed description and accompanying drawings, in which:

[0027] Figure 1 is an environmental view showing an example of a vehicle propulsion system having a substrate with a coating system configured to dissipate localized heat flux from the substrate (eg, a manifold body) according to the present disclosure.

[0028] Figure 2A According to the present disclosure Figure 1 A side cross-sectional view of a coating system is shown, illustrating a coating system including a coating having a plurality of aligned functionalized particles.

[0029] Figure 2B is a side cross-sectional view of a coating system including a coating having a plurality of non-aligned functionalized particles according to the present disclosure.

[0030] Figure 3A is a side cross-sectional view of first and second functionalized particles aligned in a linear arrangement according to the present disclosure.

[0031] Figure 3B is a side cross-sectional view of a first functionalized particle and a second functionalized particle aligned in an overlapping arrangement having a stacking angle according to the present disclosure.

[0032] Figure 4A According to the present disclosure Figure 1 2 , wherein the coating system is undeformed, comprises aligned functionalized particles, and is configured in a wavy pattern having ridges and valleys of equal width and height.

[0033] Figure 4B According to the present disclosure Figure 2BA top view of a coating system is shown, wherein the coating system is deformed, does not include aligned functionalized particles, and is configured to exhibit a wavy pattern of ridges and valleys of inconsistent width and height.

[0034] Figure 5 According to the present disclosure Figure 1 A flow chart of a method for forming a heat dissipation coating system is shown, wherein the coating system includes a coating having a plurality of aligned functionalized particles. DETAILED DESCRIPTION

[0035] Reference will now be made in detail to several embodiments of the present disclosure as illustrated in the accompanying drawings. Whenever possible, the same or similar reference numerals are used in the drawings and the description to refer to the same or similar parts or steps.

[0036] Figure 1 A vehicle propulsion system 10 according to an exemplary embodiment is shown. The vehicle propulsion system 10 may include an engine 12, for example, an automotive internal combustion engine configured to provide power to a vehicle (not shown). When configured as an internal combustion engine, the engine 12 can release energy and / or heat. However, as used herein, the terms "vehicle" and "engine" are not limited to automobiles. Although the present technology is primarily described herein in conjunction with automobiles, the technology is not limited to automobiles. These concepts can be used in a variety of applications, such as aircraft, ships, other vehicles, as well as hospitals, health care and medical facilities, fuel cells, and consumer electronic components.

[0037] In addition, if Figure 1 As shown, the vehicle propulsion system 10 may include a substrate 14 (e.g., a manifold body, a fuel cell housing, etc.). In the case where the substrate 14 is a manifold body, the manifold body may include a vehicle intake manifold or an engine inlet manifold that distributes air to the cylinders of the vehicle engine 10. Additionally, in some cases, the manifold body may include a fuel injector and / or may draw a fuel-air mixture from a carburetor and / or a throttle body into a cylinder head. In these embodiments, the manifold body may include at least one of a metal or a plastic and may be integrated with holes for air flow. Heat and / or energy from the engine (e.g., from a combustion reaction) may be conducted through the substrate 14 and / or the manifold body.

[0038] Figure 1Also shown is a coating system 16 (e.g., a surface patterned heat dissipating coating system) disposed on the substrate 14. The coating system 16 can be configured to dissipate heat from the engine 12 and conduct a localized heat flux 18 away from the substrate 14. In some cases, the coating system 16 may be exposed to high temperatures and / or high humidity in the vehicle engine 10, which may make the surface characteristics of the coating system difficult to control. Because the coating system 16 can be configured to dissipate heat and energy from the substrate 14, the surface characteristics of the coating system 16 can be better controlled and deformation can be minimized or prevented. It is contemplated that the coating system can be disposed on and / or as part of another component of the engine or system.

