Ceramic coating and non-stick utensil containing the same

Abstract

Provided are a ceramic coating and a non-stick utensil comprising the same. The ceramic coating is formed using a ceramic coating and comprises: a ceramic coating precursor; and slow-release particles dispersed in the ceramic coating precursor. The slow-release particles comprise a slow-release material and silicone oil bound to the slow-release material, and the slow-release material comprises at least one of vermiculite, zeolite, bentonite, diatomaceous earth, alpha alumina, silica aerogel, fumed silica, amorphous silica, hollow glass powder, porous silicate, layered silicate, porous phosphate, layered phosphate, porous carbonate, layered carbonate, porous sulfate, and layered sulfate.

Description

Technical Field

[0001] The present invention belongs to the technical field of non-stick coatings, and in particular relates to a ceramic coating and a non-stick utensil comprising the same. Background Art

[0002] Currently, non-stick coatings primarily fall into two categories: PTFE and ceramic. Ceramic coatings, however, are subject to significant limitations due to their short lifespan. They are far less widely used than PTFE and fall short of consumers' daily demands for non-stick utensils. For example, a typical non-stick pan will begin to stick after about a month of use. This is especially true with high-temperature cooking methods like Chinese cooking, and with the wear of metal spatulas, which can cause the non-stick properties to degrade rapidly.

[0003] Therefore, improving the long-lasting non-stick properties of ceramic coatings has become a very meaningful and urgent technical need. Summary of the Invention

[0004] In view of the above-mentioned deficiencies in the prior art, the present invention provides a ceramic coating formed by using a ceramic coating and a non-stick utensil comprising the same.

[0005] According to one aspect of the exemplary embodiment, a ceramic coating comprises: a ceramic coating precursor; slow-release particles dispersed in the ceramic coating precursor, wherein the slow-release particles comprise a slow-release material and silicone oil bound to the slow-release material, and

[0006] The sustained-release material includes at least one of vermiculite, zeolite, bentonite, diatomaceous earth, alpha alumina, silica aerogel, fumed silica, amorphous silica, hollow glass powder, porous silicate, layered silicate, porous phosphate, layered phosphate, porous carbonate, layered carbonate, porous sulfate and layered sulfate.

[0007] The particle size of the sustained-release particles may be less than or equal to 20 microns.

[0008] The particle size of the sustained-release particles may be less than or equal to 15 microns.

[0009] The ceramic coating may include a single layer, and the thickness of the single layer may be in the range of 10 microns to 80 microns.

[0010] The ceramic coating may include at least two sub-layers, and at least an uppermost sub-layer of the at least two sub-layers may include slow-release particles.

[0011] The thickness of each sub-layer may be no less than 10 micrometers, and the sum of the thicknesses of the sub-layers may be no more than 80 micrometers.

[0012] The content of the sustained-release particles included in each sub-layer may be different from each other.

[0013] The ceramic coating may be applied on a substrate, and the content of the slow-release particles in each sub-layer may increase in a direction away from the substrate.

[0014] The particle sizes of the sustained-release particles included in each sub-layer of the ceramic coating may be different from each other.

[0015] According to another aspect of the exemplary embodiment, a non-stick utensil includes the ceramic coating as described above.

[0016] The present invention forms a ceramic coating by adding slow-release particles including a slow-release material to a ceramic coating precursor. Since the slow-release material in the ceramic coating has a disordered porous structure, silicone oil is adsorbed and bonded on the surface and in the pores of the slow-release material. The ceramic coating formed by this ceramic coating has a slow-release effect of silicone oil, thereby improving the long-lasting non-stick performance of the ceramic coating. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic diagram illustrating a first embodiment of a ceramic coating according to an exemplary embodiment;

[0018] Figure 2 is a schematic enlarged view showing slow-release particles in a ceramic coating according to an exemplary embodiment;

[0019] Figure 3 is a schematic diagram illustrating a second embodiment of a ceramic coating according to an exemplary embodiment;

[0020] Figure 4 is a schematic diagram illustrating a third embodiment of a ceramic coating according to an exemplary embodiment;

[0021] Figure 5 is a schematic diagram illustrating a fourth embodiment of a ceramic coating according to an exemplary embodiment. DETAILED DESCRIPTION

[0022] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments are shown. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.

[0023] Ceramic coatings achieve their non-stick properties primarily through the use of silicone methyl groups and the addition of silicone oil. As the product is exposed to heat and wear during use, the silicone oil in the coating is gradually lost, damaging the silicone methyl groups on the surface and ultimately losing the non-stick effect, leading to sticking in cooking. If ceramic coatings could be made to continuously store oil, they could form an effective oil film that isolates food from the coating surface, achieving long-lasting non-stick properties.

[0024] Therefore, the present invention provides a ceramic coating comprising slow-release particles containing a slow-release material. The slow-release material may have a disordered porous and / or layered structure, and silicone oil is bound (e.g., adsorbed or bonded) to the slow-release material. During the cooking process, the slow-release particles in the ceramic coating can slow the release of the silicone oil, thereby maintaining a long-lasting non-stick effect of the ceramic coating.

[0025] Figure 1 is a schematic diagram illustrating a first embodiment of a ceramic coating according to an exemplary embodiment, Figure 2 is a schematic diagram illustrating slow-release particles in a ceramic coating according to an exemplary embodiment. Figure 1 and Figure 2 A first embodiment of the inventive concept will be described.

[0026] Reference Figure 1 and Figure 2 As shown, a ceramic coating 200 according to a first exemplary embodiment of the present inventive concept is applied on a substrate 100. The ceramic coating 200 is formed using ceramic paint and includes a ceramic paint precursor 1 and slow-release particles 2 dispersed in the ceramic paint precursor.

