Non-stick utensils

Abstract

A non-stick utensil is provided, comprising: a substrate; and a ceramic coating disposed on a surface of the substrate. The ceramic coating 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. 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. The surface of the substrate has a surface roughness of 3 to 15 microns.

Description

Technical Field

[0001] The invention belongs to the technical field of non-stick coatings, and in particular relates to a non-stick utensil. 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 non-stick utensil, wherein the surface of the substrate of the non-stick utensil is functionalized so that the substrate can be more firmly bonded to the ceramic coating.

[0005] According to an aspect of the exemplary embodiment, a non-stick utensil includes: a substrate; and a ceramic coating disposed on a surface of the substrate, the ceramic coating comprising 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, the slow-release material comprising 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 surface of the substrate has a surface roughness of 3 to 8 microns.

[0006] The particle size of the sustained-release particles may be less than or equal to 20 microns.

[0007] The particle size of the sustained-release particles may be in the range of 8 microns to 15 microns.

[0008] The sustained-release particles may be included in an amount of 5.15 to 32.97 parts by weight per 100 parts by weight of the ceramic coating.

[0009] The thickness of the ceramic coating 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 of the sub-layers including the slow-release particles may be not less than 10 micrometers, and the thickness of the ceramic coating layer may be not more than 80 micrometers.

[0012] The content of the sustained-release particles in each sub-layer may increase in a direction away from the substrate.

[0013] The substrate may include two or more layers composed of at least two materials selected from aluminum, aluminum alloy, titanium, titanium alloy, iron, and stainless steel.

[0014] The substrate may include a base layer and a functional layer disposed between the base layer and the ceramic coating layer, and a surface of the functional layer may have a surface roughness of 3 micrometers to 15 micrometers.

[0015] The non-stick utensil may further include a sealing layer located on the surface of the ceramic coating.

[0016] The non-stick utensil of the present invention includes a ceramic coating containing slow-release particles. Because the slow-release material in the slow-release particles has a disordered porous structure, silicone oil is adsorbed and bonded to the surface and pores of the slow-release material. This ceramic coating exhibits a slow-release effect, thereby enhancing long-lasting non-stick properties. Furthermore, because the substrate is treated to a surface roughness of 3 to 15 microns, this surface roughness allows for a more secure bond with the ceramic coating, thereby extending the service life of the non-stick utensil. 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; DETAILED DESCRIPTION

[0020] 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.

[0021] Non-stick utensils using ceramic coatings achieve their non-stick properties primarily through the presence of silicone methyl groups and the addition of silicone oil within the coating. 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 to the pan. If the ceramic coating could be made to continuously store oil, it could form an effective oil film that isolates food from the coating surface, achieving long-lasting non-stick properties.

[0022] Therefore, the present invention provides a non-stick utensil having a ceramic coating comprising slow-release particles containing a slow-release material. The slow-release material of the slow-release particles in the ceramic coating has a disordered porous and / or layered structure, and silicone oil is bound (e.g., adsorbed or bonded) to the slow-release material. During cooking, the slow-release particles in the ceramic coating can slow the release of silicone oil, thereby maintaining a long-lasting non-stick effect of the ceramic coating.

[0023] Figure 1 is a schematic diagram illustrating a first embodiment of a non-stick utensil according to an exemplary embodiment, Figure 2 is a schematic enlarged view showing the slow-release particles included in the ceramic coating of the first embodiment, Figure 3 is a schematic diagram showing a second embodiment of a non-stick utensil according to an exemplary embodiment. Figures 1 to 3 The non-stick utensil of the present invention is described below.

[0024] Reference Figure 1 and Figure 2 , a non-stick utensil according to a first exemplary embodiment of the present inventive concept includes a base 100 and a ceramic coating disposed on the base.

