Thermal Spray Coating on Composite Bicycle Wheel Rim

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Solution Overview

Problem

Existing methods for coating metal parts with ceramic or metal materials using plasma spraying often damage organic or composite materials and fail to achieve a strong, durable bond.

Innovation Solution

Thermal spraying of inorganic materials like TiO2, titanate, and aluminate directly onto organic or composite substrates, which not only avoids damage but also forms a well-adhered and effective bond coat for further layers, including zirconia and alumina.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plasma spraying is used to coat organic or composite materials with ceramic or metal material, then coating deposition is achieved, but the organic material or composite material is damaged

Engineering Contradiction:

Improvecoating depositionVSAvoiddamage to organic material

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the temperature parameter of the spraying process from plasma spraying (20,000 K) to thermal spraying (lower temperature), which allows coating deposition without damaging the organic matrix of composite materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the plasma spraying system with a thermal spraying system, substituting a high-energy plasma field with a lower-energy thermal field that is gentler on organic materials

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional coating methods are used on organic materials, then coating application is possible, but strong adhesion and durable bond are not achieved

Engineering Contradiction:

Improvecoating applicationVSAvoidadhesion strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention introduces a specifically formulated inorganic coating layer as an intermediary between the organic substrate and subsequent coating layers, which provides excellent adhesion properties and serves as a bonding interface

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention uses composite coating structures with inorganic materials (TiO2, Al2O3, aluminate) that combine the benefits of inorganic coating protection with improved bonding to organic substrates, creating a multi-functional coating system

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 enhanced wear resistance, improved adherence, and extended lifespan for coated components such as bicycle wheels, golf clubs, and implants by creating a strong bond between the substrate and subsequent layers without detrimental effects on the organic or composite materials.

Implementation Method 1

thermal sprayed first layer of coating material on the surface, the coating material of the first layer wholly comprising inorganic material

Methodology Applied

Scientific EffectThermal spraying:

Data Source

PatentEP2686459A2An article and a method of making an article

Publication Date: 2014.01.22 ZIRCOTEC IP

AI summary

An article, such as a bicycle wheel (10), includes a substrate, at least a surface of the substrate being made of or containing a composite material comprising fibres dispersed in an organic matrix, for example a carbon fibre composite. A thermal sprayed first layer of coating material is provided on the surface, such as the braking area of the rim of the bicycle, the coating material of the first layer wholly comprising inorganic material and including at least one of the group comprising TiO2, titanate, Al2O3 and aluminate.