EP0285722A2 - An air cured composite coating and method for applying same - Google Patents

An air cured composite coating and method for applying same Download PDF

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Publication number
EP0285722A2
EP0285722A2 EP87308177A EP87308177A EP0285722A2 EP 0285722 A2 EP0285722 A2 EP 0285722A2 EP 87308177 A EP87308177 A EP 87308177A EP 87308177 A EP87308177 A EP 87308177A EP 0285722 A2 EP0285722 A2 EP 0285722A2
Authority
EP
European Patent Office
Prior art keywords
composite coating
air cured
substrate
coating
cured composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP87308177A
Other languages
German (de)
French (fr)
Other versions
EP0285722B1 (en
EP0285722A3 (en
Inventor
Gary R. Carlo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plasma Coatings Inc
Original Assignee
Plasma Coatings Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB878719463A external-priority patent/GB8719463D0/en
Application filed by Plasma Coatings Inc filed Critical Plasma Coatings Inc
Priority to AT87308177T priority Critical patent/ATE71156T1/en
Publication of EP0285722A2 publication Critical patent/EP0285722A2/en
Publication of EP0285722A3 publication Critical patent/EP0285722A3/en
Application granted granted Critical
Publication of EP0285722B1 publication Critical patent/EP0285722B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Definitions

  • the present invention relates to a composite coating which imparts an abrasion resistant release surface to a substrate and a method for applying the coating to the substrate. More particularly, the present invention relates to an air cured composite coating comprising a porous metal matrix and a silicon impregnant which seals the porosity of the matrix.
  • Prior art composite coatings applied to substrates to a enhance their abrasion resistence and release properties are old in the art.
  • Prior art composite coatings usually include either a ceramic or a metal matrix applied to substrate, with the matrix being impregnated with a silicon polymer or fluorocarbon polymer release agent.
  • the major drawback to all the prior art composite coatings is that they must be heat cured at temperatures near or above 500 degrees fahrenheit. Heat curing of the composite coating presents significant problems where the substrate is of substantial size or weight or where the substrate is a component of a larger machine. Where the substrate is large and/or heavy, it may be expensive to ship the substrate to a distant coating facility. Further, when the substrate is a component of a larger machine, productivity of the machine is lost while the component is removed from the machine and sent away to be coated.
  • the air cured composite coating of the present invention comprises a porous metal matrix impregnated with a silicone to seal the porosity of the matrix.
  • the coating is continuously operable to temperatures of up to 400 degrees fahrenheit and exhibits a hardness of up to 72 Rc.
  • a porous metal matrix is initially formed on a substrate and then impregnated with a film forming, polymerizable, silicon impregnate which is polymerized in situ to serve as a release agent.
  • the resulting composite coating thus formed has the abrasion resistance of the metal matrix and the release properties of the impregnating silicon.
  • a substrate coated with the air cured conposite coating of the present invention is shown generally at 10.
  • the substrate 12 such as an idler roller or drum, carries the composite coating, represented at 14.
  • the composite coating comprises a porous metal matrix which in cross section exhibits a multitude of depressions 16 and plateaus 18 formed therein.
  • a film forming, polymerized, silicon impregnate 20 fills the depressions 16 in the matrix 14 and penetrates into the matrix to seal its porosity. It is also preferred that an excess of the impregnate 20 extends above the plateaus 18 to completely cover the matrix 14.
  • the metallic matrix is applied to the substrate 12 in a flame spraying process.
  • the material of the metal matrix 14 may vary widely within the scope of the invention, and can be of any metal which is of powder form. Metals from the group consisting of stainless steel, nickel, nickel chromium, molybdenum or the carbides are some of the materials used.
  • the metal matrix 14 is deposited onto the substrate 10 to a depth of from 0.002 to 0.010 of an inch, depending upon the purpose for which the coated substrate is employed.
  • the silicon may be applied to the metal matrix 14 such that the silicon fills the depressions 16, extends above the plateaus 18 and penetrates into the matrix 14. It is permitted to polymerize in situ at ambient temperatures for a period of from 16 to 24 hours. As noted above, this is the major advantage of the present invention over prior art composite release coatings; the coating can be applied and cured on site, eliminating the need for heat-curing in an oven.
  • the composite coating which results has a hardness of up to 72 Rc and a surface finish of from 250 to 700 microinches.
  • the composite exhibits thermal stability at continuous operating temperatures of up to 400 degrees fahrenheit and intermittent operating temperatures of up to 500 degrees fahrenheit.
  • the composite coating also provides 2 1/2 - 3 times longes release life than composite coatings utilizing fluorocarbon release agents.
  • absolute release is offered with no adhesive transfer onto the release surface, whereas resistance as well as adhesive transfer is apparent when used with the above mentioned fluorocarbon release coatings. It also has a high coefficient of friction which is desireable for web tracking.

