Colored Coating Layer for Sanitary Equipment
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Solution Overview
Problem
Existing sanitary equipment parts with colored layers, particularly black-colored layers, face issues with color stability, strength, and interference colors due to thin layers, making it difficult to maintain a consistent black appearance.
Innovation Solution
A part comprising a base material with a colored layer containing 35 at % to 99 at % carbon, 0 at % to less than 40 at % chromium, 0 at % to less than 15 at % nitrogen, and 0 at % to less than 15 at % oxygen, an intermediate layer with a metal atom selected from Cr, Zr, and Si, and an oxidized state detected by XPS, and a surface layer that is water-repellent and includes a hydrophobic group.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a colored layer mainly containing C is provided on a base material to achieve black color, then the appearance is improved, but the color stability and strength of the colored layer deteriorate
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure consisting of a base material, a colored layer containing C, Cr, N, and O in specific proportions, and a water-repellent layer. This composite structure combines the aesthetic benefits of the colored layer with the protective properties of the water-repellent layer, resolving the contradiction between appearance and color stability.
Solution Approach 2:
The patent changes the compositional parameters of the colored layer by specifying precise atomic percentage ranges: C (35-99 at%), Cr (0-40 at%), N (0-15 at%), and O (0-15 at%). This parameter optimization ensures both the black color appearance and color stability, preventing the deterioration that occurs with conventional carbon-based colored layers.
2Quantity of substance
If the colored layer is made thin to reduce material usage, then the manufacturing cost is reduced, but interference colors are generated and the intended black color cannot be achieved
Solution Approach 1:
The patent optimizes the thickness and composition parameters of the colored layer to eliminate interference colors. By controlling the atomic percentages of C, Cr, N, and O within specific ranges and adjusting the layer thickness, the patent achieves uniform black color appearance without the rainbow-like interference effects that occur in thin carbon-based layers.
3Ease of operation
If a water-repellent layer is provided on the colored layer to prevent stain adhesion, then the ease of cleaning is improved, but the adhesion of the water-repellent layer deteriorates
Solution Approach 1:
The patent introduces an intermediate functional layer between the colored layer and the water-repellent layer. This intermediate layer acts as a mediator that provides both adhesion promotion (bonding to the colored layer) and water repellency (bonding to the water-repellent layer), thereby resolving the contradiction between stain removability and layer adhesion.
Solution Approach 2:
The patent creates a composite multi-layer structure where each layer has specific functions: the colored layer provides appearance, the intermediate layer provides adhesion and water repellency, and the outer water-repellent layer provides stain resistance. This composite structure achieves both easy cleaning and strong adhesion simultaneously.
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 solution achieves improved color stability, strength, and durability of the colored layer while maintaining a consistent black appearance, and imparts water-repellency to the part without affecting the color development.
Implementation Method 1
a colored layer which contains: more than 35 at % to 99 at % or less of C, 0 at % or more to less than 40 at % of Cr, 0 at % or more to less than 15 at % of N, and more than 0 at % to less than 15 at % of O
Implementation Method 2
the intermediate layer contains at least one metal atom selected from Cr, Zr, and Si; and an oxygen atom, the metal element in an oxidized state is detected with XPS in the intermediate layer
Implementation Method 3
the surface layer is water-repellent, and includes a hydrophobic group
Data Source
AI summary
A part includes a base material, a colored layer, an intermediate layer, and a water-repellent-surface layer. The colored layer contains 35 at % to 99 at % of C, 0 at % to less than 40 at % of Cr, 0 at % to less than 15 at % of N, and more than 0 at % to less than 15 at % of O. The intermediate layer contains at least one metal atom selected from Cr, Zr, and Si; and an oxygen atom. The intermediate layer exhibits a sputtering time of 0.5 minutes or more to 9 minutes or less.