Wear Protection Coating Using Biodegradable Binders
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Solution Overview
Problem
Existing methods for coating metallic objects with wear protection layers, such as those using NiCrBSi powder and an inorganic binder, are ecologically harmful and costly due to the use of expensive and non-benign solvents.
Innovation Solution
A method employing hard particles, cellulose ether derivatives, gelatin, or starch as binders dissolved in water to create a mixture that is applied to the object's surface, where the binder is removed by heat, allowing the hard particles to bond firmly, using water as an environmentally friendly and inexpensive solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic binder or enamel powder is used to create a wear protection layer, then the coating can be applied to complex surfaces including undercuts, but the binder is expensive and ecologically harmful
Solution Approach 1:
The patent replaces expensive, ecologically harmful inorganic binders with inexpensive, biodegradable organic binders made from natural polymers (starch, cellulose, gelatin, casein). These organic binders are disposable in the sense that they are temporarily functional during application and then completely decomposed during the melting process, leaving no harmful residues. This resolves the contradiction by providing an eco-friendly alternative that maintains coating reliability while eliminating ecological harm.
Solution Approach 2:
The patent changes the chemical composition parameters of the binder from inorganic (enamel powder, metal powders) to organic natural polymers. This parameter change transforms the binder's properties: it becomes biodegradable, non-toxic, and water-soluble, yet maintains adequate binding capability at room temperature. The binder's function is temporarily required for application and then deliberately eliminated through thermal decomposition, resolving the ecological harm issue while preserving wear protection functionality.
2Reliability
If an inorganic binder is used, then the coating provides wear protection, but the binder is expensive to purchase
Solution Approach 1:
The patent substitutes expensive inorganic binders (enamel powder, metal powders) with inexpensive organic binders derived from natural polymers. These organic binders cost significantly less while providing sufficient binding functionality during the coating application process. The low cost is acceptable because the binder is temporarily functional and then completely decomposed during melting, eliminating the need for expensive, durable inorganic materials.
Solution Approach 2:
The patent uses organic binders that replicate the temporary binding function of expensive inorganic binders without requiring the same material properties. The organic binders copy the essential function of holding hard particles in place during application, then deliberately fail (decompose) during the melting process, which is actually desirable. This functional copying with cheaper materials resolves the cost contradiction.
3Object-affected harmful factors
If water is used as a solvent, then the method is ecologically friendly and inexpensive, but the binder must be highly soluble in water
Solution Approach 1:
The patent selects organic binders with specific chemical parameters that ensure high water solubility. By choosing natural polymers like starch, cellulose derivatives, gelatin, and casein, the binder's molecular structure parameters are optimized for water compatibility. These polymers contain hydrophilic groups that readily interact with water molecules, ensuring complete dissolution to form homogeneous binding solutions. This parameter selection resolves the contradiction by making the binder inherently water-soluble, thereby enabling ecological water-based application without compromising ease of manufacture.
Solution Approach 2:
The use of water as a solvent is enabled by selecting binders that are water-soluble and then completely water-washable after application. The binder serves its temporary binding function and then is completely removed during the melting process, leaving no water-soluble residues that would cause ecological problems. This temporary water-based binding followed by complete thermal decomposition resolves the contradiction between ecological friendliness and manufacturing ease.
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
This method achieves a stable, even wear protection layer with adjustable viscosity for various application methods, ensuring ecological compatibility and cost-effectiveness while preventing component wear through the use of ceramic or metallic hard particles.
Implementation Method 1
the binder adheres to the surface to be coated
Implementation Method 2
the object coated in this way is then subjected to a temperature of at least 900° C., preferably at least 1000° C., as a result of which the binder is removed from the mixture
Implementation Method 3
the hard particles are firmly bonded to the surface
Data Source
AI summary
A method for coating an object, in particular for producing a wear protection layer on the object, comprises the following steps: providing hard particles, a binder and a solvent, in particular water, and applying the hard particles, the binder and the solvent to the surface to be coated of the object; subjecting the applied hard particles to a temperature of at least 900°C, thereby removing the solvent from the mixture and firmly bonding the hard particles to the surface, cellulose ether derivatives, gelatin or starch being used as the binder.