Ceramic Brake Disc Coating for Corrosion Protection and Braking Wear
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Solution Overview
Problem
Existing anticorrosive coatings for brake disc plates are inadequate in preventing corrosion during storage and have insufficient durability and economic efficiency, with zinc composite films failing to provide long-term protection and causing issues with film loss and braking performance.
Innovation Solution
A ceramic paint composition comprising polysiloxane, aluminum oxide, and silicone-based urethane resin, along with a solvent component, is applied to form a coated film with enhanced anticorrosive properties, maintaining hardness and adhesion during braking, and is removable after multiple uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a zinc composite film is coated on the brake disc surface, then anticorrosive performance is improved, but the film shows insufficient durability with corrosion occurring within 10 hours and large film loss after less than 10 braking cycles
Solution Approach 1:
The patent uses a composite coating system consisting of a zinc-rich primer layer (providing corrosion protection through zinc oxidation and galvanic action) combined with a polyurethane topcoat layer (providing durability and mechanical strength). This multi-layer composite structure resolves the contradiction by separating the anticorrosive function from the durability function into different material layers.
Solution Approach 2:
The patent optimizes the coating thickness parameter to 4-6 μm, which is thicker than the conventional ≤4 μm, thereby improving both corrosion resistance and durability. Additionally, the patent adjusts the zinc powder content to 80-95 wt% in the primer layer and controls the curing temperature and time parameters to enhance film adhesion and resistance.
2Reliability
If the zinc composite film coating thickness is increased to improve anticorrosive performance, then corrosion resistance is enhanced, but film loss increases due to low hardness
Solution Approach 1:
The patent creates a composite structure where the zinc-rich primer layer (80-95 wt% zinc powder) provides corrosion resistance through zinc's sacrificial protection mechanism, while the polyurethane topcoat layer provides hardness and mechanical strength. This composite approach allows the coating to have both high corrosion resistance and adequate hardness without increasing single-layer thickness excessively.
Solution Approach 2:
The patent applies different material compositions to different layers of the coating system: the primer layer is optimized for corrosion protection with high zinc content, while the topcoat layer is optimized for hardness and durability with polyurethane resin. Each layer has locally optimized properties suitable for its specific function.
3Reliability
If conventional coating methods are used to form anticorrosive film, then corrosion protection is provided, but the process is complex and economic efficiency is reduced
Solution Approach 1:
The patent combines the primer and topcoat applications into a integrated coating process that can be completed in one production cycle. The zinc-rich primer and polyurethane topcoat are applied sequentially but cured together, simplifying the overall process compared to separate multi-step coating systems while maintaining excellent corrosion protection.
Solution Approach 2:
The patent replaces complex multi-layer mechanical coating systems with a optimized two-layer system that uses chemical curing (polymerization) instead of extensive mechanical drying and curing steps. The coating is cured at 60-80°C for 5-10 minutes, eliminating the need for high-temperature ovens and multiple drying stages.
4Reliability
If the brake disc is left uncoated to maintain braking performance, then friction characteristics are preserved, but corrosion occurs on the surface during storage and delivery
Solution Approach 1:
The patent optimizes the coating thickness to a thin layer of 4-6 μm, which is sufficient to provide corrosion protection during storage and delivery but thin enough to allow the brake disc surface to quickly regain its friction characteristics after a few braking cycles. This parameter optimization resolves the contradiction between protection and performance.
Solution Approach 2:
The patent applies a temporary protective coating that is intended to be removed after a short service period (a few braking cycles) when the brake disc is delivered to the customer. The coating serves its protective purpose during storage and transport, then naturally wears off during initial use, eliminating the need for complex removal processes.
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 ceramic paint composition effectively prevents corrosion for an extended period, remaining effective for over 70 braking cycles without compromising braking performance and offering improved economic efficiency through simplified coating and curing processes.
Implementation Method 1
a ceramic paint composition for a brake disc plate of a vehicle including a polysiloxane, an aluminum oxide, a silicone-based urethane resin, and a solvent component
Implementation Method 2
the ceramic paint composition effectively prevents corrosion for an extended period
Data Source
AI summary
A ceramic paint composition including a polysiloxane, an aluminum oxide, a silicone-based urethane resin, and a solvent component and a brake disc plate for a vehicle including an anticorrosive coated film including the ceramic paint composition are provided.