PERMANENT, SELF-ADHERING, SELF-LUBRICATING, ANTI-WEAR COMPOSITE SYSTEM

Abstract

An anti-wear composite structure includes an anti-wear layer that has a wear surface opposite an adhesive receiving surface and a thermosetting resin applied to the adhesive receiving surface. The thermosetting resin includes a reactive adhesive configured to bond the anti-wear composite structure to a substrate at an ambient temperature band via pressure-sensitive adhesion. The thermosetting resin has an onset to cure in the ambient temperature band and has a peak cure temperature greater than the ambient temperature band to mechanically and chemically bond the anti-wear composite structure to a substrate.

Claims

1. A method of applying an anti-wear composite structure to a substrate, the method comprising; providing an anti-wear composite structure comprising an anti-wear layer having a layer of thermosetting resin applied to an adhesive receiving surface of the anti-wear layer; and a wear surface opposite the adhesive receiving surface, the wear surface being configured for sliding engagement with a mating surface; maintaining the anti-wear composite structure at a temperature below ambient temperature before installation to prevent premature curing of the thermosetting resin; adhering the thermosetting resin portion of the anti-wear structure to the substrate via pressure-sensitive adhesion at ambient temperature; applying pressure to the anti-wear composite structure; and heating the anti-wear composite structure to a temperature sufficient to cure the thermosetting resin and mechanically and chemically bond the thermosetting resin to the substrate.

2. The method of claim 1, wherein the anti-wear layer further comprises a protective layer removably adhered to the wear surface.

3. The method of claim 2, further comprising removing the protective layer from the anti-wear layer.

4. The method of claim 1, wherein the anti-wear layer further comprises a release layer removably adhered to a surface of the thermosetting resin; and the method further comprising, before the adhering step, removing the release layer from the thermosetting resin.

5. The method of claim 1, wherein the maintaining step comprises maintaining the anti-wear composite structure at a temperature below zero degrees Celsius (32 degrees Fahrenheit) before installation to prevent premature curing of the thermosetting resin.

6. The method of claim 2, wherein the applying pressure step comprises applying pressure to the anti-wear composite structure via the protective layer disposed on the anti-wear layer.

7. The method of claim 6, wherein the applying pressure step comprises applying pressure in the range of 2.06843 Bar (30 pounds per square inch) to 6.89476 Bar (100 pounds per square inch) to the anti-wear composite structure via the protective layer disposed on the anti-wear layer.

8. The method of claim 1, wherein the heating step comprising heating the anti-wear composite structure to a temperature above ambient temperature.

9. The method of claim 1, wherein the heating step comprising heating the anti-wear composite structure to a temperature in the range of 148.89 degrees Celsius (300 degrees Fahrenheit) to 204.444 degrees Celsius (400 degrees Fahrenheit) to cure the thermosetting resin and mechanically and chemically bond the thermosetting resin to the substrate.

10. The method of claim 1, wherein the anti-wear layer comprises a woven structure.

11. The method of claim 10, wherein the woven structure comprises a thermally-consolidated, fabric reinforced-polymer matrix with self-lubricating components being at least one of integral to a weave and as an additive to the matrix.

12. The method of claim 10, wherein the woven structure comprises woven fabric comprising a plurality of fibers interwoven with one another and polytetrafluoroethylene interwoven therewith.

13. The method of claim 12, wherein the fibers comprise at least one of a polyester material, a stainless steel material, polytetrafluoroethylene, and glass material.

14. The method of claim 1, wherein the anti-wear layer is a thermally-consolidated, machinable, moldable, or non-woven fabric comprising a reinforced polymer matrix composite with self-lubricating materials integral to the non-woven fabric and/or as an additive to the matrix.

15. The method of claim 1, wherein the layer of thermosetting resin is in the form of a tape calendered, or laminated, to one side of the anti-wear layer.

16. The method of claim 14, wherein the layer of thermosetting resin tape is configured to removably bond the anti-wear composite structure to the substrate at a temperature of about 138 degrees Celsius (280 degrees Fahrenheit) to about 160 degrees Celsius (320 degrees Fahrenheit).

17. The method of claim 1, wherein the layer of thermosetting resin is configured to be applied to the anti-wear layer in viscous form via resin application techniques comprising at least one of painting, brushing, rolling, and squeezing.

18. The method of claim 1, wherein the layer of thermosetting resin is configured to be dried to increase room temperature viscosity to allow for pressure sensitive adhesion without resin flowing from the bond line during application to the substrate.

19. The method of claim 2, wherein the protective layer comprises indicia configured as advertising and/or instructions for installation and use.

