Epoxy KTL Coating for PU-Metal Bonding in Damping Elements
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Solution Overview
Problem
Current damping elements, particularly those with hybrid systems of plastic and metal components, face limitations due to insufficient bonding between plastic and metal elements, leading to adhesive detachment under tensile shear forces, which complicates production and increases costs.
Innovation Solution
A composite element comprising a metallic body with an epoxy resin coating and a polyurethane enclosure, where the epoxy resin acts as both a corrosion protection and adhesion promoter, eliminating the need for additional adhesion promoters and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an electroplated zinc-iron or zinc-nickel coating is applied for corrosion protection, then corrosion resistance is improved, but adhesion between plastic and metal is insufficient leading to adhesive detachment
Solution Approach 1:
The patent combines corrosion protection and adhesion promotion into a single coating layer. The epoxy resin coating is applied over the electroplated zinc-iron or zinc-nickel layer, merging the protective function of the metal coating with the adhesive function of the epoxy resin, thereby eliminating adhesive detachment while maintaining corrosion resistance
Solution Approach 2:
The epoxy resin coating acts as an intermediary layer between the electroplated metal coating and the plastic body. This intermediate layer provides the necessary adhesion strength to prevent detachment while allowing the underlying metal coating to maintain its corrosion protection function
2Strength
If a standard wet-chemical adhesion promoter is applied to the corrosion protection layer, then adhesion is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges the adhesion promoter function with the corrosion protection coating by applying the epoxy resin coating directly over the electroplated layer. This eliminates the need for a separate adhesion promoter application step, reducing manufacturing complexity while maintaining strong adhesion
Solution Approach 2:
The epoxy resin coating serves multiple functions simultaneously: it provides adhesion promotion for the plastic body, maintains corrosion protection by sealing the metal coating, and can be applied in a single step using cathodic dip coating, thereby reducing the number of process steps
3Strength
If an adhesion promoter is applied partially to keep screw-on surfaces clear, then adhesion is maintained, but the application process becomes complex and expensive
Solution Approach 1:
The epoxy resin coating provides universal coverage across the entire metal component surface, including areas with screw-on surfaces. The coating formulation and application process are designed to accommodate threaded surfaces without requiring selective masking or partial application, thereby simplifying manufacturing
Solution Approach 2:
The patent modifies the coating application parameters by using cathodic dip coating, which allows the coating to be applied uniformly across complex geometries including threaded surfaces. This electrochemical application method changes the deposition parameters to achieve complete coverage without the need for selective application
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 plastic and metal bodies, improving the load-bearing capacity of damping elements while reducing production costs and complexity, and can be applied economically using methods like dipping.
Implementation Method 1
The epoxy resin acts as both a corrosion protection and adhesion promoter, eliminating the need for additional adhesion promoters
Implementation Method 2
a composite element has a conversion layer (d) between the surface of the metallic body (a) and the coating (b), which comprises at least one compound selected from the group consisting of zirconium(IV) oxide, zinc(II) phosphate and chromate
Data Source
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AI summary
The present invention relates to a composite element, in particular for a damping element, comprising: a) at least one metal body having an upper surface; b) a coating comprising an epoxy resin on at least one portion of the surface of the metal body; c) a plastic body comprising at least one polyurethane which encloses at least part of the metal body according to (a) and at least part of which, in the region of said enclosure, is in direct contact with the coating according to (b), wherein the composite element has a conversion coating (d) between the surface of the metal body (a) and the coating (b), said conversion coating comprising at least one compound selected from the group consisting of zirconium(IV) oxide, zinc(II) phosphate, and chromate. The invention also relates to a damping element comprising the composite element and at least one additional body, at least part of which is in direct contact with the composite element, preferably with the plastic body according to (c). The invention also relates to manufacturing methods for the composite element and the damping element, the composite or damping elements which are manufactured or can be manufactured according to said method, and the use of said composite or damping elements.