Acidic Phosphate Ester Coating for Flexible Wire Corrosion Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing metal surface coating technologies require heat treatment, are prone to cracking, and may interfere with electrical contacts, while those without heat treatment lack sufficient adhesion and are temporary in nature, failing to provide effective corrosion protection for metal surfaces, especially in electrical and electronic components.
Innovation Solution
A composition comprising an adduct of acidic phosphate ester and a metal, where the acidic phosphate ester is represented by General Formulae (1) and (2), and a base oil, which forms an ionically bonded coating that adheres strongly to metal surfaces without requiring heat treatment, ensuring flexibility and long-term corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat treatment is applied to form a coating, then mechanical strength and sliding properties are improved, but the coating becomes prone to cracking and peeling when the metal member is deformed
Solution Approach 1:
The invention changes the chemical composition parameters of the coating by incorporating specific additives (polyol, polyester, carboxylic acid) into the polyamide resin system. This modifies the coating's molecular structure to achieve optimal balance between mechanical strength and flexibility, preventing cracking while maintaining hardness and sliding properties.
Solution Approach 2:
The invention creates a composite coating material by combining polyamide resin with multiple functional additives (polyol, polyester, carboxylic acid). This composite structure integrates the strength of polyamide with the flexibility and adhesion properties of the additives, resolving the contradiction between hardness and deformation resistance.
2Force
If a phosphate conversion coating is formed to reduce friction, then sliding properties are improved, but the coating differs fundamentally from oil-based coatings and may not provide sufficient corrosion protection
Solution Approach 1:
The invention merges the advantages of phosphate conversion coatings (low friction) with oil-based coatings (corrosion protection) by incorporating friction-reducing additives into the polyamide resin system. This creates a unified coating that provides both lubrication and corrosion protection without requiring separate coating layers.
Solution Approach 2:
The polyamide resin coating is designed to perform multiple functions simultaneously: providing mechanical strength, reducing friction through embedded lubricants, preventing corrosion via rust inhibitors, and ensuring good adhesion. This multi-functional coating eliminates the need for separate specialized coatings.
3Stability of the object's composition
If oil-based coating is applied without heat treatment, then flexibility and adhesion are improved, but the coating lacks sufficient mechanical strength and durability
Solution Approach 1:
The invention modifies the physical and chemical parameters of the oil-based coating by selecting specific polyamide resins with appropriate molecular weights and incorporating cross-linking agents. These parameter changes enhance the coating's mechanical strength while preserving its flexibility and adhesion properties.
Solution Approach 2:
The invention creates a composite material system combining polyamide resin (providing strength and adhesion) with oil-based lubricants (providing flexibility and corrosion protection). This composite structure achieves both flexibility and mechanical strength without requiring heat treatment.
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 composition provides a flexible, durable, and heat-resistant coating that maintains adhesion and corrosion protection over time, even under high temperatures and humidity, without peeling off from the metal surface, and is suitable for electrical components.
Implementation Method 1
forms an ionically bonded coating that adheres strongly to metal surfaces
Data Source
AI summary
A composition for a metal surface coating that does not require a posttreatment such as heating, has flexibility to be able to follow deformation of a member to be coated, hardly peels off from a metal surface, and can be used for the purpose of corrosion protection, and a terminal-equipped covered electric wire using the same. The composition contains an adduct and a base oil. The adduct contains an acidic phosphate ester consisting of one or more kinds of compounds represented by General Formulae (1) and (2), and a metal, P(═O)(—OR1)(—OH)2 . . . (1), P(═O)(—OR1)2(—OH) . . . (2), where R1 represents a hydrocarbon group having 4 to 30 carbon atoms.