Recycled Tyre-Modified Epoxy Coating for Steel Corrosion and Impact Resistance
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Solution Overview
Problem
High tensile strength steel components in vehicle suspension systems are susceptible to corrosion and impact damage due to their hardness and exposure to corrosive environments, requiring effective protective coatings that also provide flexibility and cost-efficiency.
Innovation Solution
A coating system comprising a zinc-rich epoxy primer layer and a top coat composition with particles of recycled vehicle tires, where the particles have an average size of 10 to 70 µm, offering corrosion and chip resistance without the need for thermoplastic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If high tensile strength steel springs are used to reduce mass, then weight is reduced, but corrosion resistance and impact resistance deteriorate due to increased hardness and susceptibility to breakage
Solution Approach 1:
The patent applies composite materials by combining zinc-rich epoxy primer with elastomer-modified epoxy thermosetting resin top coat. This composite coating system provides both corrosion protection (from zinc-rich primer) and impact/flexibility resistance (from elastomer-modified top coat), thereby protecting the high tensile strength steel springs while maintaining their weight reduction benefits.
2Reliability
If elastomer-modified epoxy thermosetting resin is used as top coat, then flexibility and impact resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the elastomer modification from conventional thermoplastic top coats and applies it specifically to the epoxy thermosetting resin layer. This allows the coating system to achieve flexibility and impact resistance through the elastomer-modified epoxy layer alone, eliminating the need for additional thermoplastic layers and simplifying the overall coating structure.
3Reliability
If thermoplastic top coat is used with epoxy primer, then chip resistance is improved, but cost and environmental friendliness deteriorate
Solution Approach 1:
The patent changes the chemical composition parameter of the top coat from thermoplastic to elastomer-modified epoxy thermosetting resin. This parameter change maintains chip resistance while eliminating the need for thermoplastic materials, thereby reducing costs and improving environmental friendliness through better resource utilization and reduced waste.
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 coating system provides enhanced corrosion and impact resistance, flexibility at low temperatures, and cost-effectiveness, suitable for high tensile steel substrates, ensuring durability and longevity.
Implementation Method 1
a primer layer composition comprising: (a) at least one epoxy resin; and (b) zinc particles wherein the zinc particles are present in an amount of 40 to 95 wt% relative to the total weight of the primer layer composition
Implementation Method 2
epoxy coatings are used mainly as part of an anti-corrosive coating system on steel substrates due to their outstanding corrosion and chemical resistance
Implementation Method 3
a top coat composition which is a coating composition comprising: a) at least one epoxy resin; and b) 8 to 40 wt% relative to the total weight of the top coat composition of particles of recycled vehicle tyres
Data Source
AI summary
The invention provides a coating composition suitable for application to a metallic substrate comprising a) at least one epoxy resin; and b) 8 to 40 wt% of particles of recycled vehicle tyres having an average particle size diameter of 10 to 70μm.