Rubber-Metal Gasket Laminate for High-Temperature LLC Adhesion
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Solution Overview
Problem
Existing rubber-metal laminated gasket materials face challenges with poor LLC resistance and adhesion durability under high temperature conditions, leading to potential engine failure due to rubber peeling.
Innovation Solution
A rubber-metal laminated gasket material comprising a metal plate with a surface treating agent layer formed by using an organic titanium compound and titanium coupling agent-treated alumina, with a specific element mass ratio of titanium to aluminum in the surface treating agent film, ensuring excellent LLC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a vulcanizing adhesive is directly applied to stainless steel plate to bond rubber, then the manufacturing process is simple, but the adhesion durability in water and LLC is poor
Solution Approach 1:
The patent introduces a surface treating agent layer as an intermediary between the stainless steel plate and the vulcanizing adhesive. This layer contains inorganic particles (alumina, silica, or zirconia) with specific surface treatments that enhance adhesion to both the metal substrate and the rubber, preventing peeling in water and LLC environments while maintaining manufacturing simplicity
2Reliability
If zinc phosphate treatment or iron phosphate treatment is applied to stainless steel plate, then adhesion to adhesive is improved, but sludge is generated and chemical agents must be continuously supplied
Solution Approach 1:
The patent changes the chemical composition parameters of the surface treating agent, replacing traditional zinc phosphate or iron phosphate treatments with a formulation containing inorganic particles (alumina, silica, or zirconia) combined with specific organic compounds. This parameter change eliminates sludge generation while maintaining adhesion performance and eliminating the need for continuous chemical agent supply
3Reliability
If coating type chromate treatment is applied to stainless steel plate, then resistance to water and LLC is improved, but Cr6+ is used which is highly carcinogenic
Solution Approach 1:
The patent extracts and removes the harmful Cr6+ component from the surface treatment system while retaining the beneficial LLC resistance properties. The surface treating agent uses inorganic particles (alumina, silica, or zirconia) with specific surface treatments that provide equivalent or superior protection without any carcinogenic substances
4Reliability
If surface treating agent containing fluorine is used, then adhesion is improved, but defluoridation facilities are required
Solution Approach 1:
The patent replaces fluorine-containing surface treating agents with a fluorine-free formulation using inorganic particles (alumina, silica, or zirconia) combined with specific organic compounds. This substitution eliminates the need for complex defluoridation facilities while maintaining adhesion performance, effectively using a simpler, disposable-like treatment approach
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 material exhibits excellent LLC resistance even under high temperature conditions (150°C for 300 hours) without adhesion peeling, reducing the risk of engine failure and environmental concerns related to chromium and fluorine use.
Implementation Method 1
titanium coupling agent-treated alumina
Data Source
Figure 1
AI summary
A rubber-metal laminated gasket material comprising a metal plate, a surface treating agent layer, an adhesive layer, and a rubber layer, the layers being sequentially laminated on the metal plate; wherein the surface treating agent layer is formed by using a surface treating agent comprising an organic titanium compound and titanium coupling agent-treated alumina, wherein the element mass ratio of titanium and aluminum in a surface treating agent film is 5:95 to 60:40. The rubber-metal laminated gasket material is exhibits the following effects. For example, adhesion peeling does not occur in a heat resistance test method in LLC in consideration of the actual use environment of engine cylinder head gaskets, and excellent LLC resistance is exhibited even under conditions of 150°C for about 300 hours, high temperature conditions.