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    • 专利摘要:
    The invention relates to a shaped carbon article in the form of a brake disc, the brake disc being coated with an antioxidant coating obtained by applying a primer coating comprising a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralized water; hardening of the primer coating; application as barrier coating of a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, deionized water, colloidal silica and boron nitride; and curing the barrier coating.
    公开号:FR3022242A1
    申请号:FR1555340
    申请日:2015-06-12
    公开日:2015-12-18
    发明作者:Craig Edwards；Johnson David Callum；Andrew Sketchley
    申请人:Meggitt Aerospace Ltd；
    IPC主号:
    专利说明:

    [0001] BACKGROUND OF THE INVENTION [0001] One aspect of the present invention relates to a carbon article, such as a brake disc, having an antioxidant coating. . Another aspect of the present invention relates to an antioxidant system for carbon. Another aspect of the present invention further relates to a primer coating composition. Another aspect of the present invention relates to a carbon antioxidant system having a primer coating comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralized water and a barrier coating comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralised water, colloidal silica and boron nitride. BACKGROUND OF THE INVENTION [0002] A problem with aircraft carbon brake rotors is that they are subject to oxidation on the basis of their operating environments. An attempt to protect these brake discs from oxidation involves the use of an antioxidant system. Antioxidant systems are used in brake discs to inhibit both catalytic oxidation and thermal oxidation. Known anti-oxidant systems include compositions of various components. These antioxidant systems have the weak points of not tackling the problem of catalytic induced oxidation from runway de-icers. The industry is shutting down the use of urea deicers for environmental concerns. Instead, potassium and sodium products are now used. Both, however, are subject to catalytic oxidation of the carbon brakes. Oxidation has a negative effect on the resistance of the brake discs. In some cases, the disc may weaken to a point where it is no longer capable of transferring torque, leading to breakage of the drive post. Oxidation includes both thermal oxidation and catalytic oxidation. [0005] Thermal oxidation is less frequently experienced, but occurs because of high brake temperatures. Catalytic oxidation occurs because of the combination of chemical contamination and heat. Catalytic oxidation can occur due to contamination by a cleaning fluid. It occurred more frequently after the introduction of new generation runway deicing fluids (RDF) based on acetates and alkali formates. Operators with road structures, where the brakes come in contact with these chemicals, experience more occurrences of catalytic oxidation. The effects of oxidation are not always immediately apparent, since the disc must be subjected to a high temperature for a certain period of time for the oxidation to develop completely. [0006] There are growing concerns in the industry regarding the effect of RDF on carbon brakes, particularly with respect to oxidation. EASA and FAA informed operators of the effects of oxidation and suggested that carbon brake discs be inspected for signs of oxidation. Thus, a need in the art exists for an improved carbon antioxidant coating for application to a carbon brake disc. One aspect of the present invention advances the art by providing an antioxidant coating and a carbon brake disc having an anti-oxidant coating that provides improved properties. Another aspect of the present invention also relates to an improved primer coating composition. SUMMARY OF THE INVENTION [0008] In a first embodiment, the present invention relates to a shaped carbon article in the form of a brake disc, the brake disc being coated with an anti-oxidant coating, the anti-oxidation coating being -oxidant, as applied, comprising: a first applied, cured primer coating comprising aluminum phosphate, the aluminum phosphate being formed by reacting orthophosphoric acid with hydrated aluminum chloride, a surfactant; industrial methylated alcohols and demineralised water; and a cured barrier coating, bonded to the cured primer coating, the cured barrier coating comprising colloidal silica, boron nitride and being formed from a composition comprising a surfactant, industrial methylated alcohols, demineralized water and aluminum phosphate, the aluminum phosphate being formed by reacting orthophosphoric acid with hydrated aluminum chloride. In a second embodiment, the present invention relates to a carbon article as in the first embodiment, wherein the antioxidant coating comprises aluminum phosphate in an amount of 5% by weight to 25% by weight. % in weight. In a third embodiment, the present invention relates to a carbon article as in any one of the first or second embodiment, wherein the antioxidant coating comprises the surfactant in an amount of 0. 0.1% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 10% by weight to 30% by weight, and demineralized water in an amount of 15% by weight to 35% by weight . In a fourth embodiment, the present invention relates to a carbon article as in any one of the first to third embodiments, wherein the anti-oxidant coating comprises colloidal silica in a quantity of 10. % by weight to 25% by weight and boron nitride in an amount of 0.01% by weight to 25% by weight. In a fifth embodiment, the present invention relates to a carbon article as in any one of the first to fourth embodiments, wherein the antioxidant coating further comprises boron. In a sixth embodiment, the present invention relates to a method of applying an antioxidant coating to a shaped carbon article in the form of a brake disc, the method comprising the steps of applying as a primer coating a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralized water; harden the primer coating; applying as a barrier coating a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralised water, colloidal silica and boron nitride; and cure the barrier coating. In a seventh embodiment, the