Anticorrosion coating, cookware and method of manufacturing cookware

Abstract

This application provides an anti-corrosion coating, cookware, and a method for manufacturing the cookware. The anti-corrosion material is a mixture comprising anti-corrosion particles and metal particles. The composition of the anti-corrosion particles, by weight percentage, includes: 50% ≤ silicon dioxide ≤ 75%, 15% ≤ aluminum oxide ≤ 30%, 0.1% ≤ potassium oxide ≤ 2%, 0.1% ≤ sodium oxide ≤ 2%, 1% ≤ calcium oxide ≤ 10%, 0.5% ≤ magnesium oxide ≤ 3%, 0.2% ≤ titanium oxide ≤ 1.3%, and 5% ≤ iron oxide + ferrous oxide ≤ 10%. According to the anti-corrosion material of this application, an anti-corrosion coating with excellent corrosion resistance can be obtained.

Description

Technical Field

[0001] This application relates to the field of cookware corrosion protection technology, and more specifically, to a corrosion-resistant material for cookware, a corrosion-resistant coating, cookware, and a method for manufacturing cookware. Background Technology

[0002] Currently, corrosion (rust) prevention in cookware can be achieved by forming a relatively dense nitrogen / oxide film on the substrate surface through nitriding and oxidation. Cookware with this nitrogen / oxide film exhibits good corrosion resistance, but weak points are prone to pitting corrosion. Alternatively, organic fluorine coatings can be sprayed onto the cookware to achieve corrosion (rust) prevention, but the resulting organic protective film is prone to aging and failure at high temperatures and is easily scratched by tools like spatulas, thus still making rusting difficult to prevent. Therefore, there is an urgent need to develop new anti-corrosion particles. Summary of the Invention

[0003] Therefore, the purpose of this application is to provide a corrosion-resistant material, a corrosion-resistant coating, a cookware, and a method for manufacturing cookware to solve the corrosion problem of cookware.

[0004] According to a first aspect of this application, a corrosion-resistant material is provided for cookware, wherein the corrosion-resistant material is a mixture comprising corrosion-resistant particles and metal particles, and the composition of the corrosion-resistant particles, by weight percentage, includes: 50%≤silicon dioxide≤75%, 15%≤alumina≤30%, 0.1%≤potassium oxide≤2%, 0.1%≤sodium oxide≤2%, 1%≤calcium oxide≤10%, 0.5%≤magnesium oxide≤3%, 0.2%≤titanium oxide≤1.3%, and 5%≤iron oxide + ferrous oxide≤10%.

[0005] In some embodiments, the composition of the anti-corrosion particles, by weight percentage, includes: 60%≤silicon dioxide≤70%, 20%≤alumina≤25%, 0.5%≤potassium oxide≤1.5%, 0.5%≤sodium oxide≤1.5%, 1.5%≤calcium oxide≤8%, 1%≤magnesium oxide≤2.5%, 0.5%≤titanium oxide≤1.0%, and 6%≤iron oxide + ferrous oxide≤9%.

[0006] In some embodiments, the weight ratio of the anti-corrosion particles to the metal particles is 7:3 to 9:1; and / or the anti-corrosion particles are materials with an amorphous phase volume fraction in the range of 15%-55%; and / or the average particle size of the anti-corrosion particles is in the range of 20μm to 100μm; and / or the average particle size of the metal particles is in the range of 60μm to 100μm; and / or the melting point of the anti-corrosion particles is lower than that of the metal particles, and the thermal conductivity of the anti-corrosion particles is lower than that of the metal particles; and / or the color of the anti-corrosion particles is black.

[0007] In some embodiments, the particle size R of the anti-corrosion particles includes a first distribution range, a second distribution range, and a third distribution range. The first distribution range is 20μm≤R<40μm, the second distribution range is 40μm≤R<70μm, and the third distribution range is 70μm≤R≤100μm. Based on the total volume of the anti-corrosion particles in the mixture being 100%, the volume percentage of anti-corrosion particles with a particle size in the first distribution range is 20%-40%, the volume percentage of anti-corrosion particles with a particle size in the second distribution range is 35%-65%, and the volume percentage of anti-corrosion particles with a particle size in the third distribution range is 10%-25%.

[0008] In some embodiments, the corrosion-resistant particles are silicate materials; and / or the metal particles are at least one of titanium particles, titanium alloy particles, and stainless steel particles.

[0009] According to a second aspect of this application, an anti-corrosion coating is provided, wherein the anti-corrosion coating comprises anti-corrosion particles and metal particles filling the pores between the anti-corrosion particles, wherein the composition of the anti-corrosion particles, by weight percentage, comprises: 50% ≤ silicon dioxide ≤ 75%, 15% ≤ aluminum oxide ≤ 30%, 0.1% ≤ potassium oxide ≤ 2%, 0.1% ≤ sodium oxide ≤ 2%, 1% ≤ calcium oxide ≤ 10%, 0.5% ≤ magnesium oxide ≤ 3%, 0.2% ≤ titanium oxide ≤ 1.3%, and 5% ≤ iron oxide + ferrous oxide ≤ 10%.

[0010] In some embodiments, the corrosion-resistant particles are silicate materials; and / or the metal particles include at least one of titanium particles, titanium alloy particles, and stainless steel particles.

[0011] In some embodiments, the weight ratio of the anti-corrosion particles to the metal particles is 7:3 to 9:1; and / or the anti-corrosion particles are materials with an amorphous phase volume ratio in the range of 15%-55%; and / or the melting point of the anti-corrosion particles is lower than that of the metal particles, and the thermal conductivity of the anti-corrosion particles is lower than that of the metal particles; and / or the color of the anti-corrosion particles is black.

[0012] In some embodiments, the anti-corrosion coating includes at least one of the following characteristics: the surface porosity of the anti-corrosion coating is 1%-10%; the pore size of the anti-corrosion coating is 0.1μm to 1μm; the hardness of the anti-corrosion coating is 400HV to 800HV; and the volume fraction of the amorphous phase in the anti-corrosion coating is 15%-70%.

[0013] According to a third aspect of this application, a method for manufacturing a cookware is provided, wherein the method comprises: providing a substrate; providing an anti-corrosion material; and spraying the anti-corrosion material onto the surface of the substrate to form an anti-corrosion coating on the surface of the substrate, wherein the anti-corrosion material comprises the anti-corrosion material provided according to the various embodiments described above.

[0014] In some embodiments, the method further includes: heat-treating the anti-corrosion coating to melt the surface of the anti-corrosion coating, and then cooling the molten anti-corrosion coating at a cooling rate of 100°C / s-200°C / s.

[0015] In some embodiments, the method of manufacturing cookware further includes: forming a sealing layer on the anti-corrosion coating, the sealing layer comprising silicone oil and / or grease, thereby sealing the surface pores of the anti-corrosion coating.

[0016] In some embodiments, the substrate has a first surface and a second surface facing away from each other, and the step of forming an anti-corrosion coating includes: cooling the second surface of the substrate and spraying the anti-corrosion material onto the first surface of the substrate to form an anti-corrosion coating.

[0017] According to a fourth aspect of this application, a cookware is provided, wherein the cookware includes a substrate and an anti-corrosion coating formed on the substrate, wherein the anti-corrosion coating includes the anti-corrosion coating provided according to the above embodiments or includes an anti-corrosion coating formed from the anti-corrosion material provided according to the above embodiments. Attached Figure Description

[0018] The above and / or other features and aspects of the inventive concept will become clear and readily understood through the description of the embodiments in conjunction with the accompanying drawings.

