Polymer coating on substrates using thermal spray techniques

• US 9,782,956 B2
• Filed: 12/27/2012
• Issued: 10/10/2017
• Est. Priority Date: 12/28/2011
• Status: Active Grant

• Current Assignee: Saint-Gobain Performance Plastics Corporation (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Performance Plastics Corporation (Compagnie De Saint-Gobain)
• Inventors: Liao, Hanlin, Demian, Camelia, Wang, Lianxiang, Liu, Xiaoye
• Primary Examiner(s): Austin, Aaron
• Assistant Examiner(s): Saberi, Jasper
• Application Number:
  US13/728,405
• Publication Number:
  US 20130183488A1
• Time in Patent Office: 1,748 Days
• Field of Search: 428141, 428422, 428421, 4289088, 384 42, 508104
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/22 using plasticisers
• CPC Class Codes: B32B 27/288 comprising polyketones
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/322 comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: C09D 127/18 Homopolymers or copolymers of tetrafluoroethene
• CPC Class Codes: C09D 171/00 Coating compositions based on polyethers obtained by reactions forming an ether link in the main chain based on polyacetals C09D159/00; based on epoxy resins C09D163/00; based on polythioether-ethers C09D181/02; based on polyethersulfones C09D181/06; Coating compositions based on derivatives of such polymers
• CPC Class Codes: F16C 2202/10 Porosity
• CPC Class Codes: F16C 2204/20 Alloys based on aluminium
• CPC Class Codes: F16C 2208/02 comprising fillers, fibres
• CPC Class Codes: F16C 2208/30 Fluoropolymers F16C2208/58 takes precedence
• CPC Class Codes: F16C 2208/32 Polytetrafluorethylene [PTFE] F16C2208/58 takes precedence
• CPC Class Codes: F16C 2208/36 Polyarylene ether ketones [PAEK], e.g. PEK, PEEK F16C2208/58 takes precedence
• CPC Class Codes: F16C 2240/54 Surface roughness
• CPC Class Codes: F16C 2240/60 Thickness, e.g. thickness of coatings
• CPC Class Codes: F16C 33/201 : Composition of the plastic
• CPC Class Codes: F16C 33/203 : Multilayer structures, e.g. sleeves comprising a plastic lining
• CPC Class Codes: F16C 33/205 : with two layers
• CPC Class Codes: F16C 33/206 : with three layers
• CPC Class Codes: F16C 33/208 : Methods of manufacture, e.g. shaping, applying coatings
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/249958 : Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/263 : Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers

Abstract

A laminate article can include a substrate and a layer of a heterogeneous mixture of a non-fluorinated polymer compound and a fluorinated polymer compound. The laminate article can include a gradual concentration gradient along an axis perpendicular to the substrate. The gradual concentration gradient can include the change of the amount of the non-fluorinated polymer and the fluorinated polymer compound relative to the axis perpendicular to the substrate. The layer can further include at least one filler. The laminate can be applied as a bearing material.

Claims

1. A laminate article, comprising

a substrate layer comprising a metal or a metal alloy;

and

a polymer layer comprising;

a stand-alone layer of a non-fluorinated polymer compound having a thickness of at least about 20 microns, the stand-alone layer being disposed directly adjacent to and contacting the substrate without an intervening support layer therebetween, the stand-alone layer comprising a plurality of interconnected voids making up at least 10 vol. % of the total volume of the stand-alone layer, and

a fluorinated polymer compound covering the stand-alone layer and filling at least a portion of the interconnected voids of the stand-alone layer;

wherein the concentration of the fluorinated polymer compound in the polymer layer increases in a direction perpendicular to, and moving away from, the substrate layer such that the polymer layer includes a gradual concentration gradient that includes a change of an amount of the non-fluorinated polymer compound and the fluorinated polymer compound relative to an axis perpendicular to the substrate.

