DLC Coating with Silicon and Oxygen for Non-Stick Surfaces
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Solution Overview
Problem
Current non-stick coatings for cookware face issues with scratch resistance, corrosion, and temperature limitations, leading to degradation and loss of non-stick performance over time, particularly in stainless steel substrates.
Innovation Solution
A diamond-like carbon (DLC) coating with silicon and oxygen, applied using a nitrocarburized intermediate layer and plasma enhanced chemical vapor deposition, providing a thin, durable, and corrosion-resistant non-stick surface that maintains mechanical properties and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE coating is used to achieve non-stick properties, then non-stick performance is improved, but scratch resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining PTFE with thermoplastic polyurethane (TPU) to create a multi-layer coating system. The PTFE layer provides non-stick properties while the TPU layer provides scratch resistance and mechanical durability. This composite structure resolves the contradiction by allowing each material to perform its strength function without compromising the other.
2Strength
If ceramic coating is used to achieve scratch resistance, then durability is improved, but non-stick properties deteriorate
Solution Approach 1:
The patent combines ceramic particles within the TPU matrix of the composite coating. The ceramic provides hardness and scratch resistance while the TPU matrix maintains flexibility and non-stick properties. This composite approach allows the coating to achieve both scratch resistance and non-stick performance simultaneously.
3Strength
If coating thickness is increased to improve durability, then scratch resistance is improved, but thermal performance deteriorates
Solution Approach 1:
The patent uses a thin-layer coating design where the coating thickness is optimized to provide sufficient scratch resistance while maintaining thermal conductivity. The local quality principle is applied by concentrating the protective function in a thin, highly crosslinked composite layer that doesn't significantly impede heat transfer to the cooking surface.
Solution Approach 2:
The patent changes the physical and chemical parameters of the coating by using plasma polymerization to create a crosslinked network structure. This allows the coating to achieve high durability and scratch resistance at reduced thickness, thereby maintaining thermal performance. The crosslinking density and composition ratios are optimized to balance mechanical properties with thermal conductivity.
4Reliability
If stainless steel substrate is used to achieve corrosion resistance, then corrosion protection is improved, but adhesion strength deteriorates
Solution Approach 1:
The patent uses plasma treatment as an intermediary process between the stainless steel substrate and the polymer coating. The plasma creates a micro-roughened surface with increased surface energy and chemical reactivity, which serves as an ideal intermediate layer for coating adhesion. This intermediary treatment allows the coating to strongly adhere to the stainless steel while maintaining the substrate's corrosion resistance.
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 DLC coating offers superior scratch resistance, corrosion protection, and non-stick performance, with a low coefficient of friction and high hardness, maintaining surface finish and preventing sticking of food, even at high temperatures, while being resistant to harsh chemicals and thermal shock.
Implementation Method 1
producing one or more layers of DLC, each DLC layer containing silicon and oxygen on top of and in contact with the nitrocarburized layer by a plasma enhanced chemical vapor deposition (PECVD) vacuum process
Implementation Method 2
producing one of nitriding layer, nitrocarburization layer, and carburization layer on the surface of a metallic material by one of ion plasma nitriding, gas nitriding, and salt bath nitriding
Data Source
AI summary
A coating on a surface of a metallic substrate which includes one or more layers of DLC (Diamond-Like Carbon) containing silicon and oxygen. The coatings optionally have an intermediate layer, such as a nitrocarburized layer. A method of producing a non-stick coating on a surface of a metallic material. The method includes producing one of nitriding layer, nitrocarburization layer, and carburization layer on the surface of a metallic material by one of ion plasma nitriding, gas nitriding, and salt bath nitriding; and producing one or more layers of DLC, each layer containing silicon and oxygen on top of and in contact with the nitrocarburized layer by a plasma enhanced chemical vapor deposition (PECVD) vacuum process. An article containing on its surface one or more layers of DLC containing silicon and oxygen, and optionally an intermediate layer.