[0025] According to an exemplary embodiment, the substrate 100 may be a substrate of a cookware known in the art, and may include a stainless steel substrate, an iron substrate, an aluminum substrate, a titanium substrate, etc. In addition, since a substrate of a single material has some defects in terms of thermal conductivity, hardness, etc., preferably, the substrate may include two or more composite layers of at least two of aluminum, aluminum alloy, titanium, titanium alloy, stainless steel, and iron. For example, the substrate may include two or more composite layers of titanium-aluminum, iron-aluminum, or stainless steel-aluminum. However, the present invention does not limit the material, use, and other properties of the substrate. That is, those skilled in the art can use any substrate on which a ceramic coating 300 is to be applied as the substrate 100 as needed. Thus, the non-stick utensil conceived by the present invention can be applied to any scenario requiring non-stick (such as non-stick coatings for cooking pots (e.g., frying spoons, inner pots of rice cookers), inner and outer coatings of transport pipelines, etc.).

[0026] In addition, the substrate 100 has an unlimited shape and thickness. For example, the substrate 100 can be a stir-fry spoon substrate, a rice cooker inner pot substrate, etc. However, the surface of the substrate 100 needs to have a surface roughness of 3 to 15 microns. Such a surface roughness can increase the roughness and hardness of the substrate 100, thereby providing better bonding strength and wear resistance. In the case where the substrate 100 has a single-layer structure, the upper surface of the substrate 100 can have a surface roughness of 3 to 15 microns. Alternatively, when the substrate has a multi-layer structure (not shown), the surface of the top layer of the multi-layer structure can have a surface roughness of 3 to 15 microns.

[0027] To achieve surface roughness of the substrate 100, the substrate 100 may be subjected to a functionalization treatment, wherein the functionalization treatment may include hard oxidation, shot blasting, embossing, graining, etching, thermal spraying, and other existing technologies. Figure 1 The substrate 100 is shown after being subjected to a functionalization treatment such as shot peening or etching, and the substrate 100 may have a surface roughness of 3 μm to 15 μm. In addition, when a functionalization treatment such as thermal spraying (e.g., thermal spraying the substrate surface by arc spraying, flame spraying, or plasma spraying) is performed on the substrate using, for example, molten iron, titanium, aluminum, alloys, metal oxides, carbides, or nitrides, the substrate may be subjected to a functionalization treatment such as thermal spraying (e.g., thermal spraying the substrate surface by arc spraying, flame spraying, or plasma spraying). Figure 3 As shown, the surface of the substrate 100 according to the second embodiment of the present invention can additionally include a hard layer as a functional layer due to partial functionalization. In this case, the substrate 100 can include a base layer 101 and a functional layer 102 formed on the base layer 101. Here, the base layer 101 can be the same as the reference Figure 1 The substrate 100 of the first embodiment described has the same or substantially the same characteristics except that the surface has no roughness, and the functional layer 102 is a layer formed on the surface of the base layer 101 using functionalization treatment, and the base layer 101 and the functional layer 102 serve as the substrate 100 for forming the ceramic coating. Therefore, the surface of the functional layer 102 located on the upper part of the substrate 100 can have a surface roughness of 3 microns to 15 microns as the surface of the substrate 100.

[0028] The ceramic coating 200 is located on the surface of the substrate 100. The ceramic coating 200 includes a ceramic coating precursor 1 and slow-release particles 2 (such as Figure 2 ).

[0029] Herein, the ceramic coating precursor 1 can be equivalent to a ceramic coating used in the art and, therefore, can have the same components as conventional ceramic coatings in the art, thereby being able to be produced using methods known in the art for producing ceramic coatings. However, exemplary embodiments are not limited thereto. As mentioned below in conjunction with exemplary embodiments regarding the method for producing a ceramic coating precursor 1 according to the present invention, the ceramic coating precursor 1 can be produced using the method described below. Furthermore, the ceramic coating precursor 1 produced using the method described below can exhibit superior non-stick properties when combined with slow-release particles.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] Preferably, the particle size of the slow-release particles according to an exemplary embodiment may be less than or equal to 20 microns. This is because excessively large particle sizes (e.g., greater than 20 microns) can significantly affect the appearance of the resulting non-stick coating. More preferably, the particle size of the slow-release particles may be in the range of 8 to 15 microns.