[0019] Figure 1 This is an XRD pattern of an anti-corrosion material provided according to an embodiment of this application;

[0020] Figure 2 This is a schematic diagram of the cross-sectional structure of the cookware provided in the embodiment of this application after being cut along the thickness direction;

[0021] Figure 3 yes Figure 2 Enlarged view of point I in the middle;

[0022] Figure 4 This is the XRD pattern of the anti-corrosion coating provided according to the embodiments of this application.

[0023] Symbol explanation:

[0024] 100. Non-stick cookware; 110. Substrate; 120. Anti-corrosion coating; 130. Base coat. Detailed Implementation

[0025] Example embodiments of the inventive concept will now be described in more detail. While example embodiments of the inventive concept are described below, it should be understood that the inventive concept can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the invention and to fully convey the scope of the inventive concept to those skilled in the art.

[0026] In existing technologies, an inorganic corrosion-resistant coating, such as a titanium coating and / or at least one metal oxide coating, can be prepared on the surface of an iron substrate. While these inorganic coatings are stable, they inherently possess large pores. During use, corrosive media can easily penetrate these pores, affecting the overall corrosion resistance of the inner coating. Long-term penetration can also lead to corrosion at the interface between the substrate and the inorganic coating, causing the coating to crack and peel off. Although existing technologies also employ sealants to seal the pores, these sealants, located on the surface of the inorganic coating, are easily worn away after a period of use, reducing the overall corrosion resistance of the inner coating.

[0027] According to this application, a certain composition and content of anti-corrosion particles can ensure the formation of a dense anti-corrosion coating on the substrate, thereby guaranteeing reliable corrosion resistance of the cookware during use. By forming a mixture of a certain amount of metal particles and the aforementioned anti-corrosion particles, the metal particles can fill the gaps between adjacent anti-corrosion particles, thereby reducing the open porosity of the coating and making the pores as closed as possible to further ensure corrosion resistance during use.

[0028] According to a first aspect of this application, a corrosion-resistant material for cookware is provided, wherein the corrosion-resistant material is a mixture comprising corrosion-resistant particles and metal particles, wherein the composition of the corrosion-resistant particles, by weight percentage, comprises: 50%≤silicon dioxide≤75%, 15%≤alumina≤30%, 0.1%≤potassium oxide≤2%, 0.1%≤sodium oxide≤2%, 1%≤calcium oxide≤10%, 0.5%≤magnesium oxide≤3%, 0.2%≤titanium oxide≤1.3%, and 5%≤iron oxide + ferrous oxide≤10%.

[0029] In some embodiments, the composition of the anti-corrosion particles, by weight percentage, includes: 60% ≤ silicon dioxide ≤ 70%, 20% ≤ aluminum oxide ≤ 25%, 0.5% ≤ potassium oxide ≤ 1.5%, 0.5% ≤ sodium oxide ≤ 1.5%, 1.5% ≤ calcium oxide ≤ 8%, 1% ≤ magnesium oxide ≤ 2.5%, 0.5% ≤ titanium oxide ≤ 1.0%, and 6% ≤ iron oxide + ferrous oxide ≤ 9%.

[0030] In this embodiment, the corrosion-resistant particles in the corrosion-resistant material are not a mixture formed by directly mixing the above-mentioned components, but rather a material with a basalt-like structure. In the mixture, the corrosion-resistant particles are the main component, and the metal particles are the auxiliary component. The mixture consists of corrosion-resistant particles and metal particles, with the weight of the corrosion-resistant particles exceeding the weight of the metal particles. For example, the weight percentage of the metal particles does not exceed 30% of the total weight of the mixture, and the weight percentage of the corrosion-resistant particles is not less than 69% of the total weight of the mixture, preferably not less than 70%.

[0031] Those skilled in the art should understand that unavoidable impurities may exist in the mixture, but it is also understood that the impurity content in the mixture does not exceed 1%. The closed pores described in this application are pores that are closed at both ends, which makes it difficult for corrosive media to enter. Open pores are pores that are closed at one end and open at the other end, or open pores are pores that are interconnected at both ends.

[0032] According to this application, the main components of the anti-corrosion particles may include silicon dioxide, iron oxides (iron oxide + ferrous oxide), aluminum oxide, potassium oxide, sodium oxide, calcium oxide, and magnesium oxide. The particles are black in color, and the anti-corrosion particles can be materials with an amorphous phase volume ratio ranging from 15% to 55%. In some embodiments, the amorphous phase volume ratio in the anti-corrosion particles can be between 15% and 55%. Compared to crystalline anti-corrosion particles, amorphous anti-corrosion particles can achieve an anti-corrosion coating with a relatively higher amorphous phase volume ratio, further enhancing corrosion resistance.

[0033] Figure 1 This is an XRD pattern of anti-corrosion particles provided according to an embodiment of this application. For example... Figure 1 As shown, the characteristic peaks are not particularly obvious, and there are many disordered impurity peaks, indicating poor crystallinity. This suggests that the anti-corrosion particles have an amorphous structure. Calculations using conventional full-spectrum fitting methods show that the amorphous phase volume ratio of the anti-corrosion particles is 25%.

[0034] According to this application, the anti-corrosion particles can be silicate-based inorganic non-metallic materials. In these particles, the various components are composite and collectively present as silicate-based materials. That is, the anti-corrosion particles can be considered as reaction products of the various components. Specifically, silica in the anti-corrosion particles mainly acts as a framework, while other components primarily provide metal cations. The silica, acting as a framework, is used to connect the metal cations. Furthermore, in the anti-corrosion particles according to this application, multiple metal element atoms occupy their original lattice positions, causing lattice distortion. Excessive atomic size differences may even lead to excessively high lattice distortion energy, making it impossible to maintain the crystal lattice configuration, thus causing the lattice to collapse and form an amorphous structure, resulting in a surface energy far lower than conventional materials. In a preferred embodiment, the more types of metal cations in the material composition, the greater the degree of crystal distortion, which is more conducive to forming a higher degree of amorphousness.

[0035] In the anti-corrosion particles for cookware provided according to the present invention, the main components of the anti-corrosion particles can be chelated with each other and exist as a silicate material as a whole. That is, the anti-corrosion particles can be the reaction products of the various components, specifically, they can be composite metal cation silicates. According to this application, the anti-corrosion particles have at least one of a framework structure and a chain structure. As an example, in some embodiments, the silicate material may include NaAlSi3O8, which has a framework structure, in which some silicon atoms are replaced by aluminum atoms with larger radii, and the oxygen atoms are all inert oxygen. The formed aluminosilicate anion can better adsorb metal cations and has a large degree of distortion. In other embodiments, the silicate material may include Ca(Mg,Fe,Al,Ti)[(Si,Al)2O6], which has a chain structure, in which some silicon atoms are replaced by aluminum atoms with larger radii, and the material has a variety of metal cations and a large degree of distortion.

