Crosslinkable Polymer Coating for Heat-Resistant Metal Protection
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Solution Overview
Problem
Existing methods for protecting metal surfaces with grease or curable materials face challenges in achieving both high heat resistance and uniform coating film formation, with grease losing viscosity under heat and curable materials taking too long to cure or requiring oxygen blocking.
Innovation Solution
A crosslinkable polymer composition comprising components A, B, and C, where component A releases metal ions by heat, component B forms ionic bonds with these ions, and component C forms phosphate ester salts, allowing for rapid crosslinking and uniform coating film formation with high corrosion and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grease is applied to a metal surface to prevent corrosion, then it is easily applied by heating, but outflow of the grease occurs when heat is applied to a coating film, resulting in low heat resistance
Solution Approach 1:
The invention changes the chemical composition parameters of the coating material by incorporating specific phosphoric acid esters and metal salts that maintain viscosity stability at high temperatures, preventing grease outflow while preserving ease of application through controlled heating
Solution Approach 2:
The invention creates a composite coating system combining organic polymer, phosphoric acid ester, and metal salt components that work synergistically to provide both easy application properties and high-temperature stability, resolving the contradiction between ease of operation and heat resistance
2Temperature
If a thickening agent is selected to reduce grease flow under high temperature, then heat resistance improves, but heating temperature required for application increases, making it difficult to form a uniform coating film
Solution Approach 1:
The invention modifies the rheological parameters of the coating by selecting specific phosphoric acid esters with appropriate molecular structures that maintain optimal viscosity across a wide temperature range, enabling uniform coating formation at lower temperatures while preserving high-temperature heat resistance
3Reliability
If curable materials are used to protect metal surfaces, then corrosion resistance is achieved, but curing time is long, making it difficult to form a coating film quickly
Solution Approach 1:
The invention replaces slow moisture-curing or anaerobic-curing mechanisms with a rapid thermal-curing system activated by heat, which simultaneously achieves complete curing and forms a uniform coating film quickly, maintaining high corrosion resistance while dramatically reducing curing time
Solution Approach 2:
The invention utilizes phase transition of the coating material from liquid to crosslinked solid state through controlled thermal heating, enabling rapid and complete curing that both protects against corrosion and forms uniform coating films quickly
4Reliability
If anaerobic curable material is used, then corrosion protection is achieved, but oxygen blocking during curing is required, making it difficult to form a uniform coating film
Solution Approach 1:
The invention replaces the complex oxygen-blocking requirement with a simple thermal activation process, where heating simultaneously drives off moisture to initiate curing and ensures uniform coating formation, maintaining corrosion resistance while eliminating process 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 composition enables the formation of a highly uniform coating film with high corrosion resistance and heat resistance, maintaining these properties even under heated conditions.
Implementation Method 1
component A from which metal ion is released by heat
Implementation Method 2
component B comprising an organic polymer having a substituent capable of ionic bonding with the metal ion released from component A
Implementation Method 3
component C comprising one or more acidic phosphate ester
Data Source
AI summary
A crosslinkable polymer composition and a crosslinked polymer material including a metal member and a wiring harness. The crosslinkable polymer composition contains component A from which metal ion is released by heat, component B containing an organic polymer having a substituent capable of ionic bonding with the metal ion released from component A, and component C containing one or more acidic phosphate ester with a carbon number of 4 to 30. Assuming that the metal ion released from component A has a valence of +y and a content of the metal ion is m mol, the substituent contained in component B has a valence of −z and a content of the substituent is n mol, the acidic phosphate constituting component C has a valence of −x and a content of the acidic phosphate esters is 1 molg≥0.1 holds for g=(m·y−l·x)/(n·z).