Abstract

An air cured composite coating for providing an abrasion resistant release surface to a substrate which comprises a metal matrix thermally sprayed onto a substrate and a film forming polymerized silicon impregnate applied to the metal matrix to seal its porosity. The composite coating is air cured in situ and exhibits a hardness of up to 72 Rc. The coating maintains thermal stability at continuous operating temperature of up to 400 degrees fahrenheit.

Description

    BACKGROUND OF THE INVENTION
  • The present invention relates to a composite coating which imparts an abrasion resistant release surface to a substrate and a method for applying the coating to the substrate. More particularly, the present invention relates to an air cured composite coating comprising a porous metal matrix and a silicon impregnant which seals the porosity of the matrix.
  • Composite coatings applied to substrates to a enhance their abrasion resistence and release properties are old in the art. Prior art composite coatings usually include either a ceramic or a metal matrix applied to substrate, with the matrix being impregnated with a silicon polymer or fluorocarbon polymer release agent. The major drawback to all the prior art composite coatings is that they must be heat cured at temperatures near or above 500 degrees fahrenheit. Heat curing of the composite coating presents significant problems where the substrate is of substantial size or weight or where the substrate is a component of a larger machine. Where the substrate is large and/or heavy, it may be expensive to ship the substrate to a distant coating facility. Further, when the substrate is a component of a larger machine, productivity of the machine is lost while the component is removed from the machine and sent away to be coated.
    • SUMMARY OF THE INVENTION
  • It is the general object of the described embodiments to provide a composite coating which imparts an abrasion resistant release surface to a substrate where, because the composite coating is air cured, it can be applied on site. That is, because the composite coating of the present invention does not require oven-heating for proper curing, the substrate does not have to be shipped to a distant coating facility. The air cured composite coating of the present invention comprises a porous metal matrix impregnated with a silicone to seal the porosity of the matrix. The coating is continuously operable to temperatures of up to 400 degrees fahrenheit and exhibits a hardness of up to 72 Rc.
    • BRIEF DESCRIPTION OF THE DRAWINGS
    • Fig. 1 is a semi-schematic, enlarged, cross-sectional view of a substrate having a composite layer produced in accordance with the present invention.
    • Fig. 2 is an enlarged cross-section of Fig. 1 on the line 2-2.
    DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • In accordance with the present invention, a porous metal matrix is initially formed on a substrate and then impregnated with a film forming, polymerizable, silicon impregnate which is polymerized in situ to serve as a release agent. The resulting composite coating thus formed has the abrasion resistance of the metal matrix and the release properties of the impregnating silicon.
  • Referring to Fig. 1, a substrate coated with the air cured conposite coating of the present invention is shown generally at 10. The substrate 12, such as an idler roller or drum, carries the composite coating, represented at 14. As shown in Fig. 2, the composite coating comprises a porous metal matrix which in cross section exhibits a multitude of depressions 16 and plateaus 18 formed therein. A film forming, polymerized, silicon impregnate 20 fills the depressions 16 in the matrix 14 and penetrates into the matrix to seal its porosity. It is also preferred that an excess of the impregnate 20 extends above the plateaus 18 to completely cover the matrix 14.
  • In accordance with the present invention, the metallic matrix is applied to the substrate 12 in a flame spraying process. The material of the metal matrix 14 may vary widely within the scope of the invention, and can be of any metal which is of powder form. Metals from the group consisting of stainless steel, nickel, nickel chromium, molybdenum or the carbides are some of the materials used. The metal matrix 14 is deposited onto the substrate 10 to a depth of from 0.002 to 0.010 of an inch, depending upon the purpose for which the coated substrate is employed.
  • Further, and in accordance with the present invention, the silicon may be applied to the metal matrix 14 such that the silicon fills the depressions 16, extends above the plateaus 18 and penetrates into the matrix 14. It is permitted to polymerize in situ at ambient temperatures for a period of from 16 to 24 hours. As noted above, this is the major advantage of the present invention over prior art composite release coatings; the coating can be applied and cured on site, eliminating the need for heat-curing in an oven.
  • The composite coating which results has a hardness of up to 72 Rc and a surface finish of from 250 to 700 microinches. The composite exhibits thermal stability at continuous operating temperatures of up to 400 degrees fahrenheit and intermittent operating temperatures of up to 500 degrees fahrenheit. The composite coating also provides 2 1/2 - 3 times longes release life than composite coatings utilizing fluorocarbon release agents. In the case of certain adhesives, absolute release is offered with no adhesive transfer onto the release surface, whereas resistance as well as adhesive transfer is apparent when used with the above mentioned fluorocarbon release coatings. It also has a high coefficient of friction which is desireable for web tracking.