present invention relates to a method as in the first six embodiments, wherein the precured primer coating comprises orthophosphoric acid in an amount of from 15% by weight to 45% by weight. % by weight, hydrated aluminum chloride in an amount of 15% by weight to 35% by weight, a surfactant in an amount of 0.01% by weight to 0.1% by weight, industrial methylated alcohols In an amount of 12% by weight to 30% by weight, and demineralized water in an amount of 15% by weight to 35% by weight. In an eighth embodiment, the present invention relates to a method as in any one of the sixth or seventh embodiment, wherein the precured barrier coating comprises orthophosphoric acid in an amount of 8. % by weight to 30% by weight, hydrated aluminum chloride in an amount of from 8% by weight to 20% by weight, a surfactant in an amount of from 0.01% by weight to 0.1% by weight weight, industrial methylated alcohols in an amount of 5% by weight to 20% by weight, demineralized water in an amount of 9% by weight to 20% by weight, colloidal silica in an amount of 10% by weight, weight at 25% by weight, and boron nitride in an amount of 5% by weight to 25% by weight. In a ninth embodiment, the present invention relates to a carbon article as in any one of the sixth to eighth embodiments, wherein the precured barrier coating further comprises boron. In a tenth embodiment, the present invention relates to an antioxidant system for carbon, as applied, comprising a primer coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralised water; and a barrier coating composition comprising orthophosphoric acid, surfactant, deionized, boron. Invention hydrated aluminum chloride, an industrial methylated alcohols, water colloidal silica and nitride of the present carbon such that in an eleventh embodiment, relates to an antioxidant system so that in the first ten embodiments, a primer coating comprises orthophosphoric acid in an amount of 15 wt.% to 45 wt.%, hydrated aluminum chloride in an amount of 15 wt.% to 35 wt.%, a surfactant in an amount of from 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 12% by weight to 30% by weight, and demineralized water in an amount of 15% by weight to 35% by weight. In a twelfth embodiment, the present invention relates to an antioxidant system for carbon such as in any one of the tenth or eleventh embodiment, wherein the barrier coating comprises orthophosphoric acid in a amount of 8% by weight to 30% by weight, hydrated aluminum chloride in an amount of 8% by weight to 20% by weight, a surfactant in an amount of 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 5% by weight to 20% by weight, demineralized water in an amount of 9% by weight to 20% by weight, colloidal silica in an amount of 10% by weight to 25% by weight, and boron nitride in an amount of 5% by weight to 25% by weight. [0020] In a thirteenth embodiment, the present invention relates to an antioxidant system for carbon as in any one of the tenth to twelfth embodiment, wherein the primer coating further comprises boron. In a fourteenth embodiment, the present invention relates to a primer coating composition comprising: orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, and demineralized water, the primer coating being capable of providing anti-oxidation properties when applied to a carbon article, the primer coating being further capable of supplying aluminum phosphate to a carbon article by reaction of orthophosphoric acid and hydrated aluminum chloride in situ after application to the carbon article. In a fifteenth embodiment, the present invention relates to a primer coating composition as in the fourteenth embodiment, wherein a primer coating comprises orthophosphoric acid in an amount of 15% by weight. 45% by weight and hydrated aluminum chloride in an amount of 15% by weight to 35% by weight. In a sixteenth embodiment, the present invention relates to a primer coating composition as in any one of the fourteenth or fifteenth embodiment, wherein a primer coating comprises the surfactant in an amount of from 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of from 12% by weight to 30% by weight, and demineralized water in an amount of 15% by weight to 35% by weight. % in weight. In a seventeenth embodiment, the present invention relates to a primer coating composition as in any one of the fourteenth through sixteenth embodiments, wherein the primer coating further comprises boron. In another embodiment, the present invention relates to a carbon article formed in the form of a brake disc, the brake disc being coated with an antioxidant coating, the anti-oxidant coating, such as applied, comprising aluminum phosphate, the aluminum phosphate being formed by reacting orthophosphoric acid with hydrated aluminum chloride; surfactant, industrial methylated alcohols and demineralised water; and colloidal silica and boron nitride. In yet another embodiment, the present invention relates to a shaped carbon article in the form of a brake disc, the brake disc 30 being coated with an anti-oxidant coating obtained by application as a primer coating. a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and deionized water; hardening of the primer coating; application as barrier coating of a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, deionized water, colloidal silica and boron nitride; and curing the barrier coating. In another embodiment, the present invention relates to an antioxidant system for carbon, as applied, comprising a primer coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralised water; and a barrier coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralized water, colloidal silica and boron nitride. In another embodiment, the present invention relates to a primer coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralised water. .
    [0002] Brief Description of the Drawings [0029] The advantages of the present invention will become more readily apparent from the following description and accompanying drawings in which: FIG. 1 is a top plan view of a disk of FIG. brake manufactured according to the invention; and [0031] FIG. 2 is a cross-sectional view of the brake disc of FIG. 1, taken along line 2-2.