[0036] In this embodiment, based on the total weight of the anti-corrosion particles as 100%, the content of silicon dioxide can be 50wt%-75wt%, optionally 55wt%-70wt%, 50wt%-75wt%, 55wt%-60wt%, or 50wt%-65wt%. The content of aluminum oxide can be 15wt%-30wt%, optionally 15wt%-25wt%, 20wt%-30wt%, 25wt%-30wt%, or 20wt%-25wt%. The content of potassium oxide can be 0.1wt%-2wt%, optionally 0.1wt%-1.5wt%, 0.2wt%-1wt%, 1wt%-2wt%, or 1.5wt%-2wt%. The content of sodium oxide can be 0.1wt%-2wt%, optionally 0.1wt%-1.5wt%, 0.2wt%-2wt%, 0.4wt%-1.5wt%, or 1wt%-2wt%. The content of calcium oxide can be 1wt%-10wt%, optionally 2wt%-10wt%, 3wt%-8wt%, 1wt%-5wt%, or 5wt%-10wt%. The content of magnesium oxide can be 0.5wt%-3wt%, optionally 0.5wt%-2.5wt%, 1wt%-3wt%, 1.5wt%-3wt%, or 2wt%-3wt%. The content of titanium dioxide is 0.2wt%-1.3wt%, optionally 0.2wt%-1.0wt%, 0.5wt%-1.3wt%, 0.9wt%-1.2wt%, or 0.8wt%-1.1wt%. The content of iron oxide (iron oxide + ferrous oxide) in the anti-corrosion particles is low. For example, the total content of iron oxide and ferrous oxide can be 5wt%-10wt%. Optionally, the content of iron oxide and ferrous oxide can be 5wt%-9wt%, 6wt%-10wt%, 8wt%-10wt%, or 7wt%-10wt%.

[0037] In some embodiments, the anti-corrosion particles are black, primarily due to the iron oxide in the composition. The black anti-corrosion particles do not cause a color change after spraying, thus forming a black anti-corrosion coating. On one hand, the black anti-corrosion coating weakens the contrast of charred discoloration, improving the visual experience; on the other hand, due to the inherent properties of the anti-corrosion particles, the resulting coating is more brittle than coatings formed from metal materials, making it easier to polish during use and ensuring the cookware remains clean and new during operation.

[0038] In some embodiments, the anti-corrosion particles are in powder form, with an average particle size ranging from 20 μm to 100 μm. If the average particle size of the non-stick powder is greater than 20 μm, the powder flowability is poor during spraying, and the flight speed is insufficient, making it prone to over-melting, resulting in dust inclusions, increasing the porosity, and thus reducing corrosion resistance. If the average particle size of the non-stick powder is less than 100 μm, the powder feeding pipe is easily clogged during spraying, the powder melting degree is insufficient, the coating strength decreases, and many powder particles bounce off after impact, resulting in powder waste.

[0039] In some embodiments, the average particle size of the metal particles is in the range of 60 μm to 100 μm.

[0040] According to this application, a method for manufacturing anti-corrosion particles is provided. Specifically, the anti-corrosion particles according to this application can be obtained from basalt.

[0041] Step S100: Prepare basalt.

[0042] In this embodiment, the basalt used here can be commercially available large blocks of natural basalt.

[0043] Step S200 involves the initial crushing of the basalt. Specifically, a jaw crusher is used to break the original large blocks of basalt into smaller pieces with a diameter of 1cm-5cm.

[0044] Step S300, mineral processing and purification, the basalt after preliminary crushing is hand-sorted based on its appearance characteristics to remove basalt containing impurities visible to the naked eye.

[0045] Step S400, coarse grinding: use a Raymond mill to grind the beneficiated and purified basalt into powder with a diameter of 0.1mm-1mm.

[0046] Step S500: Gravity separation to remove impurities. Gravity separation is used to further purify the basalt powder in order to remove as much mud and other impurities as possible from the basalt powder.

[0047] Step S600: Fine grinding. Use a medium-speed micro powder mill to process the basalt powder that has undergone gravity separation and impurity removal more finely, so that the powder reaches the micron level, for example, 20μm-100μm. In this way, granular material with anti-corrosion particles with the aforementioned composition range can be obtained.

[0048] Step S700, screening and grading: The processed basalt powder is graded and screened using screening equipment to separate the powder with particle size in the above three distribution ranges. The powder is then mixed evenly according to the volume ratio to obtain anti-corrosion particles with multiple particle sizes. The anti-corrosion particles are materials with an amorphous phase volume ratio in the range of 15%-45%.

[0049] In this application, the anti-corrosion particles can undergo certain pretreatment to obtain anti-corrosion particles with a high amorphous phase volume ratio. Specifically, the anti-corrosion particles are sintered at 1300℃-1500℃ for 3-5 hours and cooled at a preset cooling rate to obtain anti-corrosion particles with a preset amorphous phase volume ratio. The preset cooling rate can be achieved by cooling the anti-corrosion particles under cold air conditions; for example, the preset cooling rate can be 50℃ / s-100℃ / s, thereby obtaining anti-corrosion particles with an amorphous phase volume ratio in the range of 30%-60%.

[0050] In the anti-corrosion material according to this application, the anti-corrosion particles exist in the mixture with multiple particle sizes. By selecting powder with a combination of large and small particles as the anti-corrosion particles of this application, an anti-corrosion coating with closely packed particles can be obtained, reducing the porosity of the coating. At the same time, the metal particles in the anti-corrosion material have low melting points. When the anti-corrosion material is sprayed using the spraying parameters of the anti-corrosion particles, the metal particles will melt and form small droplets after melting, which fill the gaps between adjacent pores of the anti-corrosion particles and spread evenly (similar to hitting a molten substance on a wall, thereby deforming it into horizontal stripes). This seals the open pores formed by the sprayed anti-corrosion particles, thereby reducing the open pore rate of the anti-corrosion coating and making the anti-corrosion coating form closed pores as much as possible, thereby achieving the purpose of rust prevention.

[0051] Specifically, the anti-corrosion particles can also be called anti-corrosion powder. The particle size R of the anti-corrosion particles has multiple distribution ranges, including a first distribution range, a second distribution range, and a third distribution range. The first distribution range is 20μm≤R<40μm, the second distribution range is 40μm≤R<70μm, and the third distribution range is 70μm≤R≤100μm. Based on the total volume of anti-corrosion particles in the mixture being 100%, the volume proportion of anti-corrosion particles with a particle size in the first distribution range is 20%-40%, the volume proportion of anti-corrosion particles with a particle size in the second distribution range is 35%-65%, and the volume proportion of anti-corrosion particles with a particle size in the third distribution range is 10%-25%.

[0052] According to this application, the metal particles are corrosion-resistant metal particles. In exemplary embodiments, the metal particles include at least one of titanium particles, titanium alloy particles, and stainless steel particles. This application does not excessively limit the specific types of metal particles.

[0053] According to this application, the mixture consists of anti-corrosion particles and metal particles, with a weight ratio of anti-corrosion particles to metal particles of 7:3 to 9:1. In other words, in the mixture, the weight percentage of metal particles does not exceed 30% of the total weight of the mixture, and the weight percentage of anti-corrosion particles is not less than 69% of the total weight of the mixture, preferably not less than 70%. In some embodiments, the mixture may also include a balance of impurities.