[0027] According to an exemplary embodiment, substrate 100 may be a substrate known in the art for making cookware, and may include a stainless steel substrate, an iron substrate, an aluminum substrate, a titanium substrate, etc. However, the present invention is not limited to the material, application, or other properties of the substrate. In other words, those skilled in the art may use any material requiring a ceramic coating as substrate 100 as needed. Thus, the non-stick utensils of the present invention can be applied to any application requiring a non-stick coating (such as non-stick coatings for cooking utensils (e.g., frying pans, rice cooker inner pots), interior and exterior coatings for transportation pipelines, etc.).

[0028] Ceramic coating precursor 1, serving as a base layer for a ceramic coating, may be a ceramic coating commonly used in the art. However, exemplary embodiments are not limited thereto. As described below in conjunction with exemplary embodiments of the present invention in connection with the method for manufacturing a ceramic coating using a ceramic coating, ceramic coating precursor 1 may be a ceramic coating precursor prepared by the method of the present invention.

[0029] The slow-release particles 2 dispersed in the ceramic coating precursor 1 include a slow-release material 21 and silicone oil 22 bound to the slow-release material.

[0030] According to an exemplary embodiment, the slow-release material 21 may have a layered and / or porous structure, so that the silicone oil 22 may, for example, be bonded to the surface of the slow-release material and / or adsorbed within the pores and / or layered structure. According to an example, the slow-release material 21 may include at least one of vermiculite, zeolite, bentonite, diatomaceous earth, alpha alumina, silica aerogel, fumed silica, amorphous silica, hollow glass micropowder, porous silicate, layered silicate, porous phosphate, layered phosphate, porous carbonate, layered carbonate, porous sulfate, and layered sulfate. The slow-release material 21 has a porous and / or layered structure and is combined with silicone oil. Therefore, the silicone oil 22 combined with the slow-release material 21 can be slowly released during use of a cookware having a non-stick coating formed by the ceramic coating of the present invention, thereby greatly improving the long-lasting non-stick properties of the non-stick coating formed by the ceramic coating.

[0031] According to an exemplary embodiment, silicone oil 22 is bound (e.g., adsorbed or bonded) to the sustained-release material 21 and provides the primary non-stick properties of the ceramic coating. Silicone oil 22 can be selected from at least one of methyl silicone oil, dimethyl silicone oil, hydroxy silicone oil, hydrogen silicone oil, and polyether-modified silicone oil. Furthermore, by weight, silicone oil 22 can include 20%-30% low-molecular-weight silicone oil, 40%-60% medium-molecular-weight silicone oil, and 20%-30% high-molecular-weight silicone oil. The low-molecular-weight silicone oil can have a molecular weight between 500-1000, the medium-molecular-weight silicone oil can have a molecular weight between 3000-6000, and the high-molecular-weight silicone oil can have a molecular weight between 12,000-30,000. Silicone oil 22 can be prepared using a blend of different molecular weights. This is because: high-molecular-weight silicone oils bond more firmly to the sustained-release material and release more slowly; low-molecular-weight silicone oils are more mobile, resulting in better non-stick properties; and medium-molecular-weight silicone oils offer a balance between mobility and strong bonding. Therefore, by combining low molecular weight silicone oil, medium molecular weight silicone oil and high molecular weight silicone oil, the sustained release and non-stick effects can be better exerted.

[0032] In addition, in order to improve the bonding strength between the silicone oil and the slow-release material, a coupling agent may be provided between the slow-release material and the silicone oil. Here, the coupling agent may include a silane coupling agent. However, the exemplary embodiment is not limited thereto, and the coupling agent may be omitted.

[0033] Preferably, the particle size of the slow-release particles according to the exemplary embodiment may be less than or equal to 20 microns, preferably less than or equal to 15 microns, and the particle size of the slow-release particles may obey a normal distribution. This is because excessively large particle sizes (e.g., greater than 20 microns) tend to have a significant impact on the appearance of the formed non-stick coating.

[0034] According to an exemplary embodiment, the slow-release particles in the ceramic coating may include 5.15-32.97 parts by weight of the slow-release particles per 100 parts by weight of the ceramic coating 200 (i.e., when the ceramic coating is manufactured using the ceramic coating, the slow-release particles may be included in 5.15-32.97 parts by weight per 100 parts by weight of the ceramic coating). This is because when the ceramic coating precursor is excessive, the slow-release particle content is relatively low, resulting in a poor slow-release effect. However, when the slow-release particle content is relatively high, the strength and bonding force of the coating are reduced.

[0035] Figure 1 A single-layer ceramic coating 200 is shown as being applied on a substrate 100, however, exemplary embodiments are not limited thereto. Figure 3-Figure 5 As shown in , the ceramic coating may also include at least two layers (eg, two layers, three layers, etc.) of ceramic coating.

[0036] Furthermore, when the ceramic coating 200 is a single layer, the thickness of the single layer of ceramic coating 200 may be within a range of 10 to 80 microns. This is because, when the thickness of the ceramic coating 200 is less than 10 microns, the wear resistance is insufficient, and the ceramic coating is easily worn out. Conversely, when the thickness of the ceramic coating is greater than 80 microns, the coating becomes loose, thereby reducing the impact strength.

[0037] Above, combined Figure 1 and Figure 2 The case where the ceramic coating 200 is a single layer is described. Figure 3-Figure 5 The case where the ceramic coating 200 includes a plurality of sub-layers will be described.