    [0003] Detailed Description of Illustrative Embodiments [0032] Referring now to Figure 1 of the drawings, it can be seen that a carbon article, such as an aircraft brake disk, is generally designated by the numeral While a rotor disk is shown, the invention is equally applicable to stator disks, as well as to many other carbon products. The rotor disc 10 has a body 12 having a central annular space 14 for receiving a wheel shaft. Key grooves 16 are disposed around the periphery for functional engagement with an aircraft wheel. In Figure 2, a cross sectional view of the disk of Figure 1 is shown, showing the basic elements of the invention described below. The body has a carbon base 18, coated with an antioxidant coating having a primer coating bonded directly to the carbon, and a barrier coating 22 bonded to the primer coating 20. An embodiment of the present invention relates to a carbon article, such as a carbon brake disc, which is coated with an antioxidant coating. An embodiment of the present invention further relates to a coating or antioxidant system for carbon. An embodiment of the present invention further relates to a primer coating composition. In one or more embodiments, a primer coating composition comprises orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, and deionized water. In one or more embodiments, an antioxidant system for carbon comprises a primer coating and a barrier coating, wherein the primer coating comprises orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and deionized water and the barrier coating comprises orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralised water, colloidal silica and boron nitride. In one or more embodiments, a barrier coating further comprises boron. In one or more embodiments, a primer coating consists of orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and deionized water and a barrier coating consists of orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, deionized water, colloidal silica and boron nitride. In one or more embodiments, a barrier coating further comprises boron. In one or more embodiments, a carbon brake disk is coated with a primer coating and a barrier coating. Embodiments of the present invention offer improved properties over the known art. An improved carbon antioxidant system and improved primer coating composition provide better carbon brake protection. This improved protection is accomplished by improved properties of improved carbon brake surface coverage, improved thermal cycling properties, and more efficient icing and re-sealing at elevated temperatures. The primer coating composition, the carbon antioxidant coating and the carbon brakes which are coated with the primer coating composition and the antioxidant coating, will now be described in more detail. It should be noted that the specific materials and specific treatment conditions disclosed in the following disclosures are merely given as examples within the scope of the invention, and that this invention should not be limited to such materials or treatment conditions. as such. [0038] In one or more embodiments, a primer coating composition is provided. In one or more embodiments, an antioxidant system for carbon comprises two coating layers. In one or more embodiments, a carbon antioxidant system comprises a primer coating and a barrier coating. A primer coating of an antioxidant system for carbon generally works to protect a carbon brake from catalytic oxidation. [0039] A primer coating is the first coating that is applied to a carbon brake. As such, it is desired that a primer coating be able to infiltrate the pores of a carbon brake so as to better protect the pores against oxidation. A primer coating is capable of blocking or partially blocking the pores of the carbon brake, which mitigates the effects of catalytic oxidation. In one or more embodiments, a carbon antioxidant system comprises a primer coating having active ingredients that react to form a product, wherein the reaction product blocks, or partially blocks, the pores of a brake disk in carbon. In one or more embodiments, an antioxidant system for carbon comprises a primer coating which comprises orthophosphoric acid (also known as phosphoric acid) and hydrated aluminum chloride. The hydrated aluminum chloride may be represented by AlCl3H2O. The overall reaction between orthophosphoric acid and hydrated aluminum chloride, which forms aluminum phosphate and hydrochloric acid is the reaction: AlCl3 + H3 (PO4) Al (PO4) +3HCl [0041] L The purpose of a primer coating is to form the aluminum phosphate from the solution during drying and curing, rather than by a precipitation reaction during mixing or application of the solution. The formation of aluminum phosphate during drying and curing results in the aluminum phosphate being cured in exposed surfaces and open pores of the carbon brake.
    [0004] This results in the surfaces and pores being blocked or partially blocked, thereby attenuating the effects of oxidation, in particular catalytic oxidation.  Blockage of surfaces and pores results in catalyst particles being unable to penetrate the surfaces and pores of the carbon brake.  In addition to carrying out this reaction, it is theorized that embodiments having excess orthophosphoric acid provide additional protection against oxidation.  It is believed that the excess orthophosphoric acid will form a phosphate glass.  The phosphate glass then acts as a barrier and protects, or neutralizes, the carbon brake from catalytic oxidation, specifically protecting against catalysts used as runway de-icers such as potassium acetates, potassium formates, sodium acetates and sodium formates.  [0043] In one or more embodiments, a primer coating comprises 5% by weight or more of orthophosphoric acid, in other embodiments, a primer coating comprises 10% by weight or more of acid. In still other embodiments, a primer coating comprises 15% by weight or more orthophosphoric acid, and in still other embodiments, a primer coating comprises 25% by weight or more of orthophosphoric acid, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 70% by weight or less of orthophosphoric acid, in other embodiments, a primer coating comprises 60% by weight or less of acid. In yet other embodiments, a primer coating comprises 55% by weight or less orthophosphoric acid, and in still other embodiments, a primer coating comprises 45% by weight or less of orthophosphoric acid, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 5 wt.% Or more at 70 wt.% Or less of orthophosphoric acid, in other embodiments, a primer coating comprises 10% wt. 60% or more by weight or less orthophosphoric acid, in yet other embodiments, a primer coating comprises 15% or more by weight to 55% by weight or less orthophosphoric acid, and in still other embodiments other embodiments, a primer coating comprises 25 wt.% or more to 45 wt.% or less orthophosphoric acid, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 1% by weight or more of hydrated aluminum chloride, in other embodiments, a primer coating comprises 5% or more by weight of chloride. In still other embodiments, a primer coating comprises 10% by weight or more of hydrated aluminum chloride, and in still other embodiments, a primer coating comprises 15% by weight of aluminum oxide. weight or more hydrated aluminum chloride, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 50% by weight or less hydrated aluminum chloride, in other embodiments, a primer coating comprises 40% or less by weight of chloride. In still other embodiments, a primer coating comprises 35% by weight or less hydrated aluminum chloride, and in still other embodiments, a primer coating comprises 30% by weight of aluminum oxide. weight or less hydrated aluminum chloride, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 1 wt.