20. The method of claim 4, wherein the release layer comprises a siliconized paper or polymer film.

21. The method of claim 1, further comprising forming the anti-wear composite structure to specific shapes via at least one of cutting, shaping, die stamping, computer numerical controlled machining, and hand trimming.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 is a cross sectional view of the anti-wear composite structure of the present invention;

[0035] FIG. 2 is a cross sectional view of the anti-wear composite structure of the present invention shown with a release layer being peeled off;

[0036] FIG. 3 is a cross sectional view of the anti-wear composite structure of the present invention shown with the release layer peeled off and the anti-wear composite structure adhered to a substrate;

[0037] FIG. 4 is a cross sectional view of the anti-wear composite structure of the present invention shown with a protective layer being peeled off;

[0038] FIG. 5 is a cross sectional view of the anti-wear composite structure of the present invention shown with the proactive layer and release layer peeled off and the anti-wear composite structure cured and adhered to the substrate;

[0039] FIG. 6 is a schematic cross sectional view of a woven anti-wear layer;

[0040] FIG. 7 is an exploded perspective view of the anti-wear composite structure of the present invention;

[0041] FIG. 8 is a cross sectional view of the anti-wear composite structure of the present invention with a thermoplastic tape; and

[0042] FIG. 9 is a is a cross sectional view of the anti-wear composite structure FIG. 8 shown with the proactive layer and release layer peeled off, the anti-wear composite structure cured and adhered to the substrate and a panel.

DETAILED DESCRIPTION

[0043] As shown in FIG. 1, an anti-wear composite structure of the present invention is generally designated by the numeral 10. The anti-wear composite structure 10 includes an anti-wear layer 30 (e.g., a solid-state, self-lubricating, anti-wear, composite layer, a sheet, a film, or a thickness) having a wear surface 32 opposite an adhesive receiving surface 34. Thus, the wear surface 32 and the adhesive receiving surface 34 are on opposing sides of the anti-wear layer 30. The anti-wear composite structure 10 includes a thin layer of thermosetting resin 40 (i.e., adhesive) applied to the adhesive receiving surface 34.

[0044] In some embodiments, the thermosetting resin 40 (i.e., adhesive) is applied only to the adhesive receiving surface 34. In some embodiments, the thermosetting resin 40 is applied to the entire adhesive receiving surface 34. In one embodiment, the thermosetting resin 40 is applied to portions of the adhesive receiving surface 34, for example, in a pattern. The thermosetting resin 40 is applied uniformly (i.e., a predetermined thickness) to the adhesive receiving surface 34 of the anti-wear layer 30.

[0045] While the thermosetting resin 40 is shown and described as being applied uniformly (i.e., a predetermined thickness) to the adhesive receiving surface 34 of the anti-wear layer 30, the present invention is not limited in this regard as the thermosetting resin 40 may be applied in non-uniform and various thicknesses to the adhesive receiving surface 34 of the anti-wear layer 30 to comport with non-uniform shape, contour, or irregularities in the surface of a substrate 60 that the anti-wear composite structure 10 is applied to.

[0046] While FIG. 1 illustrates the anti-wear composite structure 10 as being generally flat with the protective layer 20, anti-wear layer 30, the layer of thermosetting resin 40, and the release layer 50 being substantially flat and parallel to one another, the present invention is not limited in this regard as the anti-wear composite structure 10 may have other shapes and configurations including but not limited to arcuate shapes and shapes with corners. In one embodiment, the anti-wear composite structure 10 is flexible, pliable and is conformable to a shape (e.g., arcuate shape) of the substrate 60.

[0047] The thermosetting resin 40 includes a reactive adhesive that has a first bonding step and a second bonding step. During the first bonding step the reactive adhesive is configured to initially bond (e.g., temporarily bond or a precursor bond) the anti-wear composite structure 10 to a substrate 60 (see FIG. 3) at an ambient temperature band (e.g., 22.22 degrees Celsius plus or minus 8.33 degrees Celsius; or 72 degrees Fahrenheit plus or minus 15 degrees Fahrenheit) via pressure-sensitive adhesion. The first bonding steps allows the thermosetting resin 40 of the anti-wear composite structure 10 to be positioned on the substrate in preparation for performing the second bonding step. After the first bonding step is complete, the second bonding step is performed. The thermosetting resin 40 has an onset to cure and high tack in the ambient temperature band and has a peak cure temperature greater than the ambient temperature band to perform the second bonding step which mechanically and chemically bonds (e.g., permanently bonds) the anti-wear composite structure 10 to the substrate 60 (e.g., metal or composite substrate). The anti-wear composite structure 10 is clean-handling, easy to install, dimensionally uniform, can be fixed to any roughened substrate similar to a pressure sensitive adhesion material, and cures when heated under pressure, for example, under autoclave in 1 hour.