[0038] Figure 3 is a schematic diagram illustrating a second embodiment of a ceramic coating according to an exemplary embodiment; Figure 4 is a schematic diagram illustrating a third embodiment of a ceramic coating according to an exemplary embodiment; Figure 5 is a schematic diagram showing a fourth embodiment of a ceramic coating according to an exemplary embodiment. Figures 3 to 5 In FIG. 2 , the ceramic coating 200 includes a first sub-layer 201 and a second sub-layer 202 . Figure 3 、 Figure 4 and Figure 5 There are differences between them in the content and size of the sustained-release particles.

[0039] Reference Figure 3 , the ceramic coating 200 according to the second exemplary embodiment of the present inventive concept may include a first sub-layer 201 and a second sub-layer 202, where the first sub-layer 201 and the second sub-layer 202 may be the same as the reference Figure 1 The ceramic coating 200 described has the same structure, that is, each of the first sublayer 201 and the second sublayer 202 includes a matrix containing a ceramic material and slow-release particles dispersed in the matrix, and the slow-release particles included in each sublayer are the same size or have little difference. In addition, each of the first sublayer 201 and the second sublayer 202 can have a thickness of not less than 10 microns, and the thickness difference between the first sublayer and the second sublayer is not particularly limited. For example, the first sublayer 201 can have a thickness of 20 microns, and the second sublayer can have a thickness of 30 microns, 40 microns or 50 microns. In addition, when multiple sublayers (for example, three, four, etc.) are provided, the sum of the thicknesses of the multiple sublayers can be less than or equal to 80 microns.

[0040] According to an exemplary embodiment, the first sublayer 201 and the second sublayer 202 may each include different contents of slow-release particles (i.e., the number of slow-release particles included in the sublayer per unit weight, for example, the density of the slow-release particles in the sublayer), and the content of the slow-release particles in the first sublayer 201 may be lower than the content of the slow-release particles in the second sublayer 201. That is, when a plurality of (e.g., two, three, four) sublayers are provided, the content of the slow-release particles included in each sublayer may increase in the direction away from the substrate 100. Furthermore, although the attached Figure 3 2 shows that the content of the slow-release particles included in the first sub-layer 201 is less than that in the second sub-layer 202, but the exemplary embodiment is not limited thereto. In other embodiments, the first sub-layer may also include very few slow-release particles or no slow-release particles.

[0041] In addition, when the ceramic coating includes multiple sublayers (for example, two, three), the content of the slow-release particles included in at least the topmost sublayer can be 5.15-32.97 weight parts of slow-release particles dispersed in every 100 weight parts of the sublayer, and there is no specific limitation on the content (for example, density) of the slow-release particles included in the sublayer provided thereunder.

[0042] For example, when the ceramic coating includes two sub-layers, the content of the slow-release particles arranged in the lower sub-layer 201 can be 3 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sub-layer 201, and the content of the slow-release particles arranged in the upper sub-layer 202 can be 30 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sub-layer 202.

[0043] For another example, when the ceramic coating includes three sub-layers, the content of the slow-release particles arranged in the bottom sub-layer can be 2 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sub-layer, the content of the slow-release particles arranged in the middle sub-layer can be 3 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sub-layer, and the content of the slow-release particles arranged in the top sub-layer can be 25 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sub-layer.

[0044] That is, when multiple sublayers are provided, the content of the slow-release particles included in each sublayer may gradually increase (e.g., a gradient) in a direction away from the substrate 100 and satisfy that the sublayer (e.g., 202) provided at the top has 5.15-32.97 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sublayer, or that the sublayers provided below the top sublayer (e.g., 202) have the same or different content of slow-release particles that is less than the content of the slow-release particles in the top sublayer (e.g., 202) and the top sublayer has 5.15-32.97 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sublayer. In other words, the content of the slow-release particles in each sublayer provided below the top sublayer is limited to a content of slow-release particles dispersed in every 100 parts by weight of the corresponding sublayer that is less than the content of slow-release particles distributed in the top sublayer having a range of 5.15-32.97 parts by weight of slow-release particles.

[0045] Reference Figure 4 , the ceramic coating according to the third embodiment is Figure 3 The difference between the ceramic coating of the second embodiment is that the size of the slow-release particles included in the first sub-layer 201 is different from the size of the slow-release particles included in the second sub-layer. Figure 4 As shown in , the size of the slow-release particles included in the first sublayer 201 is smaller than the size of the slow-release particles included in the second sublayer 202. For example, the size of the slow-release particles included in the first sublayer 201 can be less than or equal to 11 microns and obey a normal distribution, while the size of the slow-release particles included in the second sublayer can be less than or equal to 15 microns and obey a normal distribution. Here, the size of almost all (most) of the slow-release particles included in each sublayer can not exceed 20 microns, and the slow-release particles included in the uppermost sublayer (e.g., 202) can have an optimal particle size.

[0046] Reference Figure 5 , the ceramic coating according to the fourth embodiment is Figure 4 The difference between the ceramic coatings of the three embodiments is that the content of the slow-release particles included in each sub-layer is the same. In other words, Figure 5In the fourth embodiment, the content of the slow-release particles in the first sublayer 201 is the same as the content of the slow-release particles in the second sublayer 202 , but the size of the slow-release particles in the first sublayer 201 is smaller than that of the slow-release particles in the second sublayer 202 .

[0047] Above, the ceramic coating according to the present inventive concept is described in detail with reference to exemplary embodiments, and hereinafter, a method of manufacturing the ceramic coating will be described in detail.

[0048] The method of manufacturing a ceramic coating according to the present inventive concept may include: providing a substrate 100 and a ceramic coating; and forming a ceramic coating 200 on the substrate 100 using the ceramic coating through a laying process.

