Epoxy CED Coating for Metal-PU Adhesion in Damping Elements
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Solution Overview
Problem
Current damping elements with hybrid systems of plastics and metal components face challenges in maintaining robust connections under increasing forces, leading to partial or complete separation, which affects the damping performance and is economically inefficient due to the need for additional adhesion promoters and complex production processes.
Innovation Solution
A composite element comprising a metallic body with an epoxy resin coating and a polyurethane plastics body, where the epoxy resin acts as both a corrosion control and adhesion promoter, eliminating the need for additional adhesion promoters and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a zinc-iron coating (ZnFe) or zinc-nickel coating (ZnNi) is applied for corrosion protection, then corrosion resistance is improved, but adhesion between metal and plastics deteriorates under lap shear force
Solution Approach 1:
The patent combines corrosion protection and adhesion promotion into a single integrated coating layer. The epoxy resin coating is applied directly over the ZnFe or ZnNi corrosion protection layer, merging two previously separate functions (corrosion protection and adhesion) into one composite coating system that provides both protective and bonding capabilities simultaneously.
Solution Approach 2:
The invention uses a composite coating structure consisting of a metal substrate with corrosion protection layer (ZnFe or ZnNi) combined with an epoxy resin coating layer. This composite material system leverages the corrosion resistance of the metal coating and the adhesion properties of the epoxy resin to achieve both functions in one integrated solution.
2Strength
If an additional adhesion promoter is applied to the corrosion control layer, then adhesion between metal and plastics is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the corrosion protection layer and adhesion promoter into a single integrated coating system. Instead of applying separate layers of corrosion protection followed by adhesion promoter, the epoxy resin coating serves dual purposes: it provides the necessary adhesion to the underlying metal substrate while also serving as the final protective coating, thereby eliminating the need for additional adhesion promoter application steps.
Solution Approach 2:
The epoxy resin coating is designed to perform multiple functions simultaneously: it acts as both the adhesion promoter that bonds the plastics to the metal substrate and as the final corrosion protection layer. This multi-functional coating reduces the number of separate components and processing steps required in the manufacturing process.
3Strength
If an adhesion promoter is applied partially to preserve screw tightening faces, then adhesion is maintained in contact areas, but application difficulty and cost increase
Solution Approach 1:
The patent combines the corrosion protection function and adhesion promotion function into a single epoxy resin coating that can be applied uniformly across the entire metal surface. This eliminates the need for selective or partial application that would be required to preserve screw tightening faces, as the integrated coating system maintains adhesion properties without requiring complex application control.
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 epoxy resin coating enhances adhesion between metal and plastics, providing a more robust and economically viable damping element with improved durability and reduced production costs by integrating corrosion control and adhesion promotion in a single step.
Implementation Method 1
a coating comprising an epoxy resin on at least part of the surface of the metallic body... the epoxy resin acts as both a corrosion control and adhesion promoter
Implementation Method 2
a conversion layer (d) which comprises at least one compound selected from the group of zirconium(IV) oxide, zinc(II) phosphate, and chromate
Implementation Method 3
cathodic electrodeposition (CED) of metal components
Data Source
AI summary
The present invention relates to a composite element, especially for a damping element, comprising a) at least one metallic body having a surface; b) a coating comprising an epoxy resin on at least part of the surface of the metallic body; c) a plastics body comprising at least one polyurethane, which at least partly surrounds the metallic body of (a) and in the region of the surround is at least partly in direct contact with the coating of (b), wherein the composite element between the surface of the metallic body (a) and the coating (b) has a conversion layer (d) which comprises at least one compound selected from the group of zirconium(IV) oxide, zinc(II) phosphate, and chromate. The invention further relates to a damping element comprising the composite element and at least one further body which is at least partly in direct contact with the composite element, preferably with the plastics body of (c). The invention additionally relates to production processes for composite element and damping element, to the composite and damping elements, respectively, that are produced or producible by these processes, and the use of these composite and damping elements, respectively.