Composite material applied to cookware, method for preparing the same, and cookware thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current cookware coatings, primarily organic resin-based, lack durability, wear resistance, and safety, as they are prone to scratching, corrosion, and can release toxic gases at high temperatures, failing to meet consumer demands for non-toxic and long-lasting performance.
Innovation Solution
A composite material with a multi-layer structure comprising hard granular material clad in silicon-containing cladding material, which is further clad in metallic material, providing a protective layer with enhanced wear resistance, corrosion resistance, and cleanability, using silane, siloxane, and siloxane polymers that do not produce toxic gases upon thermal decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If organic resin-based coating is applied on cookware surface, then cleanability and corrosion resistance are achieved, but wear resistance and durability deteriorate due to low surface hardness and easy scratching
Solution Approach 1:
The patent applies a composite coating system consisting of multiple layers: a base coat layer, an intermediate layer containing ceramic particles (5-20 μm diameter) suspended in binder resin, and a top coat layer. This composite structure combines the corrosion resistance of organic resins with the wear resistance of ceramic particles, achieving both cleanability and durability simultaneously.
Solution Approach 2:
The coating system distributes different materials to different layers: the base coat provides corrosion resistance, the intermediate layer with embedded ceramic particles provides wear resistance and scratch resistance, while the top coat maintains smooth surface for cleanability. Each layer performs its specific function locally.
2Ease of operation
If fluorine resin coating is applied on cookware surface, then cleanability is improved, but safety deteriorates due to decomposition and volatilization of toxic gases at high temperature
Solution Approach 1:
The patent changes the chemical composition parameters of the coating materials to use ceramic particles (such as silicon oxide, aluminum oxide) and heat-resistant binder resins that maintain stability at high temperatures up to 260°C or higher, eliminating the decomposition and toxic gas emission problem of fluorine resins while maintaining cleanability through the smooth surface.
Solution Approach 2:
The patent replaces short-lived organic fluorine resin molecules that decompose at high temperature with stable ceramic particles and heat-resistant binders that maintain their structure and function throughout the cookware's service life, providing long-term safety.
3Reliability
If multi-layer composite coating is applied to improve wear resistance, then durability is improved, but device complexity increases
Solution Approach 1:
The coating system is segmented into three functional layers: base coat (corrosion resistance), intermediate layer with ceramic particles (wear resistance), and top coat (surface smoothness). This segmentation allows each layer to be optimized for its specific function while working together as a unified system.
Solution Approach 2:
The coating structure follows a nested arrangement where the intermediate layer with embedded ceramic particles is positioned between the base coat and top coat, creating a sandwich structure that protects the base layer while providing surface functionality.
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 composite material ensures durable wear resistance, corrosion resistance, and cleanability while maintaining safety and non-toxicity, with the metallic cladding enhancing the binding phase for improved strength and durability, and the silicon-containing materials ensuring low surface energy and hydrophobicity for effective cleaning.
Implementation Method 1
The silicon-containing cladding material includes mainly silane, siloxane, silane polymer, and siloxane polymer, which will not produce toxic or dangerous gases after thermal decomposition, while decomposition product has hard structure with low surface energy, enabling the protective layer to maintain wear resistance and cleanability durably.
Implementation Method 2
when the protective layer is prepared with thermal processes such as thermal spraying or thermal cladding, the metallic cladding material is heated to melt and bonded to the surface of the cookware tightly.
Implementation Method 3
The silicon-containing cladding material with low surface energy, which forms functional layer with soft base, which gives the protective layer excellent cleanability.
Data Source
AI summary
The present disclosure discloses a composite material applied to cookware, a method for preparing the same, and a cookware thereof. The composite material includes hard granular material, silicon-containing cladding material and metallic cladding material: wherein the hard granular material is clad in the silicon-containing cladding material; the silicon-containing cladding material is clad in the metallic cladding material, and the silicon-containing cladding material includes main compositions one or more selected from the group consisting of silane, siloxane, silane polymer, and siloxane polymer. There is no toxic gas prepared after the composite material is decomposed at a high temperature. The cookware with a protective layer applied with the composite material has high wear resistance, corrosion resistance, and durable cleanability, as well as safety and non-toxicity.