[0049] According to an exemplary embodiment, substrate 100 may be any substrate known in the art for making cookware, and may include stainless steel, iron, aluminum, titanium, etc., and the present invention is not limited by the material or other properties of the substrate. In other words, those skilled in the art may use any material requiring a ceramic coating as substrate 100, and thus the non-stick utensils of the present invention may be suitable for any application requiring a non-stick coating.

[0050] A ceramic coating may be provided before, during, or after providing the substrate. According to exemplary embodiments, the ceramic coating may include a ceramic coating precursor and slow-release particles dispersed within the ceramic coating. Thus, providing the ceramic coating may include separately preparing the ceramic coating precursor and the slow-release particles, and then mixing the ceramic coating precursor with the slow-release particles to obtain the ceramic coating. However, exemplary embodiments are not limited thereto; that is, the steps of preparing the ceramic coating precursor and the slow-release particles may be combined. Below, a method for preparing a ceramic coating according to the present invention by separately preparing the ceramic coating precursor and the slow-release particles will be primarily described.

[0051] Preparation of ceramic coating precursors

[0052] According to an exemplary embodiment, the step of preparing the ceramic coating precursor may include a step of providing materials and a step of mixing.

[0053] The step of providing materials may include the steps of separately providing A material, B material, and C material.

[0054] Here, material A may include a silane substance, material B may include silica sol and filler as essential components, optional pigments, wetting agents, thickeners and emulsifiers as unnecessary components, and a solvent, and material C may include an organic acid as an essential component, and optional pH buffer and catalyst (zirconium acetate) as unnecessary components.

[0055] In Material A, according to exemplary embodiments, a silane substance is used to form polysiloxane during the formation of the ceramic coating. Therefore, the silane substance here may include substances known in the art for polycondensation to form polysiloxane. According to exemplary embodiments, the silane substance may include at least one of methyltrimethoxysilane, methyltriethoxysilane, and dimethyldimethoxysilane, but is not limited thereto. Furthermore, in addition to the silane substance, Material A may also include tetraethyl orthosilicate, which polycondenses to form polysiloxane. In this case, the silane substance may comprise 80% to 97% of Material A by weight, and the tetraethyl orthosilicate may comprise 3% to 20% of Material A by weight.

[0056] Material B may necessarily include fillers and silica sol. Fillers enhance the wear resistance of the coating, among other things. Therefore, the present invention is not limited to the type of filler, and commonly used fillers may be selected. For example, at least one of mica powder, kaolin, montmorillonite, silicon carbide, aluminum oxide, and silicon dioxide may be selected. Furthermore, silica sol is the primary film-forming substance in ceramic coatings. It reacts with polysiloxane under acidic conditions to form a ceramic coating through a sol-gel reaction. Therefore, commercially available silica sol may be selected as the silica sol in Material B of the present invention. For example, the silica sol may be AkzoNobel 1050 (silica sol) or American Grace LUDIX AM-50.

[0057] The essential components of Material B can be dispersed in a solvent. That is, Material B can also include a solvent. Here, the solvent can include deionized water and, to regulate the solvent's volatilization rate during the coating drying process, can also include isopropyl alcohol. Furthermore, the ratio of isopropyl alcohol to water is unlimited, and the ratio of water to isopropyl alcohol can be selectively adjusted based on actual needs.

[0058] In addition to the essential components listed above, material B may optionally include one or more of a pigment, a wetting agent, a thickener, and an emulsifier as optional components. Pigments are primarily used to impart different colors to the coating, so common inorganic pigments can be used. Inorganic pigments offer excellent heat resistance and safety, and are therefore preferred for applications requiring high temperatures. According to exemplary embodiments, at least one of carbon black, copper chromium black, titanium dioxide, and iron oxide can be used as a filler. Furthermore, during the preparation of the essential components in a solvent, at least one of a wetting agent, a thickener, and an emulsifier can be added to the material to enhance its superior properties.

[0059] According to a specific example, the material B may include, by weight, 30-48 wt% of silica sol, 8-13 wt% of pigment, 8-25 wt% of filler, 0.2-1 wt% of wetting agent, 1-3 wt% of thickener, 3-5 wt% of emulsifier, and the balance being isopropyl alcohol and deionized water. However, exemplary embodiments are not limited thereto, and one or more of the unnecessary components may be omitted.

[0060] Material C serves as a strong acid catalyst and may include an organic acid as an essential component, and an optional pH buffer and catalyst (e.g., zirconium acetate) as optional components. The organic acid is used to adjust the pH of the silica sol in subsequent processes, enabling it to react with Material A in an acidic environment. Therefore, organic acids commonly used in ceramic coatings in the art can be used. According to exemplary embodiments, at least one of formic acid and acetic acid can be selected as the organic acid. When both formic acid and acetic acid are included, the weight ratio of formic acid to acetic acid can be between 4:6 and 1:1. Material C may also optionally include a pH buffer and catalyst. These pH buffers and catalysts can be known in the art for use in preparing strong acid catalysts for ceramic coatings. For example, the pH buffer can be a weak acid such as boric acid. The catalyst is used to accelerate the sol-gel reaction and can be zirconium acetate, for example. However, exemplary embodiments are not limited to the specific types of pH buffers and catalysts, and these can be omitted or appropriately selected based on existing knowledge.

[0061] According to an exemplary embodiment, the C material may include 80-97 parts by weight of a formic acid and acetic acid mixture, 1-2 parts by weight of a boric acid pH buffer, and 0.5 parts by weight of a zirconium acetate catalyst.

[0062] After providing the above-mentioned materials, a mixing step can be performed. In this article, the mixing step can include a first mixing step of mixing the B material with the C material to obtain the first material and a second step of mixing the result of the first mixing step (i.e., the first material) with the A material.