[0035] According to an exemplary embodiment, the ceramic coating 200 may include 5.15-32.97 parts by weight of slow-release particles per 100 parts by weight of the ceramic coating 200. This is because when the ceramic coating precursor is excessive, the content of the slow-release particles is relatively low, resulting in a poor slow-release effect. However, when the content of the slow-release particles is relatively high, the strength and bonding force of the coating are reduced.

[0036] Figure 1 and Figure 3 A case of a single-layer ceramic coating 200 on the substrate 100 is shown, however, exemplary embodiments are not limited thereto, that is, the ceramic coating (not shown) may also include at least two (eg, two, three, etc.) layers of ceramic coating.

[0037] 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.

[0038] In addition, when the ceramic coating includes a plurality of sub-layers (e.g., a first sub-layer, a second sub-layer, etc.), at least one of the plurality of sub-layers may be the same as the reference Figure 1 The ceramic coating 200 described above has the same structure. For example, when the ceramic coating includes a first sublayer and a second sublayer on the first sublayer, at least the second sublayer on top may have the same structure as the reference Figure 1 The ceramic coating 200 has the same or similar structure as that described above and may include a ceramic coating precursor and slow-release particles dispersed in the ceramic coating precursor. The difference between the first sublayer and the second sublayer may be that the first sublayer includes a small amount of slow-release particles or no slow-release particles. That is, when multiple (e.g., two) sublayers are provided, the content of slow-release particles included in each sublayer (i.e., the number of slow-release particles included in a sublayer, e.g., the density of the slow-release particles in the sublayer) may increase in a direction away from the substrate 100. At least the content of slow-release particles in the uppermost sublayer may be 5.15-32.97 parts by weight per 100 parts by weight of the sublayer, and there is no specific limitation on the content (e.g., density) of slow-release particles included in the sublayer provided therebelow.

[0039] In addition, although not shown, in order to further slow down the release of silicone oil in the ceramic coating 200 , a sealing layer (not shown) may be further provided on the ceramic coating 200 .

[0040] The sealing layer may include a sealing ceramic coating. Here, the sealing ceramic coating may be the same as or different from the ceramic coating precursor included in ceramic coating 200. Specifically, the sealing ceramic coating may be a ceramic coating precursor formed during the preparation of the ceramic coating described below, or prepared using the method for preparing a ceramic coating precursor. Alternatively, the sealing ceramic coating may be a ceramic coating commonly used in the art or prepared using a conventional formulation. For example, a silane substance, alkaline silica sol, and a non-sticking agent may be formulated using a conventional ratio.

[0041] The sealing layer does not include the slow-release particles, so as to further slow down the release of the silicone oil in the slow-release particles in the ceramic coating 200. Therefore, the sealing layer may have a thickness of 8 micrometers to 20 micrometers.

[0042] A non-stick utensil according to the present invention has been described in detail above with reference to exemplary embodiments. According to the present invention, the non-stick utensil may include a substrate 100 having a rough surface, a ceramic coating 200 having a single or multi-layer structure, and an optional sealing layer. A method for manufacturing the non-stick utensil will be described in detail below.

[0043] The method of manufacturing a non-stick utensil according to the present inventive concept may include: providing a substrate and treating the same; preparing a ceramic coating; and forming a ceramic coating layer 200 on a substrate 100 using the ceramic coating through a laying process.

[0044] According to an exemplary embodiment, the 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., and may have various desired shapes. The present invention is not limited to the substrate. In other words, those skilled in the art may use any material on which a ceramic coating is applied as the substrate 100 as needed, so that the non-stick utensil conceived by the present invention can be applied to any scenario requiring non-stick. In addition, preferably, the substrate may include two or more composite layers of at least two of aluminum, aluminum alloy, titanium, titanium alloy, stainless steel, and iron.