[0054] According to this application, the melting point of the anti-corrosion particles is lower than that of the metal particles, and the thermal conductivity of the anti-corrosion particles is also lower than that of the metal particles. For example, the melting point of the anti-corrosion particles is approximately in the range of 1000℃-1300℃, while the melting point of the metal material is in the range of 1400℃-1700℃. The thermal conductivity of the anti-corrosion particles is approximately in the range of 0.5W / m•K-1.5W / m•K, while the thermal conductivity of the metal material is in the range of 15W / m•K-25W / m•K. The anti-corrosion particles can be silicate-based inorganic non-metallic materials, belonging to ceramic materials, and have advantages such as low melting point and low thermal conductivity. When the anti-corrosion material is sprayed using the spraying parameters of the anti-corrosion particles, heat cannot be quickly conducted to the interior of the anti-corrosion particles, resulting in only micro-melting on the surface of the anti-corrosion particles. After deposition on the substrate surface, the "close-packed spherical" structure of the mixture is maintained, thus exhibiting good corrosion resistance due to its density. The metal particles in the mixture are corrosion-resistant metal particles, which are metallic materials. Although their melting point is higher than that of the anti-corrosion particles, their thermal conductivity is high. During plasma spraying, the corrosion-resistant metal particles can quickly and completely form a soft state and fill the pores between adjacent anti-corrosion particles. When deposited on the substrate surface, they are deformed into a thin sheet structure under the action of impact and fill (e.g., embedded, horizontally placed) the pores between adjacent anti-corrosion particles. Thus, the anti-corrosion coating formed by plasma spraying of anti-corrosion materials has relatively dense pores and mostly closed pores (low open porosity), thus exhibiting excellent anti-corrosion performance.

[0055] According to a second aspect of this application, a corrosion-resistant coating for cookware is provided, wherein the corrosion-resistant coating is formed using the corrosion-resistant materials provided in the above embodiments.

[0056] In some embodiments, such as Figure 2 and Figure 3 As shown, the anti-corrosion coating includes anti-corrosion particles 121 and metal particles 122 filling the pores between the particles of the anti-corrosion particles 121. The composition of the anti-corrosion particles, by weight percentage, includes: 50%≤silicon dioxide≤75%, 15%≤alumina≤30%, 0.1%≤potassium oxide≤2%, 0.1%≤sodium oxide≤2%, 1%≤calcium oxide≤10%, 0.5%≤magnesium oxide≤3%, 0.2%≤titanium oxide≤1.3%, and 5%≤iron oxide + ferrous oxide≤10%.

[0057] According to this application, the anti-corrosion coating has a predetermined surface pore structure. In some embodiments, the surface porosity of the anti-corrosion coating is 1% (volume) to 5% (volume), and the individual pore size of the surface of the anti-corrosion coating is 0.1 μm to 0.5 μm. Such a surface pore structure can prevent corrosive media from entering, thereby enabling it to perform the function of rust prevention.

[0058] According to some embodiments of this application, the anti-corrosion particles can be materials with an amorphous phase volume ratio ranging from 15% to 45%. According to other embodiments of this application, the anti-corrosion particles can be materials with an amorphous phase volume ratio ranging from 20% to 55%. In general, the amorphous phase volume ratio of the anti-corrosion particles according to this application can be in the range of 15% to 55%. Metal particles are crystalline materials, therefore, in the mixture, due to the doping of metal materials, the amorphous phase volume ratio of the mixture is relatively reduced, for example, it can be in the range of 10% to 50%. That is to say, the amorphous phase volume ratio of the anti-corrosion material according to this application can be in the range of 10% to 50%.

[0059] According to some embodiments of this application, the anti-corrosion coating may possess a certain degree of amorphousness. Spraying the anti-corrosion material can retain this amorphousness, forming an anti-corrosion coating with a certain volume percentage of amorphous phase. For example, the volume percentage of amorphous phase in the anti-corrosion coating is 10%-50%. This amorphous phase volume percentage is obtained because the material itself possesses amorphous properties and is retained after spraying.

[0060] According to other embodiments of this application, the anti-corrosion material itself has a certain degree of amorphousness, for example, it can have 10%-50% amorphous phase. The anti-corrosion material is sprayed and the spraying process is controlled (to be described in detail in the method of manufacturing cookware) to form an anti-corrosion coating with a relatively high amorphous phase volume ratio. For example, the amorphous phase volume ratio in the anti-corrosion coating is 15%-65%. This amorphous phase volume ratio is 5%-25% higher than in the aforementioned embodiments. This is determined by the chemical composition / content of the anti-corrosion material itself and the cooling rate of the coating during the spraying process. Therefore, an amorphous structure can be formed during spraying, thereby enabling the anti-corrosion coating to exhibit relatively superior properties (e.g., corrosion resistance, hardness, etc.).

[0061] In this specification, "amorphous phase volume percentage" refers to the volume percentage of the amorphous phase in the anti-corrosion coating. The coating exhibits a disordered structure due to the varying orientations of its atoms, which results in a lower surface energy compared to coatings with ordered structures. For example, without considering other limiting factors, a higher amorphous phase volume percentage in the anti-corrosion coating indicates stronger amorphous properties, lower surface energy, and better non-stickiness, and vice versa.

[0062] In some embodiments, the hardness of the anti-corrosion coating is between 400 HV and 800 HV. Such hardness can effectively improve wear resistance, prevent the surface molten layer from being worn away, and extend the corrosion resistance life.

[0063] According to a third aspect of this application, a method for manufacturing a cookware is provided, wherein the method for manufacturing a cookware includes: step S101, providing a substrate; step S102, providing an anti-corrosion material; and step S103, spraying the anti-corrosion material onto the surface of the substrate to form an anti-corrosion coating on the surface of the substrate.

[0064] Figure 4 This is the XRD pattern of the anti-corrosion coating provided according to the embodiments of this application. For example... Figure 4 As shown, the characteristic peaks are not particularly obvious, and there are many disordered impurity peaks, indicating poor crystallinity. This suggests that the anti-corrosion coating has an amorphous structure. The amorphous phase content of the anti-corrosion coating is calculated to be 40% using the conventional full-spectrum fitting method.

[0065] The method for manufacturing cookware according to this application will now be described in detail with reference to specific embodiments.

[0066] Provide matrix

[0067] According to this application, the substrate 110 can be made of commonly used materials. For example, the material can be an iron substrate. The substrate 110 can have a shape corresponding to its function, for example, such as... Figure 2 As shown, when the non-stick cookware 100 is a non-stick pan, the base 110 can have a conventional pan shape. It should be understood that... Figure 2 The nonstick pan is shown only as an example of the main body and other parts are not shown. The nonstick pan according to the present invention may also include common cookware structures / components such as handles (e.g., pot handles).

[0068] According to this application, the substrate 110 can be pretreated, for example, by grinding, sandblasting, pickling, etc. The substrate 110 has a certain surface roughness. In an exemplary embodiment, the Ra value of the surface roughness can be in the range of 3μm-5μm.

[0069] Forming a foundation

[0070] According to this application, a primer layer can be pre-formed on the substrate before the step of forming the anti-corrosion coating to improve the adhesion between the substrate and the anti-corrosion coating. The primer layer is formed by cold spraying or hot spraying. The primer layer material is selected from conventional metallic materials, such as at least one of nickel-based alloys, titanium, titanium alloys, iron, and iron alloys.

[0071] In an exemplary embodiment, the thickness of the underlayer is in the range of 30μm-60μm.

[0072] Spraying anti-corrosion materials forms an anti-corrosion coating.

[0073] According to this application, the anti-corrosion material may be the anti-corrosion material described in the first aspect of this application, which will not be repeated here.