[0063] Specifically, 40-60 parts by weight of material B can be mixed with 1-2 parts by weight of material C, and the pH of the mixture can be adjusted to acidic (e.g., less than or equal to 4) by utilizing the acidity of material C to obtain the first material. Since material C includes a solid filler and an optional pigment, before mixing or during the preparation of material C, material C can be added to a grinder and ground for 0.5-2 hours to fully disperse it and grind it to a particle size of less than or equal to 15 microns to obtain a uniformly dispersed slurry.

[0064] After the B material and the C material are mixed, the mixture may be tumbling dispersed for a predetermined time (eg, 0.5 h) so that the first material has a high degree of dispersion.

[0065] After obtaining the first material, material A can be added to the first material. Here, the weight ratio of material A to material B can be within a range of (20-30):(40-60). After adding material A, the mixture can be further shaken to allow the mixture to undergo a sol-gel reaction in an acidic environment, thereby forming a ceramic coating precursor.

[0066] Preparation of sustained-release granules

[0067] During, before, or after the preparation of the ceramic coating, the slow-release particles can be prepared. The slow-release particles can be prepared by mixing the slow-release material with silicone oil.

[0068] According to an exemplary embodiment, the sustained-release granules may include the above-referenced Figure 1 and Figure 2 The described sustained-release material 21 has a pore structure and / or a layer structure and the silicone oil 22 is combined with (eg, adsorbed, bonded to) the sustained-release material.

[0069] A slow-release material precursor of appropriate size (i.e., the slow-release material before grinding, when the grinding step is omitted, the slow-release material precursor can be considered as the slow-release material for final use) can be selected to prepare slow-release particles. According to an exemplary embodiment, the slow-release material precursor can have a layer gap and / or pore structure. According to an example, the slow-release material precursor can include at least one of vermiculite, zeolite, bentonite, diatomaceous earth, alpha alumina, silica aerogel, fumed silica, amorphous silica, hollow glass powder, porous silicate, layered silicate, porous phosphate, layered phosphate, porous carbonate, layered carbonate, porous sulfate and layered sulfate. The slow-release material precursor has a porous and / or layered structure and the slow-release material formed after grinding is combined with silicone oil. The silicone oil combined with the slow-release material can be slowly released during the use of an appliance such as a non-stick coating formed by the ceramic coating conceived by the present invention, thereby greatly improving the long-lasting non-stick performance of the non-stick layer formed by the ceramic coating.

[0070] According to exemplary embodiments, the particle size of the sustained-release material precursor can be within a range of 100-3000 mesh, and the particle size of the sustained-release material precursor within this range can follow a normal distribution. However, when the particle size is too large (e.g., less than 100 mesh), the excessively large particle size can easily increase the grinding process or cause the particle size of the sustained-release material after grinding to be too large, ultimately affecting the appearance of the non-stick coating made using the ceramic coating. Conversely, when the particle size is too small (e.g., greater than 3000 mesh, and the particle size becomes even smaller after grinding), it is difficult to effectively adsorb and bond silicone oil, thereby making it difficult to achieve a good silicone oil sustained-release effect.

[0071] When the sustained-release material precursor has the above-described particle size distribution, the particle size of the resulting sustained-release material can be reduced to 20 microns or less using two grinding processes, as described below. However, exemplary embodiments are not limited thereto. Specifically, when the particle size of the sustained-release material precursor is selected to have a smaller value within the range of 100-3000 mesh, one grinding process can be omitted. Furthermore, when the particle size of the sustained-release material precursor is selected to have an even smaller value within the above-described range, both grinding processes can be omitted. When at least one of the grinding processes is omitted, the omitted grinding process can be replaced by a stirring process, or the mixture can be left untreated.

[0072] The silicone oil can be selected from at least one of methyl silicone oil, dimethyl silicone oil, hydroxy silicone oil, hydrogen silicone oil, and polyether-modified silicone oil. Silicone oils of different molecular weights can be mixed in a certain proportion to form a silicone oil composition with a normal molecular weight distribution. The low molecular weight silicone oil content can be 20-30 wt%, the medium molecular weight silicone oil content can be 40-60 wt%, and the high molecular weight silicone oil content can be 20-30 wt%. The molecular weight of the low molecular weight silicone oil can be between 500-1000, the medium molecular weight silicone oil between 3000-6000, and the high molecular weight silicone oil between 12000-30000. By utilizing a normally distributed silicone oil composition, the sustained-release and non-stick properties can be better achieved. This is because: high molecular weight silicone oils bind more firmly to the sustained-release material and release more slowly; low molecular weight silicone oils have greater mobility, resulting in better non-stick properties; and medium molecular weight silicone oils offer both mobility and strong binding. Therefore, low molecular weight silicone oil, medium molecular weight silicone oil and high molecular weight silicone oil can be combined to better exert the sustained release and non-stick effects.

[0073] According to an example, 35-58 parts by weight of a slow-release material precursor can be mixed with 42-60 parts by weight of silicone oil to obtain a mixture, and 1-3 parts by weight of a coupling agent (e.g., a methoxysilane coupling agent), 0.3 parts by weight of a catalyst (e.g., a titanate catalyst), and 1-1.5 parts by weight of a dispersant can be added to the mixture. However, exemplary embodiments are not limited thereto, and the coupling agent and the catalyst are used to enhance the binding force between the silicone oil and the slow-release material, and the dispersant is used to improve the dispersion of the slow-release material in the silicone oil. However, exemplary embodiments are not limited thereto, and at least one of the coupling agent, the catalyst, and the dispersant may be omitted.