Claims (10)

1. An air cured, composite coating for imparting an abrasion resistant release surface to a substrate, said air cured composite coating comprising:
      a porous metal matrix thermally sprayed onto said substrate to a depth of 0.002 to 0.010 of an inch, said matrix comprising a metal of powdered form and
      a film of silicon impregnated into said metal matrix to seal the porosity of said matrix.
2. The air cured, composite coating of Claim 1 wherein the metal of powdered form is selected from the group consisting of stainless steel, nickel, nickel chromium, molybdenum or a carbide.
3. The air cured composite coating of claim 1 wherein said coating maintains thermal stability at a continuous operating temperature of up to 400 degrees fahrenheit and an intermittent operating temperature of up to 500 degrees fahrenheit.
4. The air cured composite coating of claim 1 wherein said coating has a hardness of up to 72 Rc.
5. The air cured composite coating of claim 1 wherein said coating has a surface finish in the range of 250 to 700 micro-inches.
6. The air cured composite coating of claim 1 wherein said coating is completely air cured within 16 - ­24 hours.
7. A method of applying an air cured composite coating to a substrate comprising the steps of:
      providing a substrate;
      applying a porous metal matrix to said substrate to a depth of 0.002 to 0.0010 of an inch in a flame spraying process, said metal matrix comprising a metal of powdered form;
      impregnating a silicon into said metal matrix to seal the porosity of said matrix; and
      air curing said composite coating on said substrate for a period of 16 - 24 hours.
8. A method of applying an air cured composite coating to a substrate as set forth in claim 6 wherein said process is of the metal spraying type.
9. A method of applying an air cured composite coating to a substrate substantially as described herein with reference to the accompanying drawings.
10. An air cured composite coating made by a method according to any one of claims 7,8, or 9.
EP87308177A 1987-04-07 1987-09-16 An air cured composite coating and method for applying same Expired - Lifetime EP0285722B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT87308177T ATE71156T1 (en) 1987-04-07 1987-09-16 AIR-CURED COMPOSITE COATING AND PROCEDURE FOR ITS APPLICATION.