[0048] During the second bonding step, the reactive adhesive in thermosetting resin 40 of the anti-wear composite structure 10 is cured at a pressure of 2.06843 Bar to 6.89476 Bar (30 to 100 pounds per square inch), a temperature of 148.89 degrees Celsius to 204.444 degrees Celsius (300 to 400 degrees Fahrenheit) with a range of time from 30 to 90 minutes. In one embodiment, during the second bonding step the reactive adhesive in thermosetting resin 40 of the anti-wear composite structure 10 is cured at a pressure of 3.44738 Bar (50 pounds per square inch) and a temperature of 176.667 degrees Celsius (350 degrees Fahrenheit) for 60 minutes.

[0049] As shown in FIG. 6, in some embodiments the anti-wear layer 30 includes a woven structure 80. The woven structure 80 is made up of a thermally-consolidated, fabric reinforced-polymer matrix with self-lubricating components integral to a weave and/or as an additive to the matrix. The woven structure 80 includes a woven fabric that has a plurality of fibers 80A, 80B, 80C, and 80D interwoven with one another and polytetrafluoroethylene (PTFE) fibers 84 interwoven therewith. The fibers 80A, 80B, 80C, and 80D include, but are not limited to, those made of a polyester material, a stainless steel material, a PTFE material, and a glass material, or combinations thereof.

[0050] In some embodiments, the anti-wear layer 30 is a thermally-consolidated, machinable, moldable or non-woven fabric that has a reinforced polymer matrix composite with self-lubricating materials integral to the non-woven fabric and/or as an additive to the matrix.

[0051] In some embodiments, the thermosetting resin 40 is in the form of a tape calendered, or laminated, to one side of the anti-wear layer 30. In some embodiments, the thermosetting resin 40 is configured to be applied to the anti-wear layer in viscous form via resin application techniques comprising at least one of painting, brushing, rolling, and squeezing.

[0052] In some embodiments, the thermosetting resin 40 is configured to be dried to increase room temperature viscosity to allow for pressure sensitive adhesion without resin flowing from the bond line during application to a substrate 60.

[0053] As shown in FIG. 1, a protective layer 20 is semi-permanently adhered to (i.e., removably adhered to) the anti-wear layer 30 and is configured to be removed before or after bonding and before use in a service application. The protective layer 20 is shown in the process of being removed (e.g., peeled off as indicated by the arrow P2) from the anti-wear layer 30 in FIG. 4. FIG. 5 illustrates the anti-wear composite structure 10 cured bonded (e.g., permanently bonded) on the substrate with both the protective layer 20 and the release layer 50 removed therefrom. In some embodiments, the protective layer 20 includes indicia such as advertising and/or instructions for installation and use printed or formed thereon. The protective layer 20 is manufactured from a non-porous material, such as a polyester film to uniformly distribute pressure across the surface of the anti-wear composite structure 10 during the heat and pressure application stage of the curing and bonding process. The protective layer 20 also prevents premature damage to the anti-wear layer 30 before installation, for example during shipping and handling.

[0054] As shown in FIG. 1, the anti-wear composite structure 10 includes a release layer 50 semi-permanently adhered to or removably adhered to a surface 42 of the thermosetting resin 40. The release layer is configured to be entirely removed from the thermosetting resin 40 prior to bonding to a substrate 60. The release layer 50 is shown in a process being removed (e.g., peeled off) in FIG. 2, as indicated by the arrow P1. In some embodiments, the release 50 layer is a siliconized paper or polymer film 52.

[0055] The protective layer 20 has a thickness T1 in the range of 0.00508 cm to 0.03048 cm (0.002 inches to 0.012 inches). The anti-wear layer 30 has a thickness T2 in the range of 0.00508 cm to 0.3048 cm (0.002 inches to 0.120 inches). The thermosetting resin 40 has a thickness T3 in the range of 0.00508 cm to 0.0254 cm (0.002 inches to 0.010 inches). The release layer 50 has a thickness T4 in the range of 0.00508 cm to 0.03048 cm (0.002 inches to 0.012 inches).

[0056] As shown in FIG. 5, the wear surface 32 of the anti-wear layer 30 is in sliding engagement with a mating surface 72 of component 70. The anti-wear layer 30 provides resistance to galling and fretting of the mating surface 72 while providing a low friction interface between the anti-wear layer 30 and the mating surface 72.

