Elastomeric Coating Adhesion via Silane Intermediate Layer
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Solution Overview
Problem
Existing methods for applying elastomeric coatings to ceramic, sapphire, or crystal substrates are not compatible with skin contact standards like FDA or Reach, and do not provide suitable adhesion without using silanes in the outer coating.
Innovation Solution
A method involving surface treatment of the substrate to generate active groups, application of a first composition with an elastomeric material and silane to form an intermediate layer, followed by a second elastomeric material coating, and firing to create a biocompatible elastomeric coating compatible with skin contact, without using silanes in the outer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silane is used in the outer coating to ensure adhesion to ceramic substrate, then adhesion is improved, but biocompatibility deteriorates due to FDA and Reach standard non-compliance
Solution Approach 1:
The coating system is divided into two distinct layers: an intermediate layer containing silane for adhesion to the ceramic substrate, and an outer elastomeric coating free of silane for skin contact. This segmentation allows each layer to fulfill its specific function without compromising the other, resolving the contradiction between adhesion and biocompatibility.
Solution Approach 2:
The intermediate layer acts as a mediator between the ceramic substrate and the outer elastomeric coating. It provides the necessary chemical bonding to the substrate while presenting a biocompatible surface to the skin, thus mediating between the conflicting requirements of strong adhesion and biocompatibility.
2Strength
If silane is used in the outer coating to ensure adhesion, then adhesion is improved, but regulatory compliance deteriorates due to FDA and Reach standard non-compliance
Solution Approach 1:
The coating system is divided into two distinct layers: an intermediate layer containing silane for adhesion to the ceramic substrate, and an outer elastomeric coating free of silane for skin contact. This segmentation allows each layer to fulfill its specific function without compromising the other, resolving the contradiction between adhesion and biocompatibility.
Solution Approach 2:
The intermediate layer acts as a mediator between the ceramic substrate and the outer elastomeric coating. It provides the necessary chemical bonding to the substrate while presenting a biocompatible surface to the skin, thus mediating between the conflicting requirements of strong adhesion and biocompatibility.
3Ease of manufacture
If elastomeric coating is applied directly to ceramic substrate, then manufacturing simplicity is improved, but adhesion deteriorates due to incompatible surface properties
Solution Approach 1:
The intermediate layer acts as a mediator between the ceramic substrate and the outer elastomeric coating. It provides the necessary chemical bonding to the substrate while presenting a biocompatible surface to the skin, thus mediating between the conflicting requirements of strong adhesion and biocompatibility.
Solution Approach 2:
The coating system uses a composite structure combining an elastomeric intermediate layer with silane for adhesion to the ceramic substrate, and an outer elastomeric coating for skin contact. This composite approach leverages the complementary properties of different materials to achieve both strong adhesion and biocompatibility.
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
This method ensures a continuous, homogeneous surface with improved mechanical properties and biocompatibility, meeting FDA and Reach standards, while allowing for the combination of rigid and elastic materials for various applications.
Implementation Method 1
treatment of the substrate to generate active groups at the surface... application to the substrate of a first composition comprising at least a first elastomeric material, at least one silane... to form an intermediate layer
Implementation Method 2
application of a second composition comprising a second elastomeric material to form said coating, and d) firing of the formed part
Data Source
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AI summary
Fabricating a part (10) comprising a substrate and an elastomeric coating (18), comprises: (a) optionally, treating the substrate to generate active groups on surface; (b) applying to the substrate a first composition comprising at least a first elastomeric material, at least one silane and optionally at least one bonding agent to form an intermediate layer; (c) applying a second composition comprising a second elastomeric material to form the coating; and (d) annealing the formed part. An independent claim is included for the part comprising a substrate and an elastomeric coating made of a second elastomeric material, where the part comprises between the substrate and the elastomeric coating an intermediate layer (16) obtained from a composition comprising at least a first elastomeric material, at least one silane and optionally at least one bonding agent.