[0039] like Figure 2A As shown, the coating system 16 may include a coating 20 having a plurality of functionalized particles 22, wherein the coating 20 is disposed on the substrate 14. The coating 20 may include, for example, an epoxy and / or phenolic coating, a polyester coating, an elastomeric coating, and / or a thermal spray coating. For example, the coating 20 may include a polymer-based automotive engine coating configured to adhere to the substrate 14 (e.g., a manifold body).

[0040] In addition, the coating 20 may include a surface pattern and / or an appearance surface. For example, the surface pattern and / or appearance surface may appear shiny, have a matte finish (e.g., lack of gloss), etc., and may include surface roughness and surface tension. In a specific embodiment, the surface roughness of the coating 20 ranges from 15-35 microns average roughness (Ra) / area average roughness (Sa). Figure 2A The illustrated embodiment, shown in a partial side cross-sectional view, shows a coating 20 having a surface appearance and surface roughness configured as a corrugated pattern, wherein the corrugated pattern comprises an undulating surface including alternating ridges 24 and valleys 26 having a uniform width W and / or an alternating curvature configuration. Figure 2A In the particular embodiment shown, the alternating ridges 24 and valleys 26 have a consistent pattern in width W and / or height H, which is a result of the heat dissipation properties of the coating system 16. In this embodiment, the surface pattern can be determined and simulated by the morphology-driven surface of the substrate 14 through the manifold body (having a rough surface). It should be understood that the coating 20 can also be configured with other surface pattern configurations.

[0041] like Figure 2AAs shown, the coating system 16 may include a plurality of functionalized particles 22 (e.g., micro-heat reflectors) disposed in a channel along the length of the coating 20, wherein at least a portion of the functionalized particles 22 are aligned and / or connected. The channel may include a path 28 along the length of the coating 20 between an inner surface 30 of the coating (e.g., a surface proximate to the substrate 14) and an outer surface 32 of the coating (e.g., a surface distal to the substrate 14). The path 28 may be linear (e.g., generally along a single axis) or may be non-linear (e.g., along multiple axes in a wavy pattern, e.g., in a corrugated configuration of the coating 20).

[0042] exist Figure 2A In the illustrated embodiment, the functionalized particles 22 can be configured as plates (e.g., rectangles, squares, and / or sheets). In addition, the functionalized particles 22 may include other forms. For example, the functionalized particles 22 may be disks, cylinders, tubes, rectangles, and the like. A plurality of functionalized particles 22 may be formed of different materials configured to conduct and / or dissipate heat and energy, such as organic / inorganic additives (such as graphene metal additives, for example, iron or iron-based additives, such as iron alloys, steel, and the like). Some specific examples of the functionalized particles 22 include graphene oxide, zinc oxide, copper oxide, zinc phosphate, and metal hydrated phosphates. In addition, the size of the functionalized particles 22 may vary, for example, ranging from one nanometer to two microns in size. In some embodiments, the size of the functionalized particles 22 may be consistent (e.g., typically about 0.5 microns), and in other embodiments, the functionalized particles 22 may include varying sizes (e.g., half are 0.5 microns and half are 0.3 microns). In addition, the functionalized particles may be disposed within the coating 20, such as Figure 2A As shown, partly within the coating 20 , partly outside the coating 20 , and / or on the surface of the coating 20 .

[0043] Figure 2B An embodiment of a coating system 16 is shown that includes a coating 20 having a plurality of non-aligned functionalized particles 22. These functionalized particles 22 are arranged in random directions and generally do not touch or contact other functionalized particles. Figure 2A This arrangement does not provide good energy and heat dissipation compared to the configuration depicted in , at least because of the lack of thermal conductivity between each functionalized particle and the low efficiency of heat reflection. Figure 2B In the configuration shown, the coating 20 is deformed.

