Fluorinated Peek Composite Coating With High Mechanical Performance
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Solution Overview
Problem
Existing non-stick coatings for cooking surfaces, particularly those with PTFE coatings, suffer from low mechanical resistance to cold and heat, leading to issues with abrasion and impact resistance.
Innovation Solution
A novel non-stick coating structure featuring a thick, discontinuous, and porous hard sublayer made from a mixture of PEEK and silicon carbide, applied using a flame spraying method, which provides specific anchoring for fluorinated polymer layers, enhancing adhesion and scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PTFE coating is applied to cooking surfaces, then non-stick performance is improved, but mechanical resistance to heat and abrasion deteriorates
Solution Approach 1:
The patent applies a composite coating structure consisting of a PTFE layer combined with a polyaryletherketone (PEEK) layer. The PTFE layer provides non-stick performance while the PEEK layer contributes high mechanical resistance to heat and abrasion. This composite approach allows both materials to work together, achieving properties that neither material could provide alone.
2Strength
If hard fillers or inorganic sublayers are added to reinforce the coating, then abrasion resistance is improved, but impact resistance deteriorates
Solution Approach 1:
The patent employs a porous PEEK sublayer with controlled porosity (5-50% void volume) that acts as a shock-absorbing intermediate between the metal substrate and the PTFE coating. This porous structure allows the sublayer to deform under impact, preventing direct transmission of impact forces to the PTFE layer, while still providing adequate abrasion resistance.
3Strength
If organic polymer sublayers are used to reduce scratches, then scratch resistance is improved, but the number of sintering steps increases
Solution Approach 1:
The patent combines the PEEK sublayer and PTFE coating into a single sintering process. The PEEK layer is applied first, then the PTFE coating is applied over it, and both layers are sintered simultaneously in one thermal treatment step. This merging of operations eliminates the need for separate sintering steps that would be required if the layers were applied and cured separately.
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 coating achieves excellent scratch resistance and adhesion while reducing the number of sintering steps, making the process more industrially viable and cost-effective.
Implementation Method 1
applied using a flame spraying method
Implementation Method 2
provides specific anchoring for fluorinated polymer layers, enhancing adhesion
Data Source
AI summary
The present invention relates to a culinary article (I) comprising a hollow metal cap (2) which comprises a bottom (211) and a side wall (212) rising from the bottom (211), said cap (2) having a concave inner face (21) suitable for receiving food and a convex outer face (25), said inner face (21) being coated with a coating (5) consisting in series, from the cap (2), of a hard underlayer (3) and a non-stick coating (4), the non-stick coating (4) including at least one layer comprising at least one fluorocarbon resin, alone or in a mixture with at least one thermostable bonding resin that can withstand at least 200° C., characterised in that the hard underlayer (3) is provided as a discontinuous layer, in that said hard underlayer (3) consists of one or more non-fluorinated polymeric materials selected from polyaryletherketones (P AEK) and mixtures thereof, optionally of inorganic hard fillers, optionally of conductive fillers and optionally less than 3% by weight of additives relative to the weight of said hard underlayer, and in that the average equivalent diameter of the pores in the hard underlayer (3) is greater than 5 11 m and in that the coating (5) has an overall porosity fraction greater than 8%.