[0074] According to this application, the anti-corrosion coating 120 can at least partially cover the inner surface of the substrate 110; in other words, the anti-corrosion coating 120 can cover a portion or all of the inner surface of the substrate 110. The anti-corrosion coating 120 may comprise an anti-corrosion material provided in the embodiments of this application, formed by spraying, thereby possessing non-stick properties and improved hardness.

[0075] According to some embodiments of this application, an anti-corrosion material is sprayed onto the surface of a substrate to form an anti-corrosion coating. The anti-corrosion material can be a material with a certain degree of amorphousness; for example, the amorphous phase volume percentage can be 10%-50%. The anti-corrosion material retains its amorphous nature to form an anti-corrosion coating with a certain amorphous phase volume percentage. For example, the amorphous phase volume percentage in the anti-corrosion coating is 10%-50%. This amorphous phase volume percentage is obtained by the material itself possessing amorphous properties and retaining them after spraying.

[0076] The spraying process employs thermal spraying, specifically plasma spraying. The parameters for plasma spraying are as follows: current 400A-650A; voltage 60V-90V; main gas (argon) flow rate 1200L / h-1800L / h; hydrogen flow rate 40L / h-100L / h; powder feeding gas flow rate 400L / h-600L / h; powder feeding rate 50g / min-100g / min; spraying distance (nozzle to workpiece) 10cm-15cm; spraying angle 45°-80°; and workpiece temperature at room temperature.

[0077] According to this application, the spraying parameters are related to the silica content in the anti-corrosion material powder. When the silica content is high, the spraying power will be relatively higher; that is, the current and hydrogen flow rate need to be increased, the main gas flow rate needs to be decreased, and the powder feed rate also needs to be reduced, and vice versa. By performing thermal spraying of the anti-corrosion material powder within the above-mentioned process parameter range, a dense anti-corrosion coating with suitable thickness and amorphous properties can be formed on the surface of the substrate. This anti-corrosion coating has properties similar to those of the anti-corrosion material, and therefore can have good non-stick properties, improved hardness, and the desired porosity for oil storage. In other words, the amorphous anti-corrosion coating of the present invention can retain the various properties of the aforementioned anti-corrosion material and can exhibit properties superior to those of the anti-corrosion material due to spraying, such as, but not limited to, corrosion resistance, wear resistance, and hardness.

[0078] According to some other embodiments of this application, an anti-corrosion material is sprayed onto the surface of a substrate, and the spraying process is controlled to form an anti-corrosion coating with a preset amorphous phase volume ratio on the surface of the substrate.

[0079] In an exemplary embodiment, controlling the spraying process includes intervention during the formation of the anti-corrosion coating. Specifically, the substrate 110 includes a first surface and a second surface facing away from each other. The step of forming an anti-corrosion coating with a preset amorphous phase volume ratio includes: cooling the second surface of the substrate and spraying an anti-corrosion material onto the first surface of the substrate, thereby forming an anti-corrosion coating with a preset amorphous phase volume ratio on the first surface of the substrate. The step of cooling the second surface of the substrate includes applying cold air to the second surface of the substrate and controlling the temperature of the cold air at -15°C to 5°C. Then, the anti-corrosion material is sprayed onto the first surface of the substrate, thereby forming an anti-corrosion coating with a preset amorphous phase volume ratio on the first surface of the substrate. The anti-corrosion coating thus formed has a relatively increased amorphous phase volume ratio. In an exemplary embodiment, the amorphous phase volume ratio in the anti-corrosion coating is 15%-65%, which can increase the amorphous content by 5%-25% compared to the initially selected anti-corrosion material. This enables the cookware to have better corrosion resistance. It should be noted that the first surface can be an inner surface, and the second surface can be an outer surface. Of course, this application does not impose any limitations on this. It is understood that those skilled in the art, under the guidance of this application, can make the first surface the outer surface and the second surface the inner surface according to actual usage requirements.

[0080] In an exemplary embodiment, the step of cooling the second surface of the substrate includes placing the second surface of the substrate in an environment of cooling gas, so that the coating on the first surface of the substrate can be rapidly cooled to form the anti-corrosion coating of this application. The cooling gas temperature is -15℃ to 5℃, and the cooling gas flow rate is 2000L / h to 4000L / h.

[0081] In some embodiments, the formed anti-corrosion coating may have a thickness of 40 μm-100 μm.

[0082] Heat treatment of the anti-corrosion coating

[0083] According to this application, a dense anti-corrosion coating can be formed by spraying an anti-corrosion material (i.e., a mixture) with specific chemical components and contents as described in this application. For example, the surface porosity of the formed anti-corrosion coating can be 1% to 10%, and the surface pore size can be 0.1 μm to 1 μm. The above-mentioned pore structure ensures corrosion resistance, thus the outer surface of the anti-corrosion coating can directly serve as the inner surface of the cookware to provide corrosion resistance. Furthermore, in some embodiments, the method of manufacturing the cookware may further include performing a certain post-processing on the obtained anti-corrosion coating to make the surface pores of the anti-corrosion coating more dense, reducing the surface porosity to 1%-5% and the surface pore size to 0.1 μm-0.5 μm. It should be noted that the surface layer here refers to a layer extending from the exposed surface of the anti-corrosion coating to a predetermined depth. In an exemplary embodiment, the predetermined depth can be 0.4 μm to 0.5 μm.

[0084] According to this application, the obtained anti-corrosion coating undergoes certain post-processing, including heat treatment to melt the surface of the anti-corrosion coating, followed by cooling at a rate of 50°C / s-100°C / s, thereby obtaining an anti-corrosion coating with a predetermined surface porosity. The heat treatment melting process closes the open pores on the surface of the anti-corrosion coating, forming closed pores. Therefore, the obtained anti-corrosion coating has mostly closed pores with a low open porosity, thus exhibiting excellent rust prevention. In this application, an open pore is a hole that is closed at one end and open at the other, or an open pore that is interconnected at both ends. A closed pore is a hole that is closed at both ends, making it difficult for corrosive media to enter.

[0085] For example, the surface porosity can be 1%-5%, and the individual size of the surface pores can be 0.1μm-0.5μm.

[0086] In some embodiments, the post-processing steps of the obtained anti-corrosion coating include sintering the anti-corrosion coating and then cooling the surface-melted anti-corrosion coating at a cooling rate of 50°C / s-100°C / s. The sintering and cooling can be performed alternately in cycles, and the number of cycles can be multiple, for example, 2-3 times. Specifically, sintering the anti-corrosion coating includes first heating the anti-corrosion coating from room temperature to 800°C-1000°C at a heating rate of 2°C / min-5°C / min and holding it at that temperature for 0.2h-3h; then heating it to 1100°C-1400°C at a heating rate of 0.5°C / min-2°C / min and holding it at that temperature for 1h-3h.

[0087] In other embodiments, the obtained anti-corrosion coating undergoes certain post-processing steps, including locally melting the surface of the anti-corrosion coating using a plasma flame, and then cooling the surface-melted anti-corrosion coating at a cooling rate of 50°C / s-100°C / s to obtain an anti-corrosion coating with a predetermined surface porosity. For example, the surface porosity can be 1%-5%, and the individual size of the surface pores can be 0.1μm-0.5μm. The plasma power is 3KW-10KW, the scanning speed is 2mm / s-5mm / s, the plasma flame spacing is 5mm-8mm, and the ionization gas flow rate is 1L / min-3L / min.