[0074] According to specific example, silicone oil, 100 mesh-3000 mesh slow-release material precursor, silane coupling agent can be mixed, and after being ground to a particle size of less than or equal to 30 microns, then catalyst is added, and continued to be ground to a particle size of less than or equal to 20 microns, then ultrasonic treatment 0.5h-1h at normal temperatures, so that slow-release particles can be obtained. Here, first silicone oil is mixed with the slow-release material and then ground to a particle size of less than or equal to 30 microns so that silicone oil and the slow-release material can be mixed, and thereafter, then ground to a particle size of less than or equal to 20 microns under the condition of catalyst so that silicone oil can be fully firmly adsorbed and bonded to its outside by the slow-release material. However, when the particle size of the slow-release material is less than 30 microns, the first grinding can be omitted, and a stirring process can be provided alternatively, or the second grinding process can be directly carried out. In addition, when the particle size of the slow-release material is less than 20 microns, the second grinding process can be further omitted, and a stirring process can be provided alternatively.

[0075] Preparation of ceramic coatings

[0076] After the ceramic coating precursor and the slow-release particles are prepared, the slow-release particles can be mixed with the ceramic coating precursor to prepare a ceramic coating according to an exemplary embodiment.

[0077] For ceramic coatings comprising slow-release particles of varying numbers and / or sizes, slow-release particles of desired sizes and / or numbers can be added to the ceramic coating. Furthermore, after the ceramic coating precursor and the slow-release particles are mixed, the mixture can be stirred at 120-200 rpm for 6-8 hours to obtain the desired ceramic coating having varying particle sizes and / or numbers.

[0078] While the above method describes a method for obtaining a ceramic coating by separately preparing a ceramic coating precursor and slow-release particles and then mixing the ceramic coating precursor and slow-release particles, in a method combining the steps of preparing the ceramic coating precursor with preparing the slow-release particles, as described above, after mixing material B and material C, material A and the slow-release particles can be simultaneously added to the mixture. For example, 40-60 parts by weight of material B can be mixed with 1-2 parts by weight of material C, and the pH of the mixture can be adjusted to an acidic level (e.g., less than or equal to 4) by utilizing the acidity of material C to obtain the first material. Subsequently, material A and the slow-release particles can be added to the mixture. Here, the weight ratio of material A to material B can be in the range of (20-30):(40-60). The amount of slow-release particles added can be adaptively selected based on the requirements of different layers. When preparing the ceramic coating for the topmost sublayer, the ratio of material A to material B can be within the range of (20-30):(40-60):(5-30) for the ceramic coating of multiple sublayers. After mixing, the mixture can be stirred at 120-200 rpm for 6-8 hours to produce the desired ceramic coating.

[0079] After obtaining the ceramic material, the ceramic coating can be applied using air spraying. Air spraying parameters are as follows: spray distance 160 mm, air pressure 0.3 MPa, and flow rate 8 L / min. Furthermore, when multiple sub-layers are provided, the above spraying parameters can be applied to any sub-layer. Furthermore, the method for forming the ceramic coating is not limited to air spraying, and various suitable layer formation methods known in the art can be used.

[0080] After air spraying, a single-layer ceramic coating or a ceramic coating having multiple sub-layers can be formed on the substrate.

[0081] According to an exemplary embodiment, when a single ceramic coating layer 200 is provided, 5.15-32.97 parts by weight of the sustained-release particles may be dispersed per 100 parts by weight of the ceramic coating layer 200 . In addition, when multiple sublayers (for example, 201, 202) are provided, the content of the slow-release particles included in each sublayer can gradually (for example, gradient) increase in the direction away from the substrate 100 and satisfy that the sublayer provided at the top (for example, 202) has 5.15-32.97 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sublayer, or satisfy that the sublayers provided below the top sublayer (for example, 202) have the same or different content of slow-release particles that is less than the content of slow-release particles in the top sublayer (for example, 202) and the top sublayer has 5.15-32.97 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sublayer, that is, the content of slow-release particles in each sublayer provided below the top sublayer is not limited to the range of 5.15-32.97 parts by weight of slow-release particles dispersed in every 100 parts by weight of the sublayer (for example, 201).

[0082] As described above in detail in conjunction with exemplary embodiments, the ceramic coating of the present invention includes slow-release particles. Therefore, during the cooking process, the release of silicone oil can be slowed down, thereby maintaining a long-lasting non-stick effect.

[0083] Hereinafter, the beneficial effects of the inventive concept will be described with reference to specific examples.

[0084] Example 1

[0085] The ceramic coating is formed by the following method.

[0086] S1: 80 wt% of methyltrimethoxysilane and 20 wt% of ethyl orthosilicate were mixed and stirred to obtain a silane composition of component A;

[0087] S2: 30 wt% of Akzo Nobel 1050 (silica sol), 8 wt% of titanium dioxide (pigment), 25 wt% of kaolin (filler), 3 wt% of Tween-80 (emulsifier), 1 wt% of water-based modified bentonite (thickener), 0.3 wt% of polyoxyethylene ether TRITONX-100 (wetting agent), 20 wt% of isopropyl alcohol and the balance of deionized water were mixed uniformly, and then added to a grinder and ground for 2 h to fully disperse and grind to a particle size of not more than 15 μm to obtain a component B slurry;

[0088] S3: 48 parts by weight of formic acid, 48 parts by weight of acetic acid, 1 part by weight of boric acid (buffer), and 0.5 parts by weight of zirconium acetate (catalyst) are uniformly mixed to obtain component C, a strongly acidic catalyst;

[0089] S4: 58 parts by weight of a hydroxy silicone oil with a molecular weight of 3000 and 42 parts by weight of vermiculite with a particle size of 100 to 3000 mesh (sustained-release material) are mixed, and then 3 parts by weight of a methoxysilane coupling agent are added and mixed evenly. The mixture is ground to a particle size of no more than 30 μm, and then 0.3 parts by weight of a titanate (catalyst) is added and the mixture is further ground to a particle size of no more than 20 μm. The mixture is then ultrasonically treated at room temperature of 22° C. for 0.5 h to obtain a sustained-release particle component D, wherein the particle size of the sustained-release particle component D obeys a normal distribution;

[0090] S5: The above four components are sequentially mixed in a weight ratio of A:B:C:D = 22:40:1:20, and tumble-cured to obtain a ceramic coating. The mixing sequence and aging method are as follows: First, 40 parts by weight of component B and 1 part by weight of component C are mixed evenly, using component C to adjust the pH to 4. The mixture is then tumble-cured for 0.5 hours. Then, 22 parts by weight of component A is added and shaken evenly. Then, 20 parts by weight of component D is added. The mixture is stirred at 200 rpm for 8 hours to obtain the desired ceramic coating.