[0045] After providing the substrate 100, the substrate 100 may be functionalized to achieve a surface roughness of 3 to 15 microns. The functionalization process for the substrate 100 may include hard oxidation, shot blasting, embossing, lathing, etching, thermal spraying, and the like. For example, the substrate 100 may be sandblasted with 60# brown corundum to achieve a surface roughness of 3 to 6 microns. The substrate may then be cleaned and preheated to 40°C to 60°C before the ceramic coating process is performed.

[0046] A ceramic coating may be provided before, during, or after providing substrate 100. According to exemplary embodiments, the ceramic coating may include a ceramic coating precursor and slow-release particles dispersed in the ceramic coating precursor. Therefore, 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.

[0047] Preparation of ceramic coating precursors

[0048] 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.

[0049] The step of providing materials may include the steps of separately providing A material, B material, and C material.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] Preparation of sustained-release granules

[0063] During, before, or after the preparation of the ceramic coating precursor, the slow-release particles can be prepared. The slow-release particles can be prepared by mixing the slow-release material with silicone oil.

[0064] 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.

[0065] 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 the cookware with the 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.

[0066] According to an exemplary embodiment, the particle size of the sustained-release material precursor can be within the range of 100 mesh sieve to 3000 mesh sieve, and the particle size of the sustained-release material within this range can follow a normal distribution. However, when the particle size is too large (e.g., above 100 mesh sieve), the excessively large particle size can easily increase the grinding process or make the particle size of the sustained-release material after grinding 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., below 3000 mesh sieve, and the particle size becomes even smaller after grinding), it is not easy to effectively adsorb and bond with silicone oil, thereby making it difficult to achieve a good silicone oil sustained-release effect.

[0067] When the sustained-release material precursor has the above-mentioned particle size distribution, the particle size of the sustained-release material finally obtained can be reduced to less than 20 microns (preferably 8 microns to 15 microns) by using two grinding processes as will be described below. However, exemplary embodiments are not limited thereto. That is, when the particle size of the sustained-release material precursor is selected to have a smaller value within the range of 100 mesh to 3000 mesh, one grinding process can be omitted; in addition, when the particle size of the sustained-release material precursor is selected to have a smaller value within the above-mentioned range, two 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.

[0068] 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.

[0069] 35-58 parts by weight of the slow-release material precursor can be mixed with 42-60 parts by weight of silicone oil to obtain a mixture, and 1 part 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 can be omitted.

[0070] 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.

[0071] Preparation of ceramic coatings and optional sealer coatings

[0072] 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.

[0073] 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.

[0074] While the above method describes separately preparing a ceramic coating precursor and slow-release particles and then mixing them to obtain a ceramic coating, in a method combining the steps of preparing the ceramic coating precursor with the steps of preparing the slow-release particles, as described above, after mixing material B and material C, material A and the slow-release particles can be added simultaneously 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) due to the acidity of material C to obtain the first material. Material A and the slow-release particles can then be added to the mixture. The weight ratio of material A to material B can be within the range of (20-30):(40-60). The amount of slow-release particles can be adjusted based on the desired coating. After mixing, the mixture can be stirred at 120-200 rpm for 6-8 hours to obtain the desired ceramic coating.

[0075] According to an exemplary embodiment, when a single ceramic coating 200 is provided, 5.15-32.97 parts by weight of slow-release particles may be dispersed in every 100 parts by weight of the ceramic coating 200. In addition, when a plurality of sub-layers are provided, the content of slow-release particles included in each sub-layer may gradually increase (e.g., a gradient) in a direction away from the substrate 100 and may satisfy that the topmost sub-layer may contain 5.15-32.97 parts by weight of slow-release particles per 100 parts by weight of the sub-layer, or that the sub-layers below the topmost sub-layer may have the same or different content of slow-release particles that is less than the content of the topmost sub-layer.

