Ceramic Coating on Heat-Sensitive Substrates via Thermal Spraying
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Solution Overview
Problem
Conventional vitreous glazing processes that use elevated temperatures are not suitable for materials like concrete, as they lead to severe degradation, making it difficult to apply ceramic coatings effectively.
Innovation Solution
A method involving thermal spraying of a fusible ceramic material onto a heat-sensitive substrate, where the surface is heated to a controlled temperature between 350°C to 800°C, allowing for the application of a durable ceramic coating without degrading the substrate, using techniques like flame or plasma spraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vitreous glazing processes are used to apply ceramic coating, then the coating has good durability and barrier properties, but the substrate undergoes severe thermal degradation
Solution Approach 1:
The patent applies local quality by heating only the surface layer of the substrate to a controlled temperature (e.g., 200-400°C) while maintaining the bulk substrate at a lower temperature. This allows the ceramic coating to be applied and fused at the surface without subjecting the entire substrate to high temperatures that would cause degradation. The selective heating of the surface region resolves the contradiction between achieving durable coating fusion and preventing substrate thermal damage.
Solution Approach 2:
The patent segments the heating process into two distinct zones: a heated surface layer where the ceramic coating is applied and fused, and a cooler bulk substrate that remains below degradation temperatures. This spatial segmentation of thermal zones enables the coating to achieve proper adhesion and durability while the substrate avoids thermal degradation, effectively resolving the technical contradiction.
2Manufacturing precision
If the substrate surface is heated to high temperature for ceramic coating application, then the coating fuses properly with good adhesion, but the substrate material degrades
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature parameter in a graduated manner - the surface is heated to a moderate temperature (e.g., 200-400°C) sufficient for ceramic coating fusion and adhesion, while the bulk substrate temperature is maintained below degradation thresholds. This differential temperature control resolves the contradiction between achieving proper coating adhesion and preventing substrate degradation.
3Stability of the object's composition
If traditional glazing temperature (up to 1400°C) is used, then complete fusion of glaze occurs, but heat-sensitive materials like concrete cannot be processed
Solution Approach 1:
The patent resolves this contradiction by applying local quality through selective surface heating - the substrate surface is heated to a temperature (e.g., 200-400°C) that is sufficient for ceramic coating fusion and adhesion but far below the 1400°C required by traditional glazing. This localized moderate heating enables processing of heat-sensitive materials like concrete while still achieving complete fusion of the ceramic coating at the surface.
Solution Approach 2:
The patent changes the temperature parameter from the traditional high-temperature glazing range (up to 1400°C) to a lower range (e.g., 200-400°C surface temperature) that is compatible with heat-sensitive substrates. This parameter modification enables the process to be applied to diverse materials including concrete, wood, and plastics while maintaining complete ceramic coating fusion and adhesion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the application of a durable, glossy or matte ceramic coating with excellent barrier and wear properties on heat-sensitive substrates like concrete, avoiding the thermal degradation issues of traditional glazing processes.
Implementation Method 1
the surface or skin of the substrate, but not the bulk of the substrate located immediately below the surface, is heated to an elevated temperature
Implementation Method 2
the ceramic material is thermal sprayed onto the heated surface
Implementation Method 3
In an embodiment of the invention, in step (c) the surface may be heated to a temperature in the range from about 550°C to 1200°C. In an embodiment of the invention, the ceramic material is flame sprayed onto the said surface layer
Implementation Method 4
In an embodiment of the invention, the ceramic material is plasma sprayed onto the said surface layer
Data Source
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AI summary
A method for applying a ceramic coating to a heat sensitive substrate is provided. The method comprises heating a surface layer of at least a portion of the substrate to a temperature in the range of from about 350 to 800°C, while maintaining a temperature of about 250°C or less in the substrate at a depth of 1 mm or more below the surface layer, providing a ceramic material in a form suitable for thermal spraying; and thermal spraying the ceramic material onto the heated surface layer of the substrate. The ceramic material to be sprayed onto the heated surface comprises a fusible ceramic material.