[0091] The ceramic coating is used to produce non-stick cookware by the following method.

[0092] S6: Substrate treatment: The stainless steel substrate is sandblasted with 60# brown corundum to form a surface roughness of 3 microns;

[0093] S7: Preheating. Clean the sandblasted substrate and preheat it to 60°C.

[0094] S8: Spraying. Use air spraying to spray the ceramic coating onto the substrate, with a spray film thickness of 70 microns. The air spraying parameters are as follows: spraying distance 160 mm; air pressure 0.3 MPa; flow rate 8 L / min.

[0095] S9: Sintering: Curing at 250°C for 10 minutes.

[0096] By the above method, the non-stick cookware of Example 1 is obtained.

[0097] Example 2

[0098] The difference from Example 1 is that the sustained-release material is bentonite.

[0099] Example 3

[0100] The difference from Example 1 is that the sustained-release material is alpha alumina.

[0101] Example 4

[0102] The difference from Example 1 is that the particle size of the slow-release granular component is not greater than 15 μm, and the particle size of the slow-release granular component D obeys a normal distribution.

[0103] Example 5

[0104] The difference from Example 1 is that the particle size of the slow-release granular component is not greater than 10 μm, and the particle size of the slow-release granular component D obeys a normal distribution.

[0105] Example 6

[0106] The difference from Example 1 is that the film thickness is 10 microns.

[0107] Example 7

[0108] The difference from Example 1 is that the film thickness is 40 microns.

[0109] Example 8

[0110] The difference from Example 1 is that component A, component B, component C and component D are mixed in sequence according to the weight ratio of A:B:C:D=30:60:2:5.

[0111] Example 9

[0112] The difference from Example 1 is that component A, component B, component C and component D are mixed in sequence according to the weight ratio of A:B:C:D=20:40:1:8.

[0113] Example 10

[0114] The difference from Example 1 is that component A, component B, component C and component D are mixed in sequence according to the weight ratio of A:B:C:D=20:40:1:15.

[0115] Example 11

[0116] The difference from Example 1 is that component A, component B, component C and component D are mixed in sequence according to the weight ratio of A:B:C:D=20:40:1:25.

[0117] Example 12

[0118] The difference from Example 1 is:

[0119] (1) preparing ceramic coating 01 by step S5;

[0120] (2) further comprising step S51, wherein the difference between step S51 and step S5 is that the components A, B, C, and D obtained in steps S1-S4 are sequentially mixed in a weight ratio of A:B:C:D=22:40:1:1 to prepare ceramic coating 02;

[0121] (3) A first sublayer having a thickness of 25 μm was formed on the substrate using ceramic coating 02 by the air spraying method of Example 1, and a second sublayer having a thickness of 45 μm was formed on the first sublayer using ceramic coating 01 by the air spraying method of Example 1.

[0122] Example 13

[0123] The difference from Example 12 is that the thickness of the first sub-layer is 10 microns.

[0124] Example 14

[0125] The difference from Example 12 is that the thickness of the first sub-layer is 30 microns.

[0126] Example 15

[0127] The difference from Example 12 is that the thickness of the second sub-layer is 10 microns.

[0128] Example 16

[0129] The difference from Example 12 is that the thickness of the second sub-layer is 20 microns.

[0130] Example 17

[0131] The difference from Example 12 is that A, B, C and D are mixed in sequence according to the weight ratio of A:B:C:D=22:40:1:10 to prepare ceramic coating 02.

[0132] Example 18

[0133] The difference from Example 12 is that A, B, C and D are mixed in sequence according to the weight ratio of A:B:C:D=22:40:1:30 to prepare ceramic coating 01.

[0134] Example 19

[0135] The difference from Example 1 is:

[0136] (1) preparing ceramic coating 01 by step S5;

[0137] (2) Step S52 is also included, and the difference between Step S52 and Step S5 is that the components A, B, and C obtained in Steps S1-S3 are sequentially mixed in a weight ratio of A:B:C=22:40:1 to prepare ceramic coating 03. That is, Step S52 differs from Step S5 in that Step S4 is omitted;

[0138] (3) A first sublayer with a thickness of 25 μm was formed on the substrate using ceramic coating 03 by the air spraying method of Example 1, and a second sublayer with a thickness of 45 μm was formed on the first sublayer using ceramic coating 01 by the air spraying method of Example 1.

[0139] Example 20

[0140] The difference from Example 19 is that the thickness of the first sub-layer is 10 microns.

[0141] Example 21

[0142] The difference from Example 19 is that the thickness of the first sub-layer is 30 microns.

[0143] Example 22

[0144] The difference from Example 19 is that the thickness of the second sub-layer is 10 microns.

[0145] Example 23

[0146] The difference from Example 19 is that the thickness of the second sub-layer is 20 microns.