% Or more to 50 wt.% Or less hydrated aluminum chloride, in other embodiments, a primer coating comprises From 40% to 40% by weight or less of hydrated aluminum chloride, in still other embodiments, a primer coating comprises from 10% by weight or more to 35% by weight or less of hydrated aluminum, and in yet other embodiments, a primer coating comprises 15 wt.% or more to 30 wt.% or less hydrated aluminum chloride, based on the total weight of the primer coating.  In one or more embodiments, an antioxidant system for carbon comprises a primer coating which comprises a surfactant.  In one or more embodiments, the surfactant is Triton X.  [0050] Triton X is a group of nonionic surfactants prepared by the reaction of octylphenol with ethylene oxide.  The products of this reaction have the general chemical structure of: (OCHCH), PH CH3 CH3 [0051] The surfactant acts as an organic wetting additive.  The surfactant increases the ability of the primer to wet the carbon surface, including open pores.  In one or more embodiments, a primer coating comprises 0.01 wt.% Or more surfactant, in other embodiments, a primer coating comprises 1 wt.% Or more of In still other embodiments, a primer coating comprises 2% by weight or more of surfactant, and in still other embodiments, a primer coating comprises 3% by weight or more surfactant, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 20% by weight or less surfactant, in other embodiments, a primer coating comprises 10% by weight or less of surfactant. In still other embodiments, a primer coating comprises 5% by weight or less of surfactant, and in still other embodiments, a primer coating comprises 0.1% by weight or less surfactant, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 0.01 wt.% Or more at 20 wt.% Or less of surfactant, in other embodiments, a primer coating comprises 1% by weight or more to 10% by weight or less surfactant, in yet other embodiments, a primer coating comprises 3% by weight or more at 5% by weight or less surfactant and in yet other embodiments, a primer coating comprises 0.01 wt% or more at 0.1 wt% or less surfactant, based on the total weight of the primer coating.  In one or more embodiments, an antioxidant system for carbon comprises a primer coating which comprises industrial methylated alcohols.  Industrial methylated alcohols (IMS), or denatured alcohol, are essentially ethanol with an additive.  IMSs interact with the demineralized water that is present.  The chemistry of this interaction is disclosed in R N Rothan, Solution-Deposited Metal Phosphate Coatings (September 1980).  The reaction produces an intermediate complex which dissolves in methanol.  The IMS give the primer coating a fast drying characteristic without impairing performance.  Water-based systems that do not have IMS tend to dry slowly.  In these systems, when the temperature is high to accelerate drying, some of the active ingredients are lost and performance is impaired.  Systems with IMS are fast-drying without impacting system performance.  In one or more embodiments, a primer coating comprises 5 weight percent or more of industrial methylated alcohols, in other embodiments, a primer coating comprises 10 weight percent or more of In yet other embodiments, a primary coating comprises 12% by weight or more of industrial methylated alcohols, and in still other embodiments, a primer coating comprises 18% by weight or more industrial methylated alcohols, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 40 weight percent or less of industrial methylated alcohols, in other embodiments, a primer coating comprises 30 weight percent or less of In still other embodiments, a primer coating comprises 25% by weight or less of industrial methylated alcohols, and in still other embodiments, a primer coating comprises 20% by weight or minus 10 industrial methylated alcohols, based on the total weight of the primer coating.  [0059] In one or more embodiments, a primer coating comprises 5 wt% or more to 40 wt% or less of industrial methylated alcohols, in other embodiments, a primer coating comprises From 30% to 30% by weight or less of industrial methylated alcohols, in yet other embodiments, a primer coating comprises from 12% by weight or more to 25% by weight or less of methylated alcohols. In yet another embodiment, a primer coating comprises from 18 wt.% or more to 20 wt.% or less of industrial methylated alcohols, based on the total weight of the primer coating.  [0060] In one or more embodiments, a carbon antioxidant system comprises a primer coating that includes deionized water.  Demineralized water is water from which mineral ions such as sodium, calcium, iron, copper, chloride and sulphate have been removed.  Methods of making and obtaining demineralized water are generally known in the art.  As mentioned above, a function of demineralized water is to react with IMS.  In one or more embodiments, a primer coating comprises 5% by weight or more of demineralized water, in other embodiments, a primer coating comprises 10% by weight or more of water. In still other embodiments, a primer coating comprises 15% by weight or more demineralised water, and in still other embodiments, a primer coating comprises 20% by weight or more of demineralized water, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 40 weight percent or less of demineralized water, in other embodiments, a primer coating comprises 35 weight percent or less of water. In yet other embodiments, a primer coating comprises 30% by weight or less demineralized water, and in still other embodiments, a primer coating comprises 25% by weight or less of demineralized water, based on the total weight of the primer coating.  In one or more embodiments, a primer coating comprises 5 wt.% Or more at 40 wt.% Or less demineralized water, in other embodiments, a primer coating comprises 10% w / w. In yet other embodiments, a primer coating comprises 15 wt.% Or more at 30 wt.% Or less of demineralised water, and in at least 35 wt. In still other embodiments, a primer coating comprises from 20% by weight or more to 25% by weight or less demineralized water, based on the total weight of the primer coating.  In one or more embodiments, after a primer coating is added to the carbon brake and is sufficiently dried, a barrier coating is added to the brake.  In one or more embodiments, a barrier coating contains all ingredients found in a primer coating.  A barrier coating generally works to protect against both catalytic oxidation and thermal oxidation.  In one or more embodiments, a barrier coating contains all the ingredients found in a primer coating as well as additional components.  In embodiments where the ingredients in a primer coating are replicated, it is believed that three advantages are achieved: ensuring that the surface has sufficient primer coverage as the primer coating is missing on areas of the surface, provide barrier coating solids that are cured and act as a binder to assist adhesion of the top coating, and improve adhesion between the primer coating and the barrier coating.  In one or more embodiments, the primer coating components have about 10% solids.  In one or more embodiments, a barrier coating comprises 5% by weight or more to 70% by weight or less of a primer coating composition, in other embodiments, a barrier coating comprises from 10% by weight or more to 60% by weight or less of a primer coating composition, in yet other embodiments, a barrier coating comprises 50% by weight or more at 60% by weight or less of a primer coating composition, and in still other embodiments, a barrier coating comprises from 25% by weight or more to 50% by weight or less of a primer coating composition, based on the total weight of the barrier coating.  [0067] In one or more embodiments, a carbon antioxidant system comprises a barrier coating that comprises orthophosphoric acid (also known as phosphoric acid) and hydrated aluminum chloride.  The properties of orthophosphoric acid and hydrated aluminum chloride in a barrier coating are as described above, other than the amount present.  In one or more embodiments, a barrier coating comprises 5% by weight or more of orthophosphoric acid, in other embodiments, a barrier coating comprises 8% by weight or more of acid. In yet other embodiments, a barrier coating comprises 20% by weight or more of orthophosphoric acid, and in still other embodiments, a barrier coating comprises 25% by weight or more of phosphoric acid. orthophosphoric acid, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 70% by weight or less of orthophosphoric acid, in other embodiments, a barrier coating comprises 60% by weight or less of acid. In yet other embodiments, a barrier coating comprises 55% by weight or less orthophosphoric acid, and in still other embodiments, a barrier coating comprises 35% by weight or less of orthophosphoric acid, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 5 wt.% Or more at 70 wt.% Or less orthophosphoric acid, in other embodiments, a barrier coating comprises 8% by weight. 60% or more by weight or less orthophosphoric acid, in yet other embodiments, a barrier coating comprises from 20% by weight or more to 55% by weight or less orthophosphoric acid, and in still other embodiments In other embodiments, a barrier coating comprises from 25 wt.% or more to 35 wt.% or less orthophosphoric acid, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 1% by weight or more of hydrated aluminum chloride, in other embodiments a barrier coating comprises 5% by weight or more of chloride. In still other embodiments, a barrier coating comprises 8% by weight or more of hydrated aluminum chloride, and in still other embodiments, a barrier coating comprises 15% by weight of aluminum oxide. weight or more hydrated aluminum chloride, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 50% by weight or less hydrated aluminum chloride, in other embodiments, a barrier coating comprises 40% by weight or less of chloride. In yet other embodiments, a barrier coating comprises 35% by weight or less hydrated aluminum chloride, and in still other embodiments, a barrier coating comprises 20% by weight weight or less hydrated aluminum chloride, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 1 wt.% Or more at 50 wt.% Or less hydrated aluminum chloride, in other embodiments, a barrier coating comprises From 40% to 40% by weight or less of hydrated aluminum chloride, in yet other embodiments, a barrier coating comprises from 10% by weight or more to 35% by weight or less of In still other embodiments, a barrier coating comprises from 15% by weight or more to 20% by weight or less hydrated aluminum chloride, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating which comprises a surfactant.  The properties of the surfactant in a barrier coating are as described above, other than the amount present.  In one or more embodiments, a barrier coating comprises 0.01% by weight or more of surfactant, in other embodiments a barrier coating comprises 1% by weight or more of 25% by weight. In yet other embodiments, a barrier coating comprises 2% by weight or more of surfactant, and in still other embodiments, a barrier coating comprises 3% by weight or more. of surfactant, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 20% by weight or less of surfactant, in other embodiments, a barrier coating comprises 10% by weight or less of surfactant. in yet other embodiments, a barrier coating comprises 5% by weight or less of surfactant, and in still other embodiments, a barrier coating comprises 0.1% by weight or less of surfactant, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 0.01 wt% or more at 20 wt% or less surfactant, in other embodiments, a barrier coating comprises 1 from 10% to 10% by weight or less of surfactant, in yet other embodiments, a barrier coating comprises 2% by weight or more at 5% by weight or less of surfactant, and in yet other embodiments, a barrier coating comprises 0.01 wt% or more at 0.1 wt% or less of surfactant, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating which comprises industrial methylated alcohols.  The properties of the industrial methylated alcohols in a barrier coating are such that otherwise than the amount present.  [0079] In one or more barrier coating modes comprising 5% of industrial methylated alcohols, in the above-described embodiments, one weight or more other embodiments, a barrier coating comprises 10% by weight. In yet other embodiments, a barrier coating comprises 15 wt.% or more of industrial methylated alcohols, and in still other embodiments, a barrier coating. comprises 18% by weight or more of industrial methylated alcohols, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 40% by weight or less of industrial methylated alcohols, in other embodiments, a barrier coating comprises 30% by weight or less of In yet other embodiments, a barrier coating comprises 25% by weight or less of industrial methylated alcohols, and in still other embodiments, a barrier coating comprises 20% by weight. or less industrial methylated alcohols, based on the total weight of the barrier coating.  [0081] In one or more embodiments, a barrier coating comprises 5 wt% or more at 40 wt% or less of industrial methylated alcohols, in other embodiments a barrier coating comprises From 30% to 30% by weight or less of industrial methylated alcohols, in still other embodiments, a barrier coating comprises 15% by weight or more to 25% by weight or less of methylated alcohols. In yet other embodiments, a barrier coating comprises from 18% by weight or more to 20% by weight or less of industrial methylated alcohols, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating which comprises deionized water.  The properties of demineralized water in a barrier coating are as described above, other than the amount present.  In one or more embodiments, a barrier coating comprises 5% by weight or more of demineralized water, in other embodiments, a barrier coating comprises 8% by weight or more of demineralised water. in still other embodiments, a barrier coating comprises 15% by weight or more of demineralized water, and in still other embodiments, a barrier coating comprises 20% by weight or more of water demineralized, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 40% by weight or less of demineralized water, in other embodiments, a barrier coating comprises 35% by weight or less of demineralized water. in still other embodiments, a barrier coating comprises 30 wt.% or less of demineralized water, and in yet other embodiments, a barrier coating comprises 23 wt.% or less of water demineralized, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 5 wt.% Or more at 40 wt.% Or less demineralized water, in other embodiments, a barrier coating comprises 8% wt. at least 35 wt.% or less of demineralised water, in still other embodiments, a barrier coating comprises 15 wt.% or more at 30 wt.% or less of demineralized water, and in still other embodiments In other embodiments, a barrier coating comprises from 20% by weight or more to 23% by weight or less demineralized water, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating that comprises colloidal silica.  Colloidal silica is a glass that acts as a binder to provide adhesion for a barrier coating, as well as adhesion between a primer coating and a barrier coating.  