[0044] like Figure 3AAs shown, each functionalized particle 22 can touch and / or contact another functionalized particle 22 in a linear configuration, for example, where the end of the first functionalized particle 34 only touches the end of the second functionalized particle 36. For example, when the first functionalized particle 34 touches and / or contacts the second functionalized particle 36 in a generally longitudinal direction, and the third functionalized particle 38 can touch and / or connect to the second functionalized particle 36 in a repeating longitudinal direction, and touch and / or connect to other multiple functionalized particles 22, aligned functionalized particles 22 can occur, so that energy and heat can be conducted between each functionalized particle 22 and dissipated and / or reflected from the substrate 14 and the coating system 16.

[0045] In other cases, such as Figure 3B As shown, the functionalized particles 22 can be aligned and contact each other in an overlapping configuration, and can include a stacking angle θ (e.g., between 30° and 160°, vertical, etc.) between each functionalized particle 22, wherein the stacking angle θ can include an angle located at the longitudinal axis A of the first functionalized particle. 1 and the longitudinal axis A of the second functionalized particle 2 In one specific instance, the functionalized particles 22 may include a stack angle θ of 30° to 160°. It is contemplated that the functionalized particles 22 may include other stack angles, such as less than 30°, including 0°.

[0046] In addition, the functionalized particles 22 may have high thermal conductivity, high bonding strength, and / or high heat dissipation capabilities. In certain instances, the functionalized particles 22 may include a thermal conductivity of 0.3 Watts per meter-Kelvin (W / mK) or greater. The aligned functionalized particles 22 may be used to effectively dissipate local heat flux 18 from the substrate 14 (e.g., the manifold body), which may be used to prevent and / or minimize deformation of the coating 20 (e.g., color deformation or color shift, thermal bonding strength of the coating 20 to the bonding interface 40, uniformity of diffraction, and / or surface pattern).

[0047] In a specific embodiment, having Figure 2A The coating system 16 with aligned functionalized particles 22 shown was placed at a similar temperature of 120° C. for about 168 hours without causing any change in the color or surface pattern of the coating system 16. Figure 2B The coating system 16 with the random and non-aligned functionalized particles 22 in the illustrated arrangement, placed at a temperature of 120° C. for approximately 168 hours, resulted in deformation of the color and surface pattern of the coating system 16. The first embodiment illustrates that the addition of aligned functionalized particles 22 to the coating system 16 results in more efficient heat dissipation from the coating system 16 and minimizes deformation of the coating system 16.

[0048] Figure 4A and Figure 4BA plan view embodiment of a surface pattern 42 of a coating system 16 is shown. Figure 4A In the figure, it is shown that according to Figure 2A A plan view of the surface pattern 42 of the illustrated embodiment wherein the functionalized particles 22 are aligned. In this embodiment, the surface pattern 42 is not deformed and the width W between the ridges and / or valleys is uniform and consistent. This configuration results in diffraction uniformity and stable coloration of the coating system 16 on the surface pattern. Figure 4B Shown according to Figure 2B A plan view of the surface pattern 42 of the illustrated embodiment wherein the functionalized particles 22 are misaligned results in a distorted surface pattern having varying and inconsistent widths W. This configuration results in diffraction distortion and impaired coloration of the coating system 16 . Figure 4B The different widths of the surface pattern 42 shown indicate damage and deformation to the coating system 16 due to ineffective heat dissipation.

[0049] Figure 5 shows the method for forming Figures 1 to 2A and Figures 3A to 4A A method 100 of coating system 16 is shown.