[0147] Example 24

[0148] The difference from Example 19 is that A, B, C and D are mixed in sequence according to the weight ratio of A:B:C:D=22:40:1:30 to prepare ceramic coating 01.

[0149] Example 25

[0150] The difference from Example 19 is that A, B, C and D are mixed in sequence according to the weight ratio of A:B:C:D=22:40:1:15 to prepare ceramic coating 01.

[0151] Example 26

[0152] The difference from Example 1 is that the silicone oil consists of 20 wt % of hydroxy silicone oil with a molecular weight of 800, 60 wt % of hydroxy silicone oil with a molecular weight of 3000 and 20 wt % of hydroxy silicone oil with a molecular weight of 12000.

[0153] Example 27

[0154] The difference from Example 1 is that the silicone oil consists of 30 wt % of hydroxy silicone oil with a molecular weight of 800, 40 wt % of hydroxy silicone oil with a molecular weight of 3000 and 30 wt % of hydroxy silicone oil with a molecular weight of 12000.

[0155] Example 28

[0156] The difference from Example 1 is that the silicone oil consists of 25 wt % of hydroxy silicone oil with a molecular weight of 800, 50 wt % of hydroxy silicone oil with a molecular weight of 3000 and 25 wt % of hydroxy silicone oil with a molecular weight of 12000.

[0157] Comparative Example 1

[0158] The difference from Example 1 is that step S4 is omitted. That is, in step S5, components A, B, and C are mixed in order according to a weight ratio of A:B:C=22:40:1, and the resulting ceramic material is used to manufacture non-stick cookware.

[0159] Comparative Example 2

[0160] The difference from Example 1 is that 30 parts by weight of hydroxy silicone oil with a molecular weight of 3000 is mixed with 60 parts by weight of vermiculite.

[0161] Comparative Example 3

[0162] The difference from Example 1 is that 60 parts by weight of hydroxy silicone oil with a molecular weight of 3000 is mixed with 40 parts by weight of vermiculite.

[0163] Comparative Example 4

[0164] The difference from Example 12 is that the second sub-layer is located on the substrate, and the first sub-layer is located on the second sub-layer.

[0165] The non-stick properties of the non-stick cookware of Examples 1-28 and Comparative Examples 1-4 were tested, and the test results are shown in the following table.

[0166]

[0167]

[0168] Performance index test

[0169] The cookware obtained above was subjected to a performance test. The specific performance test method is as follows:

[0170] (1) Long-lasting non-stick test method: refer to 4.2.1 Fried egg non-stick test in GB_T 32095.2-2015. The unit is the number of times. The higher the number, the longer the life. The non-stick result is evaluated every 1000 times, and the number of times when the non-stickiness reaches level III is recorded.

[0171] (2) Plane wear resistance test method: GB_T 32095.2-2015 4.3.1 Plane wear resistance test, using 3M7447 scouring pad, applying a force of 15N, a frequency of 33 times / minute, and replacing the scouring pad every 500 times.

[0172] By comparing and analyzing Examples 1-28 of the present invention with Comparative Examples 1-4, it is readily apparent that the conventional ceramic coating in Comparative Example 1 exhibits a sustained non-stick performance of no more than 500 times. The silicone oil content in Comparative Example 2 is low, thus failing to provide an effective sustained-release effect. Furthermore, the sustained-release material content in Comparative Example 3 is too low, resulting in a low amount of bound silicone oil and an ineffective sustained-release effect. Furthermore, although Comparative Example 4 includes two sublayers, the content of sustained-release particles in the uppermost sublayer is lower than that in the lower sublayer. Consequently, the tested performance of the resulting dual-layer ceramic coating is inferior to that of the ceramic coatings in the Examples. Compared to Comparative Examples 1-4, the ceramic coatings according to the present invention exhibit superior sustained non-stick properties.

[0173] Although one or more embodiments of the present invention have been described with reference to the drawings, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the claims.

Claims

1. A ceramic coating, characterized in that: The ceramic coating comprises: Ceramic coating precursors; Slow-release particles dispersed in a ceramic coating precursor, wherein The slow-release particles include a slow-release material and silicone oil bound to the slow-release material, and The sustained-release material includes at least one of vermiculite, zeolite, bentonite, diatomaceous earth, alpha alumina, silica aerogel, fumed silica, amorphous silica, hollow glass powder, porous silicate, layered silicate, porous phosphate, layered phosphate, porous carbonate, layered carbonate, porous sulfate and layered sulfate.

2. The ceramic coating according to claim 1, wherein The particle size of the sustained-release particles is less than or equal to 20 microns.

3. The ceramic coating according to claim 2, wherein: The particle size of the sustained-release particles is less than or equal to 15 microns.

4. The ceramic coating according to claim 1, wherein The ceramic coating includes a single layer, and a thickness of the single layer is in a range of 10 micrometers to 80 micrometers.

5. The ceramic coating according to claim 1, wherein The ceramic coating includes at least two sub-layers, and at least an uppermost sub-layer of the at least two sub-layers includes slow-release particles.

6. The ceramic coating according to claim 5, wherein: The thickness of each sub-layer is not less than 10 microns, and the sum of the thicknesses of the sub-layers is not greater than 80 microns.

7. The ceramic coating according to claim 6, wherein The contents of the sustained-release particles included in the respective sub-layers are different from each other.

8. The ceramic coating according to claim 7, wherein The ceramic coating is located on a substrate, and the content of the slow-release particles in each sub-layer increases in a direction away from the substrate.

9. The ceramic coating according to claim 1, characterized in that The particle sizes of the sustained-release particles included in each sub-layer of the ceramic coating are different from each other.

10. A non-stick utensil, characterized in that: The non-stick utensil comprises the ceramic coating according to any one of claims 1 to 9.

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