[0088] Form a closed layer

[0089] According to this application, after forming the anti-corrosion coating, a sealing layer can be provided outside the anti-corrosion coating to further optimize the corrosion resistance. Specifically, the method of manufacturing cookware also includes forming a sealing layer on the anti-corrosion coating to seal the surface pores of the anti-corrosion coating, thereby ensuring the corrosion resistance of the cookware with the coating.

[0090] In some embodiments, the step of forming a sealing layer on the anti-corrosion coating includes applying silicone oil to the surface of the anti-corrosion coating, allowing it to penetrate into the surface pores of the anti-corrosion coating, and sintering at a first predetermined temperature for a first predetermined time, thereby forming a sealing layer on the anti-corrosion coating. In an exemplary embodiment, the silicone oil may be polydimethyl silicone oil. After coating, the cookware coated with polydimethyl silicone oil can be placed in a sintering furnace for curing, wherein the first predetermined curing temperature is 300°C-400°C, and the first predetermined curing time is 3-10 minutes.

[0091] In some embodiments, the step of forming a sealing layer on the anti-corrosion coating includes: immersing the anti-corrosion coating in an grease at a second predetermined temperature and maintaining the grease in the grease for a second predetermined time, thereby allowing the grease to penetrate the surface pores of the anti-corrosion coating and thus forming a sealing layer on the anti-corrosion coating. In an exemplary embodiment, the grease may include peanut oil or palm oil, heating the peanut oil or palm oil to a temperature below the second predetermined temperature and maintaining the temperature for a second predetermined time to form a sealing layer on the anti-corrosion coating, wherein the second predetermined temperature is 80°C-100°C and the second predetermined time is 10-30 minutes.

[0092] According to this application, the anti-corrosion coating applied with silicone oil or grease has hydrophobic properties, preventing corrosive media from penetrating and thus improving the corrosion resistance of cookware. Furthermore, it achieves non-stick properties due to its low surface energy and sealed-layer principle. For example, before silicone oil treatment, the anti-corrosion coating may have a surface energy of 30 to 40 dynes. Although this is lower than the surface energy of fluoropolymer anti-corrosion coatings (18 to 25 dynes), after silicone oil treatment, its surface energy can be reduced to 10 to 20 dynes, thus achieving non-stick performance comparable to or even better than fluoropolymer anti-corrosion coatings. Silicone oil is superior to grease in optimizing non-stick properties.

[0093] According to a fourth aspect of this application, a cookware is provided, specifically relating to a corrosion-resistant cookware. The cookware includes a substrate and a corrosion-resistant coating, the corrosion-resistant coating being formed on the substrate. The corrosion-resistant coating includes the corrosion-resistant coating provided according to the various embodiments described above, or includes a corrosion-resistant coating formed by spraying the corrosion-resistant materials provided in the various embodiments described above.

[0094] Figure 3 This is a schematic diagram of the cross-sectional structure of the cookware provided in the embodiment of this application after being cut along the thickness direction. Figure 4 yes Figure 3 A magnified structural diagram at point I. (Refer to...) Figure 3 and Figure 4 The nonstick cookware 100 may include a substrate 110 and an anti-corrosion coating 120.

[0095] In some embodiments, the substrate is an iron substrate, and the anti-corrosion material belongs to the category of ceramic materials, which have relatively poor adhesion to the metal substrate. In order to increase the adhesion between the anti-corrosion coating and the substrate, in some embodiments, the cookware also includes a base coat 130, which is made of a metal material, wherein the base coat 130 is disposed between the substrate 110 and the anti-corrosion coating 120.

[0096] In an exemplary embodiment, the undercoat can be prepared using a metallic material through thermal spraying or cold spraying. The material for the undercoat is selected from conventional metallic materials, such as at least one of nickel-based alloys, titanium, titanium alloys, iron, and iron alloys.

[0097] In an exemplary embodiment, the thickness of the underlayer is in the range of 30μm-60μm.

[0098] According to this application, the outer surface of the anti-corrosion coating can be directly used as the inner surface of the cookware; that is, the anti-corrosion coating is directly used as the surface layer of the cookware coating. By spraying the anti-corrosion material with the specific chemical composition and content of this application, a dense anti-corrosion coating can be formed. For example, the surface porosity of the formed anti-corrosion coating can be 15% to 35%, and the surface pore size can be 0.1 μm to 5 μm. Such a pore structure ensures corrosion resistance. Furthermore, the obtained anti-corrosion coating can be subjected to a certain heat treatment to make the surface pores of the anti-corrosion coating even denser.

[0099] In some embodiments, the formed anti-corrosion coating may have a thickness of 40 μm-100 μm.

[0100] The present application will now be described in detail with reference to specific embodiments, but the scope of protection of the present application is not limited to the embodiments.

[0101] Example 1

[0102] The cookware according to Example 1 is manufactured by the following method.

[0103] Step S10, Prepare the cookware base. Specifically, prepare the cookware base by deep drawing an iron sheet, washing the surface with alkali to remove oil, drying, and sandblasting to obtain a cookware base with a thickness of 1.5cm.

[0104] Step S20: Provide an anti-corrosion material. Specifically, anti-corrosion particles with an average particle size of 20 μm to 100 μm are prepared as the anti-corrosion material in this embodiment. The main components of the anti-corrosion particles include: 50.29% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, and 6.5% (iron oxide + ferrous oxide), with the balance being impurities (e.g., organic matter and / or water).

[0105] Step S30: Apply anti-corrosion material by spraying.

[0106] The outer surface of the cookware substrate is placed in a circulating cooling air environment, where the temperature of the cooling air is 5°C. Anti-corrosion material is loaded into a powder feeder, and the plasma spraying parameters are set as follows: powder feeding speed 80 g / min, spraying distance 110 mm, arc current 550 A, hydrogen pressure 0.7 MPa, hydrogen flow rate 100 L / h, argon pressure 1.2 MPa, and argon flow rate 1600 L / h. The anti-corrosion material powder is formed on the inner surface of the cookware substrate by plasma spraying, resulting in an anti-corrosion coating with a thickness of 65 μm. Post-treatment processes such as sandblasting, cleaning to remove ash, and drying complete the manufacturing of the cookware of Example 1.

[0107] Example 2

[0108] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 50.29% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 5% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 2 is manufactured using the same method as in Example 1.

[0109] Example 3

[0110] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 50.29% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, and 10% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 3 is manufactured using the same method as in Example 1.

[0111] Example 4

[0112] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 59% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 7.5% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 4 is manufactured using the same method as in Example 1.

[0113] Example 5

[0114] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 65% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 7.5% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 5 is manufactured using the same method as in Example 1.

[0115] Example 6

[0116] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 69% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 7.5% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 6 is manufactured using the same method as in Example 1.

[0117] Example 7

[0118] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 60% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, and 5.0% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 7 is manufactured using the same method as in Example 1.

[0119] Example 8

[0120] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 60% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, and 10% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 8 is manufactured using the same method as in Example 1.

[0121] Example 9

[0122] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 65% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 5% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 9 is manufactured using the same method as in Example 1.

[0123] Example 10

[0124] Except in step S20, where a different anti-corrosion material (the main components of the anti-corrosion material in this embodiment include: 65% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide and 10% iron oxide + ferrous oxide) is used to replace the anti-corrosion material of Example 1, the cookware of Example 10 is manufactured using the same method as in Example 1.

