Abradable dry film lubricant and the method for applying same and article made therefrom

Abstract

An article with an abradable dry powder coating thereon comprises an abradably coated article with a substrate surface and having at least one coating of a liquid primer on the substrate surface and then coating with at least one abradable dry powder coating on the surface of the liquid primer. The sequence of layers may also be reversed, or additional layers may be useful. The abradable dry powder coating is formed of a dry powder coating composition including a thermoset resin having a cure temperature combined with at least one filler material, wherein the filler is formed of a material which does not melt substantially at or below the cure temperature of the resin, whereby an abradable coating results employing a filler to make the coating. A method of making a composition for coating an article with a coating curable into an abradable coating is also disclosed, comprising melt- mixing an evaporative carrier-free mixture of a dry powder thermoset resin having a cure temperature, to form a mass composite, wherein the filler is formed of a material which does not substantially melt at or below the cure temperature of the resin, cooling the mass composite, and breaking the cooled mass composite into powder particles, thereby forming the composite powder composition.

Description

[0001] Cross References to Related Applications [0002] This patent application claims co-pending U.S. Provisional Patent Application No. 60 / 863,533, filed October 30, 2006, and co-pending U.S. Patent Application No. 10 / 258,934, filed June 1, 2006, and Priority to US Provisional Patent Application No. 60 / 527,193, filed December 3, 2003, each of which is incorporated herein by reference. Background of the invention [0003] I. Field of Invention [0004] The present invention relates generally to abradable coatings and methods of application to provide coatings with improved adhesion, methods of abradable dry film lubricants, and articles made therefrom. [0005] II. Description of related technologies [0006] The efficiency of a pump, piston or compressor depends on the movement of internal components relative to each other to pump liquids or compress gases. For these devices to operate at their highest efficiency, leakage between moving elements needs to be minimized wit...

AI Technical Summary

Problems solved by technology

In addition, cleaning and maintaining solvent handling equipment often necessitates significant downtime

In addition to the issues associated with handling solvents, solvent-based materials pose some unique issues and additional costs when shipping

Another issue with coating thickness is that thick coatings are limited in thickness as they sag and run

[0010] While any water-based system is greener, there is additional cost and time involved in evaporating and disposing of the water from the coating, and still requires downtime to clean and maintain the equipment

In addition, not all resins can be formulated in water-based systems, so the types of resins that can be used in water-based systems are limited

[0011] Another disadvantage of spraying liquid-based formulations is the inability to recycle any overspray

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