[0076] In order to further improve the silicone oil slow-release effect of the non-stick utensil, a sealing layer can be formed on the ceramic coating. Therefore, a sealing coating for forming the sealing layer can be prepared before, during or after the preparation of the ceramic coating.

[0077] According to an exemplary embodiment, the sealing coating may be a ceramic coating commonly used in the art, and thus, may be prepared using conventional formulations in the prior art.

[0078] According to the example, a sealing coating can be prepared by the following method: (1) silane and ethyl orthosilicate are mixed and stirred evenly to obtain a silane composition of component E; (2) silica sol is mixed evenly with isopropyl alcohol and deionized water, and an emulsifier and a thickener are added to obtain a slurry of component F; (3) formic acid, acetic acid, a buffer (e.g., boric acid) and a catalyst (e.g., zirconium acetate) are mixed evenly to obtain a strong acid catalyst of component G; (4) the above three components are mixed in sequence according to a mass ratio of E:F:G=(20-30):(40-60):(1-2), and rolling and aging are performed to obtain a sealing coating, wherein the mixing order and aging method are as follows: first, components F and G are mixed evenly according to the required parts, the pH is adjusted to below 4, rolling and dispersing for 0.5h, and then the required parts of E are added and shaken evenly to obtain the required sealing coating.

[0079] Formation of ceramic coating and optional sealing layer

[0080] After obtaining the ceramic coating (or further sealing coating), the ceramic coating (or further sealing coating) can be sprayed on the preheated substrate 100 described above by air spraying. For example, the ceramic coating (or further sealing coating) can be sprayed by air spraying. Here, the spraying of the ceramic coating and the sealing coating does not limit the air spraying parameters, and the difference between the spraying of the ceramic coating and the spraying of the sealing coating can only be that ceramic coatings of different thicknesses are formed by different spraying times. Here, the air spraying parameters are as follows: the spraying distance is 160 mm; the air pressure is 0.3 MPa; the flow rate is 8 L / min. However, the exemplary embodiment is not limited to this, and the parameters of the air spraying can be adaptively adjusted according to the specific process, and those skilled in the art can also use other layer formation methods to form ceramic coatings and sealing layers using the ceramic coating and sealing coating conceived by the present invention.

[0081] After air spraying, the resultant can be cured at a temperature of 230°C-280°C for 10 minutes to 15 minutes to form a single ceramic coating 200 with a thickness of 10 microns to 80 microns or a ceramic coating including multiple sub-layers, and a sealing layer with a thickness of 8 microns to 20 microns can be optionally further formed on the ceramic coating.

[0082] As described above in detail in conjunction with exemplary embodiments, the ceramic coating of the non-stick utensil according to the present invention includes slow-release particles. Therefore, during cooking, the release of silicone oil can be slowed, thereby maintaining a long-lasting non-stick effect. Furthermore, by treating the substrate surface, the bonding between the substrate and the ceramic coating can be enhanced. Furthermore, the addition of a sealing layer can further enhance the slow-release effect of the silicone oil.

[0083] Hereinafter, embodiments of the inventive concept will be described in detail.

[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] A non-stick frying pan was produced using the ceramic coating described above by the following method.

[0092] S6: Substrate treatment: Sandblast the stainless steel frying spoon 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 sustained-release granular component is in the range of 8 microns to 12 microns.

[0103] Example 5

[0104] The difference from Example 1 is that the particle size of the sustained-release granular component is in the range of 16 microns to 20 microns.

[0105] Example 6

[0106] The difference from Example 1 is that the particle size of the sustained-release granular component is in the range of 6 microns to 10 microns.

[0107] Example 7

[0108] The difference from Example 1 is that the film thickness is 10 microns.