2. The laminate according to claim 1, wherein the non-fluorinated polymer compound is selected from a poly-ether-ether-ketone (PEEK), an ultra-high-molecular-weight polyethylene (UHMWPE), a polyimide (PI), a polyamide (PA), a polyamideimide (PAI), a polyphenylsulfide (PPS), a polyhydroxybutyrate (PHB), and any combination thereof.

3. The laminate according to claim 1, wherein the non-fluorinated polymer compound consists essentially of a poly-ether-ether-ketone.

4. The laminate according to claim 1, wherein the fluorinated polymer compound is selected from polytetrafluoroethylene (PTFE), a perfluoroalkoxy polymer (PFA), fluorinated ehylene-propylene (FEP), polyvinylfluoride (PVF), polyvinylidene fluoride (PVDF), polychlorotrifluoroethylene (PCTFE), a polyethylenetetrafluoroethylene (ETFE), a polyethylenechlorotrifluoroethylene (ECTFE), or any combination thereof.

5. The laminate according to claim 1, wherein the fluorinated polymer compound consists essentially of polytetrafluoroethylene.

6. The laminate according to claim 1, wherein a combined thickness of the stand-alone layer and the fluorinated polymer compound is at least about 30 microns.

7. The laminate according to claim 1, wherein a combined thickness of the stand-alone layer and the fluorinated polymer compound is not greater than about 1 mm.

8. The laminate according to claim 1, wherein the non-fluorinated polymer compound comprises at least about 10 wt % of the combined weight of the stand-alone layer and the fluorinated polymer compound.

9. The laminate according to claim 1, wherein the non-fluorinated polymer compound comprises not greater than about 80 wt % of the combined weight of the stand-alone layer and the fluorinated polymer compound.

10. The laminate according to claim 1, wherein the stand-alone layer, the fluorinated polymer compound, or both, further includes a filler.

11. The laminate according to claim 10, wherein the filler comprises a filler selected from the group consisting of fibers, glass fibers, carbon fibers, aramids, inorganic materials, ceramic materials, carbon, glass, graphite, aluminum oxide, molybdenum sulfide, bronze, silicon carbide, woven fabric, powder, sphere, thermoplastic material, polyimide (PI), polyamidimide (PAI), polyphenylene sulfide (PPS), polyethersulofone (PES), polyphenylene sulfone (PPSO2), liquid crystal polymers (LCP), polyetherketone (PEK), polyether ether ketones (PEEK), aromatic polyesters (Ekonol), mineral materials, wollastonite, barium sulfate, and any combinations thereof.

12. The laminate according to claim 1, wherein the substrate layer has a surface roughness of from 1 micron to 200 microns.

13. The laminate according to claim 1, wherein the non-fluorinated polymer compound further includes a softener or plasticizer.

14. The laminate according to claim 13, wherein the softener or the plasticizer includes a fluoropolymer.

15. The laminate according to claim 1, wherein the voids make up at least about 20 vol. % of the stand-alone layer.

16. The laminate according to claim 1, wherein the laminate consists of the substrate and the polymer layer.

17. A bearing article, comprising

a continuous substrate comprising a metal or a metal alloy;

a polymer layer comprising;

a stand-alone layer of a non-fluorinated polymer compound having a thickness of at least about 20 microns, the stand-alone layer being disposed directly adjacent to and contacting the substrate without an intervening support layer therebetween, the stand-alone layer comprising a plurality of interconnected voids making up at least 10 vol. % of the total volume of the stand-alone layer, and

a fluorinated polymer compound covering the stand-alone layer and filling at least a portion of the interconnected voids of the stand-alone layer;

wherein the concentration of the fluorinated polymer compound in the polymer layer increases in a direction perpendicular to, and moving away from, the substrate layer such that the polymer layer includes a gradual concentration gradient that includes a change of an amount of the non-fluorinated polymer compound and the fluorinated polymer compound relative to an axis perpendicular to the substrate.

18. The bearing article of claim 17, wherein the substrate has a roughened surface.

19. The bearing article of claim 18, wherein the substrate layer has a surface roughness in a range of from about 1 micron to about 200 microns.