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US3534687A 1987-04-07 1987-04-07
GB8719463 1987-08-18
GB878719463A GB8719463D0 (en) 1987-04-07 1987-08-18 Air cured composite coating
US35346 1993-03-22

Publications (3)

Publication Number Publication Date
EP0285722A2 true EP0285722A2 (en) 1988-10-12
EP0285722A3 EP0285722A3 (en) 1988-12-14
EP0285722B1 EP0285722B1 (en) 1992-01-02

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP87308177A Expired - Lifetime EP0285722B1 (en) 1987-04-07 1987-09-16 An air cured composite coating and method for applying same

Country Status (5)

Country Link
EP (1) EP0285722B1 (en)
AT (1) ATE71156T1 (en)
DE (1) DE3775759D1 (en)
ES (1) ES2039245T3 (en)
GR (1) GR3003755T3 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999062683A1 (en) 1998-05-29 1999-12-09 Unilever Plc Hybrid stamping die
CN111139476A (en) * 2019-12-26 2020-05-12 一汽解放汽车有限公司 Method for eliminating surface coating defects of metal bipolar plate, metal bipolar plate prepared by method and application of metal bipolar plate

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9521929B1 (en) 2013-11-19 2016-12-20 Vermont Herb & Spice Accessories, Inc. Self cleaning tribological coated tobacco and herb grinders

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3010843A (en) * 1958-04-28 1961-11-28 Gen Motors Corp Abradable protective coating for compressor casings
FR1523222A (en) * 1967-02-06 1968-05-03 Pneumatiques, Caoutchouc Manufacture Et Plastiques Kleber-Colombes Process for producing a coating with a low coefficient of friction and parts provided with this coating
JPS589971A (en) * 1981-07-09 1983-01-20 Seiko Epson Corp Analog display wristwatch
JPS60138064A (en) * 1983-12-27 1985-07-22 Showa Denko Kk Surface treatment of sprayed film
JPS60234960A (en) * 1984-05-04 1985-11-21 Seiko Instr & Electronics Ltd Surface treatment of external parts

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3010843A (en) * 1958-04-28 1961-11-28 Gen Motors Corp Abradable protective coating for compressor casings
FR1523222A (en) * 1967-02-06 1968-05-03 Pneumatiques, Caoutchouc Manufacture Et Plastiques Kleber-Colombes Process for producing a coating with a low coefficient of friction and parts provided with this coating
JPS589971A (en) * 1981-07-09 1983-01-20 Seiko Epson Corp Analog display wristwatch
JPS60138064A (en) * 1983-12-27 1985-07-22 Showa Denko Kk Surface treatment of sprayed film
JPS60234960A (en) * 1984-05-04 1985-11-21 Seiko Instr & Electronics Ltd Surface treatment of external parts

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN, Vol. 10, No. 103 (C-340)[2160], 18th April 1986; & JP-A-60 234 960 (SEIKO DENSHI KOGYO K.K.) (21-11-1985) *
PATENT ABSTRACTS OF JAPAN, Vol. 7, No. 77 (C-159)[1222], 30th March 1983; & JP-A-58 009 971 (SUWA SEIKOSHA K.K.) (20-01-1983) *
PATENT ABSTRACTS OF JAPAN, Vol. 9, No. 301 (C-316)[2024], 28th November 1985; & JP-A-60 138 064 (SHOWA DENKO K.K.) (22-07-1985) *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999062683A1 (en) 1998-05-29 1999-12-09 Unilever Plc Hybrid stamping die
US6283744B1 (en) 1998-05-29 2001-09-04 Unilever Home & Personal Care Usa, Division Of Conopco Hybrid soap stamping bars
CN111139476A (en) * 2019-12-26 2020-05-12 一汽解放汽车有限公司 Method for eliminating surface coating defects of metal bipolar plate, metal bipolar plate prepared by method and application of metal bipolar plate

Also Published As

Publication number Publication date
GR3003755T3 (en) 1993-03-16
EP0285722B1 (en) 1992-01-02
EP0285722A3 (en) 1988-12-14
DE3775759D1 (en) 1992-02-13
ATE71156T1 (en) 1992-01-15
ES2039245T3 (en) 1993-09-16

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