[0109] Example 8

[0110] The difference from Example 1 is that the film thickness is 40 microns.

[0111] Example 9

[0112] The difference from Example 1 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 the ceramic coating.

[0113] Example 10

[0114] The difference from Example 1 is that A, B, C and D are mixed in sequence according to the weight ratio of A:B:C:D=30:60:2:5 to prepare the ceramic coating.

[0115] Example 11

[0116] The difference from Example 1 is:

[0117] (1) preparing ceramic coating 01 by step S5;

[0118] (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;

[0119] (3) A first sublayer having a thickness of 35 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 35 μm was formed on the first sublayer using ceramic coating 01 by the air spraying method of Example 1.

[0120] Example 12

[0121] The difference from Example 11 is that the thickness of the first sub-layer is 10 microns.

[0122] Example 13

[0123] The difference from Example 11 is that the thickness of the first sub-layer is 20 microns.

[0124] Example 14

[0125] The difference from Example 11 is that the thickness of the second sub-layer is 10 microns.

[0126] Example 15

[0127] The difference from Example 11 is that the thickness of the second sub-layer is 20 microns.

[0128] Example 16

[0129] The difference from Example 11 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 02.

[0130] Example 17

[0131] The difference from Example 11 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.

[0132] Example 18

[0133] The difference from Example 1 is:

[0134] (1) preparing ceramic coating 01 by step S5;

[0135] (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 mixed in order according to a weight ratio of A:B:C=22:40:1 to prepare ceramic coating 03. That is, the difference between step S52 and step S5 is that step S4 is omitted;

[0136] (3) A first sublayer having a thickness of 35 μm was formed on the substrate using ceramic coating 03 by the air spraying method of Example 1, and a second sublayer having a thickness of 35 μm was formed on the first sublayer using ceramic coating 01 by the air spraying method of Example 1.

[0137] Example 19

[0138] The difference from Example 18 is that the thickness of the first sub-layer is 10 microns.

[0139] Example 20

[0140] The difference from Example 18 is that the thickness of the first sub-layer is 20 microns.

[0141] Example 21

[0142] The difference from Example 18 is that the thickness of the second sub-layer is 10 microns.

[0143] Example 22

[0144] The difference from Example 18 is that the thickness of the second sub-layer is 20 microns.

[0145] Example 23

[0146] The difference from Example 18 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.

[0147] Example 24

[0148] 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.

[0149] Example 25

[0150] 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.

[0151] Example 26

[0152] 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.

[0153] Example 27

[0154] The difference from Example 1 is that a sealing layer is further provided on the ceramic coating, and the sealing layer is formed by using a sealing material.

[0155] The sealing material is formed by the following method.

[0156] W1: 80 wt% of methyltrimethoxysilane and 20 wt% of ethyl orthosilicate were mixed and stirred to obtain a silane composition of component E;

[0157] W2: 30 wt% of Akzo Nobel 1050 (silica sol), 3 wt% of Tween-80 (emulsifier), 1 wt% of water-based modified bentonite (thickener), 20 wt% of isopropyl alcohol, and the balance of deionized water were mixed to obtain component F slurry;

[0158] W3: 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 G, a strongly acidic catalyst;

[0159] W4: Mix the above three components in the weight ratio of E:F:G = 20:40:1, and roll-cure to obtain the sealing coating. The mixing order and aging method are as follows: First, mix 20 parts by weight of component F and 1 part by weight of component G, adjusting the pH to 4 with component G. Roll-disperse for 0.5 hours, then add 40 parts by weight of component E and shake evenly to obtain the desired sealing coating.

[0160] After the sprayed ceramic coating is formed, a sealing layer with a thickness of 8 μm is formed on the ceramic coating using a sealing coating using the same process as the spraying process for forming the ceramic coating.

[0161] Example 28

[0162] The difference from Example 27 is that the thickness of the sealing layer is 12 microns.

