Alloy Wheel Plasma Coating for Corrosion and Chip Resistance
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Solution Overview
Problem
Existing methods for coating cast alloy wheels are laborious and fail to provide the desired durability, particularly on the face of the wheel, while being cost-prohibitive and not meeting consumer expectations.
Innovation Solution
A method involving a plasma jet treatment is applied to the surface of the alloy wheel, forming an alloy oxide and enhancing the surface energy, followed by a polymeric coating to improve adhesion and durability, reducing the number of process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conversion coating and multiple paint layers are applied to alloy wheels, then corrosion resistance is improved, but the coating is still susceptible to chipping and abrasion failure
Solution Approach 1:
The patent changes the chemical composition and structure of the conversion coating by controlling the alloy chemistry (specific elements and their ranges) and heat treatment parameters (temperature, time, atmosphere) to create a more durable coating structure that resists both corrosion and chipping
Solution Approach 2:
The patent creates a composite coating system consisting of a conversion coating layer with specific chemical composition combined with polymeric paint layers, where the conversion coating serves as an enhanced primer that improves adhesion and durability of the entire coating system
2Reliability
If multiple coating steps including conversion coating and multiple paint layers are used, then coating durability is improved, but the process becomes exceedingly laborious and costly
Solution Approach 1:
The patent combines the conversion coating step with the paint application process by applying the polymeric paint coating immediately after conversion coating while the coating is still warm, eliminating separate drying and handling steps between layers
Solution Approach 2:
The patent performs preliminary heat treatment of the wheel before coating application to optimize surface properties and promote better coating adhesion, and applies subsequent coatings while the previous layer is still warm to enhance inter-layer bonding
3Reliability
If conventional conversion coating processes are used, then paint adhesion is improved, but the cost of maintenance and operation becomes increasingly prohibitive
Solution Approach 1:
The patent optimizes conversion coating parameters including chemical composition, temperature, and time to achieve maximum paint adhesion with minimal material usage and processing cost, eliminating the need for expensive additional treatment steps
Solution Approach 2:
The patent enables the conversion coating process to self-optimize by controlling the alloy chemistry and heat treatment parameters that automatically promote better paint adhesion without requiring additional expensive chemicals or post-treatment steps
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 enhances durability by preventing corrosion and chipping, achieving superior results in tests like filiform testing and gravelometer tests, with no chipping observed and improved multi-layer coating adhesion.
Implementation Method 1
A nozzle element for projecting a plasma jet toward the wheel is provided. The plasma jet is projected toward the smooth surface of the face, toward the edge, and toward at least a portion of the recessed surfaces forming an alloy oxide
Data Source
AI summary
An alloy wheel is formed having a three dimensional configuration defining a face and recessed surfaces. The face of the wheel is machined providing a smooth surface at the face and defining an edge between the smooth surface of the face and the recessed surfaces. A nozzle element for projecting a plasma jet toward the wheel is provided. The plasma jet is projected toward the smooth surface of the face, the edge, and toward at least a portion of the recessed surfaces forming an alloy oxide at least on the face and the edge disposed between the face and the recessed surfaces. A first polymeric coating is applied over the face, the recessed surfaces and the edge disposed between the face and the recessed surfaces.