A glass of silicas is generally formed at a temperature above a boron glass.  A boron silicate glass is generally formed at a temperature between the silica glass and the boron glass.  Colloidal silica also has the ability to glaze and re-clog at elevated temperatures.  This icing and re-capping is particularly suitable since a carbon heat sink is subjected to thermal cycling.  Colloidal silica may exist in the form of layers, providing additional protection for a carbon brake surface during icing and re-capping.  Colloidal silica also allows the viscosity to be controlled.  The colloidal silica particles are generally very fine.  In one or more embodiments, the colloidal silica has an average particle diameter of 10 nm or greater at 100 nm or less.  This fineness allows the particles to fill the pores with a carbon brake surface on the basis of sufficient dispersion properties.  An example of a suitable colloidal silica is LEVASIL 200N.  In one or more embodiments, a barrier coating comprises 2% by weight or more of colloidal silica, in other embodiments, a barrier coating comprises 5% by weight or more of colloidal silica, in still other embodiments, a barrier coating comprises 10% or more by weight of colloidal silica, and in yet other embodiments, a barrier coating comprises% by weight or more of colloidal silica, on the basis of the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 35% by weight or less of colloidal silica, in other embodiments, a barrier coating comprises 30% by weight or less of colloidal silica, in still other embodiments, a barrier coating comprises 25% by weight or less of colloidal silica, and in still other embodiments, a barrier coating comprises 20% by weight or less of colloidal silica, on 10 basis of the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 2 wt.% Or more to 35 wt.% Or less of colloidal silica, in other embodiments, a barrier coating comprises 5% by weight. 30% or more by weight or less of colloidal silica, in yet other embodiments, a barrier coating comprises from 10% by weight or more to 25% by weight or less of colloidal silica, and in still other embodiments In other embodiments, a barrier coating comprises 15% by weight or more to 20% by weight or less of colloidal silica, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating which comprises boron nitride.  Boron nitride is a high temperature ceramic which in itself has good resistance to oxidation at about 900 degrees Celsius.  Boron nitride is included because of its inherent high resistance to oxidation.  Also, the boron nitride powders have a flake-like morphology, which leads to good coatings.  In one or more embodiments, a barrier coating comprises 0.01 wt.% Or more of boron nitride, in other embodiments, a barrier coating comprises 10 wt.% Or more of nitride. In still other embodiments, a barrier coating comprises 15 wt% or more of boron nitride, and in still other embodiments, a barrier coating comprises 20 wt% or more of boron nitride, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 40 wt% or less of boron nitride, in other embodiments, a barrier coating comprises 35 wt% or less of boron nitride. in still other embodiments, a barrier coating comprises 30 wt.% or less of boron nitride, and in yet other embodiments, a barrier coating comprises 25 wt.% or less of boron, based on the total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 0.01 wt.% Or more to 40 wt.% Or less of boron nitride, in other embodiments, a barrier coating comprises % by weight or more to 35% by weight or less of boron nitride, in yet other embodiments, a barrier coating comprises 15% by weight or more at 30% by weight or less of boron nitride, and in yet other embodiments, a barrier coating comprises 20% by weight or more to 25% by weight or less of boron nitride, based on the total weight of the barrier coating.  In one or more embodiments, an antioxidant system for carbon comprises a barrier coating that comprises boron.  In one or more embodiments, the boron is in the form of elemental boron.  In one or more embodiments, the boron is in a crystalline form.  In one or more embodiments, the boron is in an amorphous form.  As used herein, it should be understood that the term boron is defined as consisting essentially of boron.  It should be understood that some forms of boron may include small amounts of other elements, such as carbon.  Boron reacts with available oxygen to form a glass.  The glass then has the ability to glaze and re-clog at elevated temperatures as described above.  This icing and re-capping provides additional protection when the carbon heat sink is subjected to thermal cycling.  In combination with some of the available oxygen, boron still protects the carbon brake by preventing this oxygen from reacting with the carbon in the brake.  In one or more embodiments, a barrier coating comprises 0.01 wt.% Or more of boron, in other embodiments, a barrier coating comprises 10 wt.% Or more of boron, in which further embodiments, a barrier coating comprises 15 wt.% or more of boron, and in yet other embodiments, a barrier coating comprises 20 wt.% or more of boron, based on total weight of the barrier coating.  In one or more embodiments, a barrier coating comprises 40 wt.% Or less boron, in other embodiments, a barrier coating comprises 35 wt.% Or less of boron, in addition to In other embodiments, a barrier coating comprises 30 wt% or less of boron, and in still other embodiments, a barrier coating comprises 25 wt% or less of boron, based on the total weight barrier coating.  In one or more embodiments, a barrier coating comprises 0.01 wt.% Or more to 40 wt.% Or less boron, in other embodiments, a barrier coating comprises 10% wt. 35% or more by weight or less of boron, in still other embodiments, a barrier coating comprises from 15% by weight or more to 30% by weight or less of boron, and in still others In embodiments, a barrier coating comprises from 20% by weight or more to 25% by weight or less boron, based on the total weight of the barrier coating.  In one or more embodiments, a carbon article is formed as a brake disc and the brake disc is coated with an antioxidant coating.  In one or more embodiments, the antioxidant coating comprises a composition comprising the curing products of a primer coating and a barrier coating.  In one or more embodiments, the antioxidant coating comprises 5 wt% or more to 35 wt% or less of aluminum phosphate, in other embodiments, the antioxidant coating comprises from 10 wt.% or more to 30 wt.% or less of aluminum phosphate, in yet other embodiments, the antioxidant coating comprises 15 wt.% or more at 25 wt.% or less of phosphate In aluminum, and in yet other embodiments, the antioxidant coating comprises 18 wt.% Or more to 23 wt.% Or less of aluminum phosphate, based on the total weight of the anti-oxidant coating. oxidant.  These percentages are based on the applied primer coating (ie wet or uncured).  In light of the foregoing, it should be understood that the present invention advances the art.  One aspect of the present invention enhances the art by providing an improved antioxidant system and an improved primer coating composition protecting against potassium and sodium deicers.  Another aspect of the present invention relates to carbon articles, such as brake disks, which are coated with an improved antioxidant coating.  While particular embodiments of the invention have been disclosed in detail herein, it should be understood that the invention is not limited thereto or by them to the extent that variants of the invention will be easily understood by those skilled in the art.  The scope of the invention should be understood from the following claims.