[0163] Example 29

[0164] The difference from Example 27 is that the thickness of the sealing layer is 15 microns.

[0165] Example 30

[0166] The difference from Example 1 is that a functional layer having a surface roughness of 8 μm is formed on the surface of the substrate by thermal spraying using molten titanium.

[0167] Example 31

[0168] The difference from Example 30 is that the surface roughness of the substrate is 15 microns.

[0169] Comparative Example 1

[0170] The difference from Example 1 is that the substrate is not subjected to functionalization treatment to have a smooth surface.

[0171] Comparative Example 2

[0172] The difference from Example 30 is that the surface roughness of the substrate is 20 microns.

[0173] Comparative Example 3

[0174] 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 coating is used to manufacture non-stick cookware.

[0175] Comparative Example 4

[0176] The difference from Example 11 is that the second sublayer is located on the substrate, and the first sublayer is located on the second sublayer.

[0177] The non-stick properties of the non-stick cookware of Examples 1-31 and Comparative Examples 1-4 were tested, and the test results are shown in the following table.

[0178]

[0179]

[0180] Performance index test

[0181] The cookware obtained above was subjected to a performance test. The specific performance test method is as follows:

[0182] (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.

[0183] (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.

[0184] By comparing and analyzing the embodiments 1-31 and comparative examples 1-4 of the present invention, it is found that:

[0185] (1) The substrate surface of Comparative Example 1 was not functionalized, so the coating formed thereon was easy to fall off;

[0186] (2) The surface roughness of the substrate of Comparative Example 2 is relatively large. Although it has good long-lasting non-stick properties, the surface of the coating formed is too rough, which affects the appearance and user experience of the product.

[0187] (3) The conventional ceramic coating in Comparative Example 3 has a long-lasting non-stickiness of no more than 500 times, while the ceramic coating according to the present invention has a long-lasting non-stickiness of 10,000-25,000 times;

[0188] (4) Although Comparative Example 4 includes two sublayers, the content of slow-release particles in the uppermost sublayer is lower than the content of slow-release particles in the lower sublayer. Therefore, the test performance of the ceramic coating with a double-layer structure formed is lower than the test performance of the ceramic coating in the embodiment.

[0189] 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 non-stick utensil, characterized in that: The non-stick utensil comprises: matrix; A ceramic coating is located on the surface of a substrate, wherein the ceramic coating comprises a ceramic coating precursor and slow-release particles dispersed in the ceramic coating precursor, wherein: The sustained-release particles include a sustained-release material and silicone oil bound to the sustained-release material. The sustained-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, and Wherein, the surface of the substrate has a surface roughness of 3 micrometers to 15 micrometers.

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

3. The non-stick utensil according to claim 1, wherein The sustained-release particles are contained in an amount of 5.15-32.97 parts by weight per 100 parts by weight of the ceramic coating.

4. The non-stick utensil according to claim 1, wherein The thickness of the ceramic coating is in the range of 10 microns to 80 microns.

5. The non-stick utensil 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 non-stick utensil according to claim 5, wherein: The thickness of each of the sub-layers including the slow-release particles is not less than 10 micrometers, and the thickness of the ceramic coating is not more than 80 micrometers.

7. The non-stick utensil according to claim 5, wherein: The content of the sustained-release particles in each sub-layer increases in the direction away from the matrix.

8. The non-stick utensil according to claim 1, wherein The substrate includes two or more layers composed of at least two materials selected from aluminum, aluminum alloy, titanium, titanium alloy, iron, and stainless steel.

9. The non-stick utensil according to claim 1, characterized in that The substrate includes a base layer and a functional layer arranged between the base layer and the ceramic coating layer, and the surface of the functional layer has a surface roughness of 3 micrometers to 15 micrometers.

10. The non-stick utensil according to claim 1, characterized in that The non-stick utensil further comprises a sealing layer located on the surface of the ceramic coating.

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