Electroplated Phosphate Adhesive Coating for Corrosion-Resistant Wire Bonding
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Solution Overview
Problem
Current methods for adhering conductive wire elements to elastomeric matrices in tires and belts either require halogenated polymers and metal oxides or surface treatments like brass coating, which limit compatibility with various elastomeric matrices and increase the risk of corrosion and pre-vulcanization.
Innovation Solution
A process involving electroplating a phosphate salt-based adhesive composition onto conductive elements, using compounds with hydroxymethyl and aldehyde functions, to create a passivation layer ensuring strong adhesion and corrosion resistance without specific elastomer or halogenated polymer requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If RFL adhesive is used to make steel wires adhere to elastomeric matrices, then good adhesion is achieved without surface treatment, but the adhesive requires halogenated polymer, metal oxide, and specific acrylic rubber composition
Solution Approach 1:
The invention extracts and eliminates the restrictive components (halogenated polymer and metal oxide) from the adhesive system while retaining the core adhesion mechanism. The new adhesive composition uses only phenolic resin and diene elastomeric latex, removing the need for specific elastomeric matrix requirements and enabling universal compatibility.
Solution Approach 2:
The simplified adhesive composition achieves universal applicability across different elastomeric matrices by removing specialized components. The phenolic resin-based adhesive can now be used with any elastomeric matrix without requiring specific acrylic rubber compositions, achieving multi-functionality and broad compatibility.
2Reliability
If steel wires are coated with brass to adhere to elastomeric matrices, then effective adhesion is achieved, but the process requires high sulfur content elastomeric matrix which has limited shelf life due to pre-vulcanization risk
Solution Approach 1:
The invention eliminates the need for brass surface treatment and high sulfur content additives by using a phenolic resin-based adhesive system. This removes the cause of pre-vulcanization issues while maintaining effective adhesion between steel wires and elastomeric matrices.
Solution Approach 2:
The phenolic resin-based adhesive acts as an intermediary substance between the steel wire and elastomeric matrix, providing the adhesion function without requiring reactive sulfur compounds that cause pre-vulcanization. This mediator enables adhesion while preserving the stability and shelf life of the elastomeric matrix.
3Manufacturing precision
If electroplating process is used to coat adhesive composition onto conductive elements, then better coverage and uniformity are achieved, but additional equipment and process complexity are required
Solution Approach 1:
The invention replaces complex electroplating equipment with a simpler dip-coating or spray-coating process. By optimizing the adhesive composition itself (phenolic resin with controlled viscosity and solids content), the process achieves sufficient coverage uniformity without requiring electrical fields or electroplating infrastructure.
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 process enhances the service life of composites by improving adhesion and corrosion resistance, particularly under wet conditions, without the need for specific elastomeric matrices or surface treatments.
Implementation Method 1
a process for electroplating an adhesive composition onto at least one conductive element
Implementation Method 2
a potential difference is applied between the conductive element and the adhesive composition so as to coat the conductive element with an adhesive layer
Data Source
AI summary
The present invention relates to a process for electroplating an adhesive composition onto at least one conductive element, in which the conductive element is placed in contact with the adhesive composition comprising: a phosphate salt and a resin based on: a compound A1, compound A1 being chosen from a compound A11 comprising at least two functions, one of these functions being a hydroxymethyl function and the other being an aldehyde function or a hydroxymethyl function, or a compound A12 comprising at least one aldehyde function, or a mixture of a compound A11 and of a compound A12; and a phenol A21. A potential difference is applied between the conductive element and the adhesive composition to coat the conductive element with an adhesive layer.