    [0005] Examples [0104] Control: The starting point for the comparison was a baseline anti-oxidant system. These baseline samples were coated, cured, immersed (for 30 minutes in 25 w / w potassium acetate solution) and dried. The samples were then tested for oxidation in calm air at 550 ° C for 8 hours and recorded an average weight loss of 15%. In one example, 174 g of hydrated aluminum chloride were placed in a graduated beaker. In a separate beaker, 158 g of industrial methylated alcohols, 200 g of demineralized water and 0.22 g of Triton X-100 were combined. 151 g of orthophosphoric acid were placed in a third beaker. Then enough of an IMS / water solution was added to dissolve the aluminum chloride while stirring manually (or mechanically). Then orthophosphoric acid was added. Cuboid carbon / carbon samples were given two coatings of the resulting combination, by brush. The samples were then cured using a standard thermal cycle and immersed for 30 minutes in a 25 w / w potassium acetate solution. The samples were then dried. The samples were tested for oxidation in calm air at 550 ° C for 24 hours and recorded an average weight loss of 5.3%. [0106] Primary Coating 2 (Primary DJ011): In another example, 174 grams of hydrated aluminum chloride was placed in a graduated beaker. In a separate beaker, 158 g of industrial methylated alcohols, 200 g of demineralized water and 0.22 g of Triton X-100 were combined. 288 g of orthophosphoric acid were placed in a third beaker. Then enough of an IMS / water solution was added to dissolve the aluminum chloride while stirring manually (or mechanically). Then orthophosphoric acid was added. Cuboid carbon / carbon samples were given two coats of the resulting combination by brush. The samples were then cured using a standard thermal cycle and immersed for 30 minutes in a 25 w / w potassium acetate solution. The samples were then dried. The samples were tested for oxidation in calm air at 550 ° C for 24 hours and recorded an average weight loss of 0.26%. In another example, 174 g of hydrated aluminum chloride were placed in a graduated beaker. In a separate beaker, 158 g of industrial methylated alcohols, 200 g of demineralized water and 0.22 g of Triton X-100 were combined. 347 g of orthophosphoric acid were placed in a third beaker. Then enough of an IMS / water solution was added to dissolve the aluminum chloride while stirring manually (or mechanically). Then orthophosphoric acid was added. Cuboid carbon / carbon samples were given two coatings of the resulting combination, by brush. The samples were then cured using a standard thermal cycle and immersed for 30 minutes in a 25 w / w potassium acetate solution. The samples were then dried. The samples were tested for oxidation in calm air at 550 ° C for 24 hours and recorded an average weight loss of 0.29%. [0108] Barrier Coating 1 (AS302): In another example, 17 g of Levasil 200N (30%) and 20 g of boron nitride were added to 50 g of the Primary Coating 2 (DJ011). The combination was mixed using a high speed dispersion mixer (or a bead mixer could be used) to obtain good dispersion. Using the resulting mixture, a cuboid / carbon carbon sample was given a coating of Primary Coating 2 (DJ011), applied with a spray gun. The samples were then dried for 1 hour and cured using a standard thermal cycle. Two Coatings of Barrier Coating 1 (AS302) were then applied using a spray gun. The samples were then cured using a standard thermal cycle and immersed for 30 minutes in a 25 w / w potassium acetate solution. The samples were tested for oxidation in calm air at 550 ° C for 264 hours and recorded an average weight loss of 1.66%. [0109] Barrier Coating 2 (AS304): In another example, 20.6 g of Levasil 200N (30%) and 23 g of boron were added to 73.5 g of the Primary Coating 2 (DJ011). The combination was mixed using a high speed dispersion mixer (or a bead mixer could be used) to obtain good dispersion. Using the resultant mixture, a cuboid / carbon carbon sample was given a Coating of Primary Coating 2 (DJ011) coating, applied with a spray gun. The samples were then dried for 1 hour and cured using a standard thermal cycle. Two Coatings of Barrier Coating 1 (AS302) were then applied using a spray gun. The samples were cured using a standard thermal cycle and immersed for 30 minutes in 25 w / w potassium acetate solution. The samples were tested for oxidation in calm air at 550 ° C for 264 hours and recorded an average weight loss of 7.13%. Various modifications and changes that do not depart from the scope and spirit of this invention will be apparent to those skilled in the art. This invention should not be limited simply to the illustrative embodiments set forth herein.
