Method of forming a laminate

• US 9,981,284 B2
• Filed: 12/27/2012
• Issued: 05/29/2018
• 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: Guo, Qiang, Pan, Guoliang, Wang, Lianxiang, Liu, Xiaoye
• Primary Examiner(s): LA VILLA, MICHAEL EUGENE
• Application Number:
  US13/728,262
• Publication Number:
  US 20130183539A1
• Time in Patent Office: 1,979 Days
• Field of Search: 428626
• CPC Class Codes: B05D 1/06 Applying particulate materials
• CPC Class Codes: B05D 2202/00 Metallic substrate
• CPC Class Codes: B05D 2350/65 metal layer
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 2451/00 Type of carrier, type of coating (Multilayers)
• CPC Class Codes: B05D 3/0218 Pretreatment, e.g. heating the substrate
• CPC Class Codes: B05D 5/083 involving the use of fluoropolymers
• CPC Class Codes: B05D 7/54 No clear coat specified
• CPC Class Codes: F16C 2202/10 Porosity
• 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 2223/42 by spraying the coating material, e.g. plasma spraying
• CPC Class Codes: F16C 2223/80 by powder coating
• CPC Class Codes: F16C 2240/48 Particle sizes
• CPC Class Codes: F16C 2240/54 Surface roughness
• CPC Class Codes: F16C 2240/60 Thickness, e.g. thickness of coatings
• CPC Class Codes: F16C 33/206 with three layers
• CPC Class Codes: F16C 33/208 Methods of manufacture, e.g. shaping, applying coatings
• CPC Class Codes: Y10T 428/12049 Nonmetal component
• CPC Class Codes: Y10T 428/12472 Microscopic interfacial wave or roughness
• CPC Class Codes: Y10T 428/12549 : Adjacent to each other

Abstract

A bearing article can include a metal substrate having a bronze layer; a PEEK layer; a PTFE composition layer overlying and penetrating the PEEK layer. A method for preparing a bearing article can include providing a metal substrate with a sintered bronze layer, electrostatic spraying a non-fluorinated polymer onto the metal substrate followed by spraying a fluorinated polymer onto the non-fluorinated polymer and heat rolling to form a laminate.

Claims

1. A method of forming a laminate, the method comprising:

providing a metal substrate to which a layer of bronze particles is sintered;

electrostatic spraying the metal substrate with a non-fluorinated thermoplastic powder comprising a ultra-high-molecular-weight polyethylene (UHMWPE), a polyimide (PI), a polyamide (PA), a polyamideimide (PAI), or any combination thereof, and covering the bronze particles with the non-fluorinated thermoplastic powder to form a transition layer; and

spraying the transition layer with a fluorinated thermoplastic powder to form a compound layer, wherein the transition layer comprises PEEK, and wherein the fluorinated thermoplastic powder comprises polyvinylfluoride (PVF), polychlorotrifluoroethylene (PCTFE), a polyethylenechlorotrifluoroethylene (ECTFE), or any combination thereof.

2. The method according claim 1, further comprising preheating the metal substrate to a temperature between 25 deg C. and 100 deg C. prior to the electrostatic spraying with the non-fluorinated thermoplastic powder.

3. The method according to claim 1, wherein the transition layer has a thickness of at least about 10 microns.

4. The method according to claim 1, wherein the fluorinated thermoplastic powder further comprises polytetrafluoroethylene (PTFE), a perfluoroalkoxy polymer (PFA), fluorinated ethylene-propylene (FEP), polyvinylidene fluoride (PVDF), a polyethylenetetrafluoroethylene (ETFE), or any combination thereof.

5. The method according to claim 1, further comprising calendering the compound layer, heating the compound layer, pressing the compound layer, or any combination thereof.

6. The method according to claim 1, further comprising calendering the compound layer.

7. The method according to claim 1, further comprising heating the compound layer.

8. The method according to claim 1, further comprising pressing the compound layer.

9. The method according to claim 1, further comprising heat rolling the compound layer.

10. The method according to claim 1, wherein the transition layer and the compound layer have a combined thickness of at least about 20 microns.

11. The method according to claim 1, wherein the transition layer and the compound layer have a combined thickness of no greater than 1 mm.

12. The method according to claim 1, wherein the bronze layer has a surface roughness of at least about 1 micron.

13. The method according to claim 1, wherein the transition layer has a thickness of not greater than 500 microns.

14. The method according to claim 1, wherein the non-fluorinated powder has an average particle size of at least 1 micron.

15. The method according to claim 1, wherein the non-fluorinated powder has an average particle size of not greater than 1400 microns.

16. The method according to claim 1, wherein the fluorinated thermoplastic powder comprises a filler.

17. The method according to claim 16, wherein the filler comprises 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, mineral materials, wollastonite, barium sulfate, or any combinations thereof.