Frictional Connection Coating for High Grip and Corrosion Resistance
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Solution Overview
Problem
Existing frictional connections in machine, plant, and motor vehicle construction face challenges in achieving high static friction coefficients while maintaining corrosion resistance and requiring cost-effective, reliable pre-assembly solutions, especially in corrosive environments and applications with different material combinations.
Innovation Solution
A frictional connection comprising a metal substrate with hard particles fixed by a metallic binder layer, combined with a polymeric material on at least one component joining surface, which increases the static friction coefficient and provides corrosion resistance, and allows for easy pre-assembly of the connecting element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hard particles are fixed on metal substrate by metallic binder layer to increase friction, then static friction coefficient is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies a composite material structure consisting of three layers: a metallic binder layer (first material) providing friction enhancement, and a polymeric coating layer (second material) providing corrosion protection. This composite structure resolves the contradiction by combining materials with complementary properties - the metallic layer increases static friction coefficient while the polymeric layer protects against corrosion, allowing both requirements to be satisfied simultaneously.
2Reliability
If connecting element is pre-assembled to component using welding, then pre-assembly reliability is improved, but manufacturing cost deteriorates
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a friction-based pressing system. The connecting element with hard particles is pressed against the component surface, and the friction force generated during pressing provides sufficient holding force for pre-assembly and transportation. This substitution eliminates the need for separate welding equipment and operations, reducing manufacturing cost while maintaining reliability.
Solution Approach 2:
The frictional connection mechanism serves the dual function of both joining and self-fixation during pre-assembly. The hard particles embedded in the polymeric layer create sufficient friction to hold the connecting element in place without external fixation, allowing the system to self-secure during handling and transportation.
3Ease of operation
If connecting element is pre-assembled using elastic locking mechanism, then pre-assembly is facilitated, but device complexity deteriorates
Solution Approach 1:
The patent extracts and eliminates the complex elastic locking mechanism from the design. Instead of incorporating springs, clips, or other mechanical locking features, the solution relies solely on the frictional interaction between the hard particles and the component surface. This extraction of unnecessary complexity maintains ease of pre-assembly while significantly reducing device complexity.
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 significantly enhances the static friction coefficient and corrosion resistance, making it suitable for applications where electrochemical corrosion and fretting are concerns, while facilitating reliable and cost-effective pre-assembly of the connecting element.
Implementation Method 1
hard particles fixed on the metal substrate by a metallic binder layer
Implementation Method 2
the polymeric material comprises at least one continuous layer... significantly enhances the static friction coefficient
Implementation Method 3
provides corrosion resistance, and allows for easy pre-assembly of the connecting element... makes it suitable for applications where electrochemical corrosion and fretting are concerns
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present disclosure relates to a frictional connection comprising a connecting element and two components, the two components being frictionally joined with the connecting element. The present disclosure further relates to a process for making said frictional connection.