Epoxy Pore-Sealing Agent for Thermally Sprayed Bearings

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Solution Overview

Problem

Conventional pore-sealing methods for thermally sprayed materials fail to effectively permeate and fill pores, leading to poor adhesion and environmental intercepting performance, which results in corrosion, insulation failure, and reduced adhesive strength over time.

Innovation Solution

A pore-sealing agent containing a monoglycidyl ether compound with 3.0 to 4.0 mmol of epoxy groups and diethylglutaric anhydride as a hardener, which permeates deeply into the spray deposit, forming a three-dimensional reticulate structure that enhances adhesion and maintains performance even after grinding or high-temperature exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a pore-sealing agent containing synthetic resin dissolved in organic solvent is applied to the surface of the spray deposit, then the surface is sealed, but the agent does not permeate to the bottom of pores and the sealing effect is lost after grinding or abrasion

Engineering Contradiction:

Improvepore-sealing effectVSAvoidconfiguration accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the physical and chemical parameters of the pore-sealing agent by using epoxy resin with specific viscosity (50-5000 cP) and epoxy group content (3.0-4.0 mmol/g), along with specific hardeners, to achieve deep pore penetration while maintaining surface sealing effectiveness even after grinding

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite pore-sealing system by combining epoxy resin with specific hardeners (acid anhydride, amine compound, or imidazole) and optional additives, forming a multi-component system that achieves both deep penetration and durable sealing

Inventive Principle:

Principle #40Composite materials

2Strength

If the spray deposit surface is modified to increase roughness for better adhesion, then adhesive strength improves, but dimensional accuracy deteriorates and insufficient firing occurs

Engineering Contradiction:

Improveadhesive strengthVSAvoiddimensional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies the pore-sealing agent to the spray deposit surface before final grinding operations, allowing the sealing material to penetrate and set in advance, so that subsequent grinding does not remove the sealing layer

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pore-sealing agent acts as an intermediary substance that chemically bonds to both the spray deposit surface and the base material, creating a strong adhesive bridge without requiring extensive surface modification

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conventional pore-sealing agents are used, then surface sealing is achieved, but the agents wear away during use and the sealing effect does not continue for a long time

Engineering Contradiction:

Improveenvironmental intercepting performanceVSAvoidsealing effect duration

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent modifies the chemical composition parameters by using epoxy resin with specific molecular weight and crosslinking density, controlled through epoxy group content and hardener selection, creating a more wear-resistant sealing layer

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent forms a composite cured resin system through chemical reaction between epoxy resin and hardeners, creating a crosslinked network structure that provides superior wear resistance and long-term durability compared to simple synthetic resin coatings

Inventive Principle:

Principle #40Composite materials

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 provides excellent permeability and pore-filling performance, significantly improving the adhesion and insulation resistance of thermally sprayed materials, preventing corrosion and insulation failure, and maintaining mechanical and electrical properties over time.

Implementation Method 1

the pore-sealing agent is merely applied to the surface of the spray deposit and does not permeate to the bottom of pores

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

forming a three-dimensional reticulate structure that enhances adhesion

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP2009145B1Sealer, members covered with sprayed coatings, and bearings

Publication Date: 2017.11.15 NTN CORP

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AI summary

The present invention provides a pore-sealing agent and a member of coating a spray deposit. The pore-sealing agent is excellent in permeability into pores (gaps) of a spray deposit and can be favorably filled thereinto and is capable of sealing pores until a state in which gaps in a spray deposit material are substantially entirely filled is obtained. The pore-sealing agent contains an epoxy group-containing component and a hardener and does not contain a polymerizable vinyl group-containing solvent. The epoxy group-containing component is a mixture containing a polyglycidyl ether compound in which the number of epoxy groups contained in one molecule is not less than three as an essential component thereof and in addition, an alkylenediglycidyl ether compound or a cyclic aliphatic diepoxy compound, both of which contain two epoxy groups in one molecule thereof. Excluding the hardener, the mixing ratio of the polyglycidyl ether compound to the epoxy group-containing component of the mixture is 10 to 95 wt%.