[0057] While FIGS. 1-5 show and describe the anti-wear composite structure 10 with the thin layer of thermosetting resin 40 applied to the adhesive receiving surface 34 of the anti-wear layer 30, the present invention is not limited in this regard as the thin layer of thermosetting resin 40 may be replaced with a thin layer of thermoplastic adhesive tape 140, as shown in FIG. 8 for the anti-wear composite structure 110. The thin layer of thermoplastic adhesive tape 140 is applied to the adhesive receiving surface 34 of the anti-wear layer 30 via a suitable process such as calendaring. In one embodiment, the thermoplastic adhesive tape 140 is a thermoplastic polyurethane and is installed with heat to about 138 degrees Celsius (280 degrees Fahrenheit) to about 160 degrees Celsius (320 degrees Fahrenheit) and preferable to approximately 149 degrees Celsius (300 degrees Fahrenheit). The anti-wear composite structure 110 has the release layer 50 applied to the surface 42 of the thermoplastic adhesive tape 140. In addition, the protective layer 20 is applied to the wear surface 32 of the anti-wear layer 30.

[0058] The anti-wear composite structure 110 shown in FIG. 8 is suitable for situations where an anti-wear layer 30 requires temporary fixation to a panel because the panel will ultimately be fixed by mechanical means to a substrate. For example, as shown in FIG. 9, the anti-wear composite structure 110 has the protective layer 20 removed and the release layer 50 removed. The anti-wear layer 30 is removably adhered to the substrate 60 (e.g., a panel) with the thermoplastic adhesive tape 140 by heating to approximately 149 degrees Celsius (300 Fahrenheit). The substrate 60 is mechanically secured to the component 70 with mechanical fasteners such as bolts 77 and nuts 78. The anti-wear layer 30 prevents galling of the mating surface 72 of the component 70. When it comes time to replace the anti-wear composite structure 110, the thermoplastic adhesive tape 140 will peel away cleanly from the substrate 60, with minimal effort.

[0059] The substrate 60 has a service temperature of −54 degrees Celsius to 52 degrees Celsius (−65 degrees Fahrenheit to 125 degrees Fahrenheit). The overall advantage of the thermoplastic adhesive tape 140 is ease (and speed) of installation and cleanup at the sacrifice of a permanent chemical bond (which imparts creep resistance, temperature resistance, modulus, strength, and chemical resistance). If for some reason, the substrate 60 reached the melting temperature of the thermoplastic adhesive tape 140, the thermoplastic adhesive tape 140 would lose structure, but would this be inconsequential due to the mechanical fixation of the substrate 60 to the component 70.

[0060] The present invention also includes a method of applying an anti-wear composite structure 10 to a substrate 60. The method includes providing the anti-wear composite structure 10 illustrated in FIG. 1, including providing the anti-wear layer 30 having the thin layer of thermosetting resin 40 applied to the adhesive receiving surface 34; the protective layer 20 removably adhered to the wear surface 34 of the anti-wear layer 30; and the release layer 50 removably adhered to the surface 42 of the thermosetting resin 40. The temperature of the anti-wear composite structure 10 is maintained at a temperature below an ambient temperature (e.g., 22.22 degrees Celsius plus or minus 8.33 degrees Celsius; or 72 degrees Fahrenheit plus or minus 15 degrees Fahrenheit) before installation on the substrate 60 to prevent premature curing of the thermo setting resin 40. For example, the anti-wear composite structure 10 is maintained at a temperature below zero degrees Celsius (below 32 degrees Fahrenheit). The method includes removing the release layer 50 from the thermosetting resin 40. The thermosetting resin 50 portion of the anti-wear structure 10 is adhered (e.g., temporarily bonded or precursor bonded) to the substrate 60 via pressure-sensitive adhesion at the ambient temperature (e.g., 22.22 degrees Celsius plus or minus 8.33 degrees Celsius; or 72 degrees Fahrenheit plus or minus 15 degrees Fahrenheit). The method includes applying pressure to the anti-wear composite structure 10 via the protective layer 20. The method further includes heating the anti-wear composite structure 10 to a temperature sufficient to cure the thermosetting resin and mechanically and chemically permanently bond to the substrate 60. The curing of the thermosetting resin 40 can further include applying pressure to the anti-wear composite structure 10, for example, via application of pressure to the protective layer 20.

[0061] The method further includes removing the protective layer 20 from the anti-wear layer 30.

[0062] There is disclosed herein a method of manufacturing the anti-wear composite structure 10 that includes forming the anti-wear composite structure 10 to specific shapes via at least one of cutting, shaping, die stamping, computer numerical controlled machining (CNC), and hand trimming.

[0063] Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of the appended claims.