Ceramic Substrate Coatings for Scratch Resistance and Low Energy Curing
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Solution Overview
Problem
Existing coatings for ceramic substrates fail to achieve a high decorative finish with outstanding mechanical and chemical performance, particularly in terms of scratch resistance, chemical resistance, and heat shock resistance, while also being energy-intensive.
Innovation Solution
A process involving a thermosetting or radiation curable powder coating composition as a base coat, followed by a liquid coating composition cured with a cross-linking agent at temperatures above 90°C, providing a combination of pigments and additives for enhanced durability and decoration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional enamel coating is applied to ceramic substrates, then scratch resistance and wear resistance are improved, but energy consumption increases significantly
Solution Approach 1:
The patent changes the curing temperature parameter from traditional high-temperature enameling (typically above 900°C) to low-temperature curing (90-200°C). This is achieved by using a two-component liquid coating system with isocyanate crosslinking agents that cure at much lower temperatures, thereby reducing energy consumption while maintaining scratch and wear resistance
Solution Approach 2:
The patent employs a composite coating system consisting of polyester or polyurethane resin combined with isocyanate crosslinking agents. This composite material formulation enables the coating to achieve enamel-like durability and scratch resistance at significantly lower curing temperatures, resolving the contradiction between strength and energy consumption
2Manufacturing precision
If high decorative finish is achieved through traditional glazing, then appearance quality is improved, but manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent incorporates pigments, colorants, and decorative additives directly into the liquid coating composition before application. This preliminary incorporation of decorative elements eliminates the need for separate glazing and decoration steps required in traditional ceramic manufacturing, thereby simplifying the process while maintaining high decorative finish quality
Solution Approach 2:
The patent merges the coating and decoration functions into a single liquid coating application step. By combining pigments, colorants, and decorative effects within the same coating composition that provides protection, the process integrates multiple functions into one operation, reducing manufacturing complexity compared to traditional multi-step glazing and decoration processes
3Ease of operation
If single-layer powder coating is applied, then application simplicity is improved, but chemical resistance and durability are insufficient
Solution Approach 1:
The patent segments the coating system into two distinct liquid layers: a base coat containing polyester or polyurethane resin with isocyanate crosslinking for durability and chemical resistance, and a topcoat that can provide additional protective or decorative functions. This segmentation allows each layer to be optimized for specific performance requirements while maintaining ease of application through liquid form
Solution Approach 2:
The patent uses composite material formulations in both the base coat and topcoat, incorporating polyester or polyurethane resins with isocyanate crosslinking agents. This composite approach enhances chemical resistance and durability beyond what single-layer powder coatings can achieve, while the liquid formulation maintains application simplicity
4Strength
If high cross-linking density is achieved for improved hardness, then scratch resistance is improved, but brittleness and heat shock resistance worsen
Solution Approach 1:
The patent optimizes the cross-linking density parameter by controlling the ratio of isocyanate groups to hydroxyl or carboxyl groups, typically maintaining a ratio between 0.8:1 and 1.2:1. This controlled cross-linking density achieves sufficient scratch resistance while preventing excessive brittleness, thereby maintaining heat shock resistance. The low curing temperature (90-200°C) also helps preserve the ceramic substrate's thermal properties
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 process results in ceramic substrates with a high decorative finish and superior mechanical and chemical performance, including scratch resistance, chemical resistance, and reduced energy consumption compared to traditional glazing methods.
Implementation Method 1
curing the applied composition; and applying as a further layer a liquid coating composition, and curing the applied liquid composition by stoving i.e. above 90°C
Implementation Method 2
curing the applied liquid composition by stoving i.e. above 90°C in the presence of a cross-linking agent or hardener
Implementation Method 3
outstanding mechanical and chemical performance, such as scratch resistance and chemical resistance
Data Source
AI summary
A process for making highly mechanical and chemical resistant ceramic substrates, especially tiles is provided, wherein the process comprises coating said substrates with a base coat layer of a thermosetting or radiation curable powder coating composition, curing the applied powder coating composition, and applying a further layer of a liquid coating composition and curing the composition by exposure to heat. Coated ceramic substrates, in particular tiles are also provided.