Epoxy resin-based cathodic electrodeposition (CED) of metal components as an adhesion promoter for PU systems

Abstract

The present invention relates to a composite element, especially for a damping element, comprising a) at least one metallic body having a surface; b) a coating comprising an epoxy resin on at least part of the surface of the metallic body; c) a plastics body comprising at least one polyurethane, which at least partly surrounds the metallic body of (a) and in the region of the surround is at least partly in direct contact with the coating of (b), wherein the composite element between the surface of the metallic body (a) and the coating (b) has a conversion layer (d) which comprises at least one compound selected from the group of zirconium(IV) oxide, zinc(II) phosphate, and chromate. The invention further relates to a damping element comprising the composite element and at least one further body which is at least partly in direct contact with the composite element, preferably with the plastics body of (c). The invention additionally relates to production processes for composite element and damping element, to the composite and damping elements, respectively, that are produced or producible by these processes, and the use of these composite and damping elements, respectively.

Claims

1. A shock absorber comprising a damping element, wherein the damping element comprises (1) a composite element and (2) a further body which is at least partly in direct contact with the composite element, wherein the composite element comprises: a) a metallic body having a surface; b) a coating comprising an epoxy resin on at least part of the surface of the metallic body of (a); and c) a plastics body comprising a polyurethane, which at least partly surrounds the metallic body of (a) and, in a region in which the plastics body at least partly surrounds the metallic body, is at least partly in direct contact with the coating of (b), wherein the composite element of (1) has, between the surface of the metallic body of (a) and the coating of (b), a conversion layer (d) which comprises a compound selected from the group of consisting of zirconium(IV) oxide, zinc(II) phosphate, and chromate, wherein the metallic body has an annular or perforated disk shape with a central hole, wherein the coating comprising the epoxy resin is on at least an outer part of the surface of the metallic body, wherein the plastics body is between the metallic body and the further body, wherein the further body has a coating comprising an epoxy resin on at least part of its inner surface, and wherein the further body comprises a polyurethane body.

2. The shock absorber element of claim 1, wherein the polyurethane body is a cellular polyurethane.

3. The shock absorber element of claim 1, wherein the polyurethane body is a cellular polyurethane having a density in the range from 200 to 1100 kg/m.sup.3.

4. The shock absorber element of claim 1, wherein the metallic body of (a) comprises an iron alloy or aluminum.

5. The shock absorber element of claim 4, wherein the metallic body of (a) comprises steel as the iron alloy.

6. The shock absorber element of claim 1, wherein the polyurethane body is a cellular polyurethane having a density in the range from 200 to 750 kg/m.sup.3.

7. A process for producing the shock absorber element of claim 1, the process comprising: (1) introducing the metallic body the coating comprising the epoxy resin on at least part of the surface of the metallic body into a mold, (2) introducing the further body into the mold, with a part of the mold remaining empty; and (3) introducing a plastics composition into the part of the mold from (2) that has remained empty.

Description

DESCRIPTION OF THE FIGURES

(1) FIG. 1 shows a perspective view of a coated metallic body 1, with the metallic body 2 being present here in the form of a ring which has a coating 3 comprising an epoxy resin on at least part of its surface;

(2) FIG. 2 shows a section through a damping element 4, comprising a composite element 5 which has a plastics body 6 comprising at least one polyurethane and a coated metallic body 1, which is in turn at least partly surrounded by a further body 7, here a further plastics body 7;

(3) FIG. 3 shows a metallic body 1 in the form of a (hollow) cylinder (inner sleeve), and a further, likewise metallic body 7 in the form of a further hollow cylinder (outer sleeve) for a round bearing, where the outer sleeve has a coating at least on part of its inner surface 8 (not shown) and the inner sleeve has a coating at least on part of its outer surface 9 (not shown);

(4) FIG. 4 shows a section through a round bearing comprising an inner sleeve 1, an outer sleeve 7, and a plastics body 6 between inner and outer sleeves;

(5) FIG. 5 shows, schematically, a sample body used for the study of the adhesive strength, where the numerical figures are to be understood as length figures in millimeters (e.g. 12.5=12.5 mm), and where (a) shows a side view and (b) shows the corresponding front view;

(6) FIG. 6 shows the results of the adhesive strength studies (lap shear strength) for an epoxy resin-coated metallic body+plastics body in comparison to a metallic body electroplated with ZnFe+plastics body;

(7) FIG. 7 shows the results of the bursting force studies for a damping element based on an epoxy resin-coated metallic body+plastics body, in comparison to those for a damping element based on a metallic body electroplated with ZnFe+plastics body;

(8) FIG. 8 shows, schematically, the apparatus (bursting test bearing) used for the bursting test studies;

(9) FIG. 9 shows the results of the adhesive strength studies (lap shear strength) for a conversion-coated and epoxy resin-coated metallic body (aluminum)+plastics body in comparison to a metallic body (aluminum) which has only been conversion-coated+plastics body and in comparison to a metallic body (aluminum) which has been sandblasted and coated with a conventional PU adhesion promoter+plastics body;

(10) FIG. 10 shows the results of the adhesive strength studies (lap shear strength) for a conversion-coated and epoxy resin-coated metallic body (steel)+plastics body in comparison to a metallic body (steel) which has only been conversion-coated+plastics body and in comparison to a metallic body (steel) which has been sandblasted and coated with a conventional PU adhesion promoter+plastics body.

CITED LITERATURE

(11) U.S. Pat. No. 8,459,621 B1 EP 0 961 797 B1 EP 1 379 588 B1 EP 1 171 515 B1