[0050] Step 102 depicts applying a coating 20 to a substrate 14, wherein the coating 20 includes a plurality of functionalized particles 22, and the plurality of functionalized particles 22 are configured to dissipate local heat flux from the substrate 14 (e.g., a manifold body). Applying the coating 20 may include methods such as painting, casting, injection molding, and / or additive manufacturing. In one embodiment, the coating 20 may be applied to the substrate 14 using a brush or by spraying a vehicle paint onto the vehicle manifold body. In another embodiment, the coating 20 may be applied to the substrate 14 using a casting (e.g., spin casting) process, wherein the coating 20 is poured into a casting mold, such as a disc-shaped mold, which rotates along its central axis and at a set speed. In some cases, the coating 20 may be cured in the mold and then bonded to the substrate 14. It is contemplated that other types of casting may be used. In yet another embodiment of applying the coating 20, the coating 20 may be applied to the substrate 14 using an injection molding process, wherein the coating 20 is injected into a mold having a desired configuration. In another embodiment, the coating 20 may be applied to the substrate 14 using an additive manufacturing process (e.g., 3D printing). In this particular embodiment, the coating 20 may be applied to the substrate 14 in a single layer or multiple layers at a time. It is contemplated that other types of application processes may be used to apply the coating 20.

[0051] In some cases, such as in the case of painting, spin casting, injection molding, and / or additive manufacturing, a coating 20 comprising a plurality of functionalized particles 22 may be applied. In other cases, a plurality of functionalized particles 22 may be added to the coating 20 after the coating 20 is applied. For example, the coating 20 may be sprayed onto the substrate 14, and then the functionalized particles 22 may be added to the coating 20, such as by spraying or otherwise depositing the functionalized particles 22 into or onto the coating 20.

[0052] Step 104 describes aligning the plurality of functionalized particles 22. Aligning the plurality of functionalized particles 22 may include bringing a portion of the functionalized particles 22 into contact with each other in a longitudinal configuration, such as Figure 2A and / or Figure 2B In one embodiment, aligning the plurality of functionalized particles 22 may include using a magnetic field from a magnet to cause the iron-based and / or steel-based functionalized particles 22 to align with each other and along the magnetic field. In another embodiment, aligning the plurality of functionalized particles 22 may include spin coating a coating 20 containing the functionalized particles 22, wherein the centrifugal force caused by the rotation of the spin coating acts on the functionalized particles 22, causing them to align with each other in a longitudinal configuration. It is contemplated that other methods may be used to align the functionalized particles 22.

[0053] Step 106 shows curing the coating 20. Curing the coating 20 may include causing the coating 20 to at least partially harden and / or become solid. For example, curing the coating 20 may include curing the coating 20 by applying a vehicle paint curing agent. In other embodiments, curing the coating 20 may include drying the coating 20 using air and / or heat convection and / or exposing the coating 20 to light (e.g., ultraviolet light).

[0054] This specification is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific embodiments, the true scope of the present disclosure should not be limited thereto, as other modifications will become apparent after studying the drawings, the specification and the appended claims.

Claims

1. A coating system comprising: a coating disposed on a substrate; as well as A plurality of functionalized particles within the coating, the plurality of functionalized particles configured to dissipate a localized heat flux from a substrate, wherein at least a portion of the plurality of functionalized particles are aligned.

2. The coating system according to claim 1, wherein: The substrate is at least one of metal or plastic and is integral with holes for airflow.

3. The coating system according to claim 2, wherein: The substrate is a vehicle intake manifold.

4. The coating system according to claim 1, wherein: The coating includes an exterior surface.

5. The coating system according to claim 4, wherein: The surface roughness of the exterior surface is 15 to 35 micrometers Ra / Sa.

6. The coating system according to claim 5, wherein: The surface roughness can be surface patterned with a matte finish.

7. The coating system according to claim 1, wherein: The plurality of functionalized particles includes at least one of zinc oxide, copper oxide, zinc phosphate, or a metal hydrated phosphate.

8. The coating system according to claim 1, wherein: The plurality of functionalized particles comprises a stack angle of 30° to 160° and a thermal conductivity greater than 0.3 W / mK.

9. The coating system according to claim 1, wherein: The plurality of functionalized particles includes at least one of an organic conductive additive or an inorganic conductive additive.

10. The coating system according to claim 1, wherein: The plurality of functionalized particles have a size of 1 nanometer to 2 micrometers.

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