    权利要求:
    Claims (17)
    [0001]
    CLAIMS 1 - A carbon article formed as a brake disc, the brake disk being coated with an antioxidant coating, the anti-oxidant coating, as applied, comprising: a primer coating applied first cured, comprising aluminum phosphate, the aluminum phosphate being formed by reacting orthophosphoric acid with hydrated aluminum chloride, a surfactant, industrial methylated alcohols, and demineralized water; and a cured barrier coating, bonded to the cured primer coating, the cured barrier coating comprising colloidal silica, boron nitride, and being formed from a composition comprising a surfactant, industrial methylated alcohols, and , demineralized water and aluminum phosphate, the aluminum phosphate being formed by reacting orthophosphoric acid with hydrated aluminum chloride.
    [0002]
    2 - carbon article according to claim 1, characterized in that the antioxidant coating comprises aluminum phosphate in an amount of 5% by weight to 25% by weight.
    [0003]
    3 - carbon article according to one of claims 1 or 2, characterized in that the antioxidant coating comprises the surfactant in an amount of 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 10% by weight to 30% by weight and demineralized water in an amount of 15% by weight to 35% by weight.
    [0004]
    4 - carbon article according to one of claims 1, 2 or 3, characterized in that the antioxidant coating comprises colloidal silica in an amount of 10% by weight to 25% by weight and boron nitride in an amount of 0.01% by weight to 25% by weight.
    [0005]
    5 - carbon article according to any one of the preceding claims, characterized in that the antioxidant coating further comprises boron.
    [0006]
    6 - Process for applying an antioxidant coating to a shaped carbon article in the form M of a brake disc, the method being characterized in that it comprises the steps of: - applying as a primer coating a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols and demineralized water; - harden the primer coating; applying as a barrier coating a composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralized water, colloidal silica and boron nitride; and - curing the barrier coating.
    [0007]
    7 - Process according to claim 6, characterized in that the precured primer coating comprises orthophosphoric acid in an amount of 15% by weight to 45% by weight, hydrated aluminum chloride in an amount of 15% by weight. % by weight to 35% by weight, a surfactant in an amount of from 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 12% by weight to 30% by weight, and demineralized water in an amount of 15% by weight to 35% by weight.
    [0008]
    8 - Method according to one of claims 6 or 7, characterized in that the precured barrier coating comprises orthophosphoric acid in an amount of 8% by weight to 30% by weight, hydrated aluminum chloride in from 8% by weight to 20% by weight, a surfactant in an amount of from 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 5% by weight to 20% by weight, demineralized water in an amount of 9% by weight to 20% by weight, colloidal silica in an amount of 10% by weight to 25% by weight and boron nitride in an amount of 5% by weight to 25% by weight.
    [0009]
    9 - Process according to claim 6, characterized in that the precured barrier coating further comprises boron.
    [0010]
    An antioxidant system for carbon, as applied, comprising: a primer coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, and 'Demineralized Water ; and a barrier coating composition comprising orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, demineralized water, colloidal silica and boron nitride.
    [0011]
    11 - antioxidant system for carbon according to claim 10, characterized in that a primer coating comprises orthophosphoric acid in an amount of 15% by weight to 45% by weight, hydrated aluminum chloride in an amount of from 15% by weight to 35% by weight, a surfactant in an amount of from 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 12% by weight to 30% by weight % by weight and demineralized water in an amount of 15% by weight to 35% by weight.
    [0012]
    12 - antioxidant system for carbon according to one of claims 10 or 11, characterized in that the barrier coating comprises orthophosphoric acid in an amount of 8% by weight to 30% by weight, chloride of aluminum hydrate in an amount of 8% by weight to 20% by weight, a surfactant in an amount of 0.01% by weight to 0.1% by weight, industrial methylated alcohols in an amount of 5% by weight % by weight to 20% by weight, demineralized water in an amount of 9% by weight to 20% by weight, colloidal silica in an amount of 10% by weight to 25% by weight and boron nitride in an amount of 5% by weight to 25% by weight. 25
    [0013]
    13 - antioxidant system for carbon according to one of claims 10, 11 or 12, characterized in that the primer coating further comprises boron. 30
    [0014]
    A primer coating composition comprising: orthophosphoric acid, hydrated aluminum chloride, a surfactant, industrial methylated alcohols, and demineralized water, the primer coating being capable of providing anti-oxidation when applied to a carbon article, the primer coating being further capable of supplying aluminum phosphate to a carbon article by reacting orthophosphoric acid and hydrated aluminum chloride in situ after application on the carbon article. 10
    [0015]
    The primer coating composition according to claim 14, characterized in that a primer coating comprises orthophosphoric acid in an amount of from 15% by weight to 45% by weight and hydrated aluminum chloride in the form of a primer coating. from 15% by weight to 35% by weight.
    [0016]
    16 - primer coating composition according to one of claims 14 or 15, characterized in that a primer coating comprises the surfactant in an amount of 0.01% by weight to 0.1% by weight industrial methylated alcohols in an amount of from 12% by weight to 30% by weight and demineralized water in an amount of 15% by weight to 35% by weight. 25
    [0017]
    17 - primer coating composition according to one of claims 14, 15 or 16, characterized in that the primer coating further comprises boron. 30
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    同族专利:
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    优先权:
    申请号 | 申请日 | 专利标题
    GB1410549.8A|GB2518032B|2014-06-13|2014-06-13|A carbon article having an improved primer coating and an improved anti-oxidant coating|
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