SBIR Phase II: Low friction and high durability PTFE nanoparticle composite coating for bearings

这个小型企业创新研究(SBIR)二期项目将展示一种新型聚四氟乙烯(PTFE)复合涂层与目前市场上的金属-聚合物轴承的兼容性，扩大涂层沉积工艺，并实施中试生产线。目前，需要一种方法来改善聚四氟乙烯/金属界面的附着力，同时还减少腐蚀、摩擦和磨损。这项技术的实施将有助于制造业从传统润滑油向固体润滑油的过渡，并对美国经济和环境产生重大影响。目前，每年与润滑油相关的维护成本高达1万亿美元，截至2016年，石油润滑油的消费量预计将达到4378万吨。这项技术的有效实施将通过消除轴承过早故障来降低维护成本和停机时间。该项目将作为采用纳米涂层技术在机械系统中减少摩擦和磨损的证明。它还将降低这些涂层在以过时的润滑做法为主的行业中的进入门槛。金属聚合物轴承的总适用市场规模估计为10亿美元，该领域拟议技术的巨大近期收入机会将是这一努力的重点。这一滩头阵地机会是建议技术的行业验证点，也是其他工业和制造业应用的切入点。该项目的智力优势是基于使用粘合剂仿生聚合物改善金属-聚合物轴承中聚四氟乙烯衬里的附着力和机械性能。这项技术延长了聚四氟乙烯涂层的耐磨寿命，使它们可以应用于历史上因高磨损和分层而被排除在外的应用。在第一阶段，通过展示强大的粘附力、40%的摩擦、80%的磨损和消除当前金属-聚合物轴承的腐蚀敏感性，建立了概念验证。第二阶段的重点将是为特定的产品应用和实施量身定做涂料。拟议的SBIR第二阶段工作将克服剩余的技术障碍，并验证这项技术的使用既是改善聚四氟乙烯与基材之间附着力的解决方案，也是金属聚合物轴承中当前聚四氟乙烯衬里的替代方案。该项目的实施将允许实现工业合作伙伴所需的关键证据点，并加快将这项技术应用到产品线中。

This Small Business Innovation Research (SBIR) Phase II project will demonstrate compatibility of a novel polytetrafluoroethylene (PTFE) composite coating with metal-polymer bearings currently on the market, scale up the coating deposition process, and implement pilot processing lines. Currently, there is a need for a method to improve adhesion at the PTFE/metal interface while also reducing corrosion, friction, and wear. The implementation of this technology will aid in the transition from traditional lubricants to solid lubricants in manufacturing and has significant implications for the US economy and the environment. Currently, annual lubrication-related maintenance costs are as high as $1 trillion, and consumption of petroleum-based lubricants is estimated to reach 43.78 million metric tons as of 2016. The effective implementation of this technology will reduce maintenance costs and downtime by eliminating premature bearing failure. This project will serve as a proof point for the adoption of nano-coating technologies for reducing friction and wear in mechanical systems. It will also reduce barriers to entry for these coatings in industries dominated by outdated lubrication practices. The total applicable market size for metal-polymer bearings is estimated to be $1.0 billion, and a substantial near-term revenue opportunity for the proposed technology in this sector will be the focus of this effort. This beachhead opportunity serves as an industry validation point for the proposed technology and an entry point to other industrial and manufacturing applications.The intellectual merit of this project is based on improving the adhesion and mechanical properties of PTFE liners in metal-polymer bearings using an adhesive biomimetic polymer. This technology increases the wear-life of PTFE coatings, allowing for applications from which they have historically been precluded due to high wear and delamination. During Phase I, the proof of concept was established through demonstration of strong adhesion, 40% reduction in friction, 80% reduction in wear and elimination of susceptibility to corrosion in current metal-polymer bearings. The focus of Phase II will be in tailoring the coatings for specific product applications and implementation. The proposed SBIR Phase II work will overcome the remaining technical hurdles and validate the use of this technology as both a solution for improving the adhesion between PTFE and substrates and as a replacement for current PTFE liners in metal-polymer bearings. The execution of this project will allow the realization of critical proof points needed by industrial partners and speed the adoption of this technology into product lines.