A process for making a release surface coated subtrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for an alternative method to create multilayer articles with a release surface using an aqueous fluoropolymer dispersion that does not rely on binders, while ensuring strong adhesion between the fluoropolymer layer and the metal substrate.
Innovation Solution
The method involves forming a silicon compound layer on a metal surface using silicon-containing particles delivered by a fluid jet, followed by coating with an aqueous fluoropolymer dispersion containing partially fluorinated or functionalized fluoropolymers, and sintering to create a strong adhesion without the use of binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a non-fluorinated heat resistant binder is used to adhere fluoropolymers to metal substrates, then adhesion strength is improved, but the anti-stick properties and release performance deteriorate
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary substance between the metal substrate and fluoropolymer coating. The silane coupling agent contains both inorganic-binding groups that attach to the metal substrate and organic-reactive groups that bond with the fluoropolymer, thereby mediating the adhesion interface and achieving strong bonding without compromising the release properties of the fluoropolymer
Solution Approach 2:
The patent creates a composite primer layer consisting of silane coupling agent and binder that combines the adhesion benefits of non-fluorinated materials with the anti-stick properties of fluoropolymers. This composite structure allows the system to simultaneously achieve strong substrate bonding and maintain release performance
2Ease of manufacture
If conventional coating methods with binders and solvents are used, then ease of manufacture is improved, but environmental friendliness and cost-effectiveness deteriorate
Solution Approach 1:
The patent extracts and eliminates harmful solvents and excessive binders from the coating formulation, using a water-based or solvent-