Ceramic-Bonded Fiber Reinforced Plastic for Wear and Corrosion Isolation
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Solution Overview
Problem
Fiber reinforced plastic objects face challenges with low wear resistance and adhesion issues when in contact with other parts, particularly due to galvanic corrosion when electrically conductive carbon fibers come into contact with aluminum.
Innovation Solution
A ceramic material with high porosity on the surface facing the fiber reinforced plastic and decreasing porosity towards the opposite side is applied using plasma electrolytic oxidation, forming a strong bond and preventing galvanic corrosion, while also enhancing wear resistance with a hard surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ceramic layer is applied on fiber reinforced plastic to improve wear resistance, then wear resistance is improved, but adhesion between the ceramic layer and fiber reinforced plastic deteriorates
Solution Approach 1:
The patent applies a porous ceramic layer with controlled porosity (5-50%) on the fiber reinforced plastic surface. The porous structure increases surface area and creates mechanical interlocking, significantly improving adhesion between the ceramic coating and the substrate while maintaining wear resistance. The porosity is achieved through controlled formation processes that create a network of pores within the ceramic layer.
Solution Approach 2:
The patent creates a composite structure combining fiber reinforced plastic with a ceramic layer. This composite material approach allows integration of materials with complementary properties: the fiber reinforced plastic provides structural strength and toughness, while the ceramic layer provides wear resistance. The interface between these materials is optimized through surface treatment and controlled bonding mechanisms.
2Reliability
If carbon fiber reinforced plastic contacts aluminum directly to achieve electrical conductivity, then electrical conductivity is improved, but galvanic corrosion increases
Solution Approach 1:
The patent introduces a ceramic layer as an intermediary barrier between the carbon fiber reinforced plastic and aluminum components. This ceramic intermediate layer is electrically insulating but provides a controlled interface that prevents direct galvanic contact between dissimilar metals and conductive fibers, thereby eliminating galvanic corrosion while allowing the system to maintain its electrical properties through alternative pathways.
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 solution achieves excellent adhesion and significantly improved wear resistance by forming a hard, insulating ceramic layer between the fiber reinforced plastic and aluminum, preventing galvanic corrosion and providing a durable surface.
Implementation Method 1
wherein the inner layer of ceramic material is prepared by plasma electrolytic oxidation of the metal layer
Data Source
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AI summary
The invention relates to an object comprising a. a fiber reinforced plastic (1) and b. a ceramic material (2, 4), wherein the ceramic material is prepared by plasma electrolytic oxidation of aluminium (3). The invention further relates to a process for the preparation of the object, comprising the steps of a. Providing aluminium (3), a fiber reinforced plastic (1) and a resin, or providing aluminium (3) and a precursor of a fiber reinforced plastic (1) comprising fibers and a resin, b. Treating, at least partially, the aluminium (3) with plasma electrolytic oxidation to provide a ceramic material (2,4), c. Attaching the ceramic material to the fiber reinforced plastic with the resin, or attaching the ceramic material to the fibers with the resin, d. Curing the resin to provide the object comprising the fiber reinforced plastic and the ceramic material at least partly bound to the fiber reinforced plastic.