[0125] Example 11

[0126] Except for the step of applying silicone oil and curing it after step S30 (curing time is 5 min, curing temperature is 350°C), the cookware of Example 11 was manufactured using the same method as in Example 1.

[0127] Example 12

[0128] Except for the step of soaking the anti-corrosion coating in palm oil (soaking time of 15 min and soaking temperature of 100°C) after step S30, the cookware of Example 12 was manufactured using the same method as in Example 1.

[0129] Example 13

[0130] Except for the heat treatment step of the anti-corrosion coating after step S30 (the anti-corrosion coating is first heated from room temperature to 9000°C at a heating rate of 3°C / min and held for 1 hour; then heated to 1300°C at a heating rate of 1°C / min and held for 2 hours, and then cooled at a cooling rate of 150°C / s), the cookware of Example 13 is manufactured by the same method as in Example 1.

[0131] Example 14

[0132] Except for the step of heat treatment of the anti-corrosion coating after step S30 (locally melting the surface of the anti-corrosion coating with plasma flow and then cooling it at a cooling rate of 200°C / s), the cookware of Example 14 was manufactured using the same method as in Example 1.

[0133] Example 15

[0134] Except for the preparation of a 40μm thick underlayer formed on the cookware substrate by plasma spraying of titanium alloy before step S20 (spraying parameters: powder feeding speed 40g / min, spraying distance 120mm, arc current 350A, hydrogen pressure 0.7MPa, flow rate 30L / h, argon pressure 1.6MPa, flow rate 2000L / h), the cookware of Example 15 was manufactured using the same method as in Example 1.

[0135] Example 16

[0136] Except in step S30, where the outer surface of the cookware substrate is placed at room temperature and not in an environment of circulating cooling air, the cookware of Example 16 is manufactured using the same method as in Example 1.

[0137] Example 17

[0138] Except for step S20, in which the anti-corrosion particles of Example 1 are pre-sintered (the composition of the anti-corrosion particles in this example is the same as that in Example 1, the anti-corrosion particles of Example 1 are sintered at 1400°C for 4 hours and cooled at a cooling rate of 50°C / s to obtain the anti-corrosion particles of this example), the cookware of Example 17 is manufactured using the same method as in Example 1.

[0139] Example 18

[0140] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 formed by the anti-corrosion particles and titanium powder in a weight ratio of 7:3, the cookware of Example 18 is manufactured by the same method as that of Example 1.

[0141] Example 19

[0142] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 formed by the anti-corrosion particles and titanium powder in a weight ratio of 6:1, the cookware of Example 19 is manufactured by the same method as that of Example 1.

[0143] Example 20

[0144] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 by forming a mixture of anti-corrosion particles and titanium powder in a weight ratio of 9:1, the cookware of Example 20 is manufactured by the same method as that of Example 1.

[0145] Example 21

[0146] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 by forming a mixture of the anti-corrosion particles of Example 1 and stainless steel in a weight ratio of 9:1, the cookware of Example 21 is manufactured by the same method as that of Example 1.

[0147] Example 22

[0148] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 by forming a mixture of anti-corrosion particles and titanium powder of Example 17 in a weight ratio of 7:3, the cookware of Example 22 is manufactured by the same method as that of Example 1.

[0149] Example 23

[0150] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 by forming a mixture of anti-corrosion particles and titanium powder of Example 17 in a weight ratio of 6:1, the cookware of Example 23 is manufactured by the same method as that of Example 1.

[0151] Example 24

[0152] Except in step S20, in which the anti-corrosion material of Example 1 is replaced by the anti-corrosion material of Example 1 by forming a mixture of anti-corrosion particles and titanium powder of Example 17 in a weight ratio of 9:1, the cookware of Example 24 is manufactured by the same method as that of Example 1.

[0153] Comparative Example 1

[0154] Except that in step S20, a different material (the material in this comparative example is a mixture of 50.29% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, 6.5% iron oxide, and the balance being impurities) was used to replace the corrosion-resistant material of Example 1, the cookware of Comparative Example 1 was manufactured using the same method as in Example 1.

[0155] Comparative Example 2

[0156] Except that in step S20, a different material (the material in this comparative example is a mixture of 60% silicon dioxide, 15% aluminum oxide, 0.55% potassium oxide, 0.85% sodium oxide, 5.25% calcium oxide, 0.57% magnesium oxide, 0.6% titanium oxide, 10% iron oxide, and the balance being impurities) was used to replace the corrosion-resistant material of Example 1, the cookware of Comparative Example 2 was manufactured using the same method as in Example 1.

[0157] Comparative Example 3

[0158] Except in step S20, where a different material (the material in this comparative example is an amorphous material, wherein the amorphous material includes 63 wt% titanium dioxide, 27 wt% iron oxide + ferrous oxide, 8% calcium oxide + magnesium oxide and the balance phosphorus, carbon and silicon impurities) is used to replace the corrosion-resistant material of Example 1, the cookware of Comparative Example 3 is manufactured using the same method as in Example 1.

[0159] Comparative Example 4

[0160] Except for replacing the corrosion-resistant material of Example 1 with a different material (ferrous aluminum magnesium titanate in this comparative example) in step S20, the cookware of Comparative Example 4 was manufactured using the same method as in Example 4.

[0161] Test methods and evaluation criteria, test results

[0162] The degree of amorphization of the anti-corrosion materials in Examples 1 to 10, Examples 17 to 24 and the materials in Comparative Examples 1 to 4 was tested, and the test results are shown in Table 1 below.

[0163] I. Testing Methods and Evaluation Criteria

[0164] 1. Amorphousness Test Method

[0165] Amorphousness testing method: XRD testing was used, followed by conventional full-spectrum fitting analysis to obtain the amorphousness of the sample. The steps of the conventional full-spectrum fitting method are as follows: First, a crystalline phase with the same chemical structure as the amorphous phase is found. It is assumed that the amorphous phase is a tiny grain of this crystalline phase, and this crystalline phase can be used to establish a model of the peak position and intensity of the amorphous phase. Second, the spectrum of the pure amorphous phase is fitted to determine the grain size and microstrain. Finally, the grain size and microstrain are fixed, and this phase is included in the traditional Rietveld quantitative calculation to obtain the volume fraction of the amorphous phase (i.e., the amorphousness) of the corresponding material.

[0166] II. Test Results

[0167] Table 1 Results Test Table

[0168]

[0169] As shown in Table 1, the anti-corrosion particles in this embodiment are materials with a certain volume fraction of amorphous phase. Looking at the composition of the anti-corrosion particles, the lower the silica content and the higher the iron oxide content, the more large-diameter metal cations are present, resulting in more severe lattice distortion and a higher degree of amorphization. In contrast, ordinary metal oxides have no amorphous phase or have extremely low amorphization. Furthermore, it can be seen that as the metal powder content increases, the degree of amorphization decreases.

[0170] The coatings of the cookware obtained in Examples 1-21 and Comparative Examples 1-4 were subjected to performance tests, and the results are recorded in Table 2 below. The specific performance test methods are as follows:

[0171] I. Testing Methods and Evaluation Criteria

[0172] 1. Porosity Measurement

[0173] The porosity of the samples was measured using a microscopic method. Specifically, the surface pores of the samples were directly observed using a metallographic microscope at a certain magnification, or parallel cross-sections of the samples were taken sequentially to observe their pores, and the porosity was calculated. Here, the sample refers to the coating of the cookware in the examples and comparative examples.

[0174] Regarding porosity, it is desirable for the sample to have a porosity of no more than 3%.

[0175] 2. Corrosion resistance testing and evaluation standards

[0176] According to "6.17 Corrosion Resistance Test Method" in GB / T 32432-2015 Household Steel Cookware, a 5% salt solution prepared with distilled water is placed in the pot on which the sample has been formed on its inner surface and boiled, maintaining a gentle boil. The time elapsed until rust appears in the pot is recorded. This time is the result of the corrosion resistance test and the basis for evaluation. Here, the sample refers to the coating of the cookware in the examples and comparative examples.

[0177] For corrosion resistance testing, the corrosion resistance should be no less than 3 hours as expected by the project.

[0178] 3. Abrasion resistance testing and evaluation standards

[0179] According to GB / T 32095.2-2015 "Performance and Test Specifications of Non-stick Surfaces of Household Food Metal Cooking Utensils, Part 2: Test Specifications for Non-stick and Abrasion Resistance", the planar abrasion method was used. A specified scouring pad was used to abrade the sample formed on the substrate surface, and the number of abrasion cycles until the substrate was exposed was recorded. Here, the sample refers to the coating of the cookware in the examples and comparative examples.

[0180] For abrasion resistance testing, the more times friction is recorded, the stronger the abrasion resistance.

[0181] 4. Adhesion test and evaluation standards for thermal spray coatings

[0182] According to GB / T 8642-1988 "Determination of Bond Strength of Thermal Spray Coatings", the bond strength (i.e., adhesion force) of the samples was determined. Here, the samples refer to the surface coatings of the cookware in the examples and comparative examples.

[0183] For the adhesion of the thermal spray coating, the final measured value should not be less than 25 MPa, as expected by the project. If it is less than 25 MPa, the thermal spray coating is prone to peeling or even collapse.

[0184] 5. Amorphousness Test Method

[0185] Amorphousness testing method: XRD testing was used, followed by analysis and calculation using a conventional full-spectrum fitting method to obtain the amorphousness of the sample. The steps of the conventional full-spectrum fitting method are as follows: First, a crystalline phase with the same chemical structure as the amorphous phase is found. It is assumed that the amorphous phase is a tiny grain of this crystalline phase, and this crystalline phase can be used to establish a model of the peak position and intensity of the amorphous phase. Second, the spectrum of the pure amorphous phase is fitted to determine the grain size and microstrain. Finally, the grain size and microstrain are fixed, and this phase is included in the traditional Rietveld quantitative calculation to obtain the corresponding amorphous phase volume ratio of the coating (i.e., the amorphousness).

[0186] II. Test Results

[0187] Table 2 Results Test Table

[0188]

[0189] As can be seen from Table 2, a highly amorphous and dense anti-corrosion coating can be obtained by thermal spraying anti-corrosion particles, thereby achieving the expected corrosion resistance. Moreover, the higher the titanium powder content within the range, the better the corrosion resistance.

[0190] While the invention has been specifically shown and described with reference to exemplary embodiments thereof, those skilled in the art will understand that various changes in form and detail may be made herein without departing from the spirit and scope of the invention as defined by the claims and their equivalents. The embodiments should be considered in a descriptive sense and not for limiting purposes only. Therefore, the scope of the invention is not defined by the specific embodiments thereof, but by the claims, and all differences within that scope will be construed as included in the invention.

Claims

1. An anticorrosive coating for cookware, characterized by, The anti-corrosion coating comprises anti-corrosion particles and metal particles filling the pores between the anti-corrosion particles. The anti-corrosion particles are silicate materials composed of silicon dioxide, aluminum oxide, potassium oxide, sodium oxide, calcium oxide, magnesium oxide, titanium oxide, and iron oxides. The iron oxides are iron oxide and ferrous oxide. The anti-corrosion particles, by weight percentage, comprise: 50% ≤ silicon dioxide ≤ 75%, 15% ≤ aluminum oxide ≤ 30%, 0.1% ≤ potassium oxide ≤ 2%, 0.1% ≤ sodium oxide ≤ 2%, 1% ≤ calcium oxide ≤ 10%, 0.5% ≤ magnesium oxide ≤ 3%, 0.2% ≤ titanium oxide ≤ 1.3%, and 5% ≤ iron oxide + ferrous oxide ≤ 10%.

2. The corrosion protection coating of claim 1, wherein, The metal particles include at least one of titanium particles, titanium alloy particles, and stainless steel particles.

3. The corrosion protection coating of claim 1, wherein, The weight ratio of the anti-corrosion particles to the metal particles is 7:3 to 9:1; and / or, the anti-corrosion particles are materials with an amorphous phase volume ratio in the range of 15%-55%; and / or, the melting point of the anti-corrosion particles is lower than that of the metal particles, and the thermal conductivity of the anti-corrosion particles is lower than that of the metal particles; and / or, the color of the anti-corrosion particles is black.

4. The corrosion protection coating of claim 1, wherein, The anti-corrosion coating includes at least one of the following characteristics: The surface porosity of the anti-corrosion coating is 1%-10%; The pore size of the anti-corrosion coating is 0.1 μm to 1 μm; The hardness of the anti-corrosion coating is 400HV to 800HV; The amorphous phase volume ratio of the anti-corrosion coating is 15%-70%.

5. The anti-corrosion coating according to claim 1, characterized in that, The particle size R of the corrosion-resistant particles includes a first distribution range, a second distribution range, and a third distribution range. The first distribution range is 20μm≤R<40μm, the second distribution range is 40μm≤R<70μm, and the third distribution range is 70μm≤R≤100μm. Based on the total volume of the corrosion-resistant particles being 100%, the volume percentage of corrosion-resistant particles with a particle size in the first distribution range is 20%-40%, the volume percentage of corrosion-resistant particles with a particle size in the second distribution range is 35%-65%, and the volume percentage of corrosion-resistant particles with a particle size in the third distribution range is 10%-25%.

6. The anti-corrosion coating according to any one of claims 1 to 5, characterized in that, The silicate material is obtained by processing basalt.

7. A method of manufacturing a cookware, characterized by, The method for manufacturing the cookware includes: Provide a matrix; Provide corrosion-resistant materials; The anti-corrosion material is sprayed onto the surface of the substrate to form an anti-corrosion coating on the surface of the substrate. The anti-corrosion coating includes the anti-corrosion coating according to any one of claims 1 to 6.

8. The method of claim 7, wherein, The method further includes: The anti-corrosion coating is heat-treated to melt its surface, and then cooled at a cooling rate of 100℃ / s-200℃ / s.

9. The method of claim 7, wherein, The method of manufacturing cookware further includes: forming a sealing layer on the anti-corrosion coating, the sealing layer comprising silicone oil and / or grease, thereby sealing the surface pores of the anti-corrosion coating.

10. The method of claim 7, wherein, The substrate has a first surface and a second surface that are opposite to each other, and the step of forming an anti-corrosion coating includes: The second surface of the substrate is cooled, and the anti-corrosion material is sprayed onto the first surface of the substrate.

11. A cooking appliance characterized by, The cooking utensils include: Matrix; An anti-corrosion coating is formed on the substrate; The anti-corrosion coating includes the anti-corrosion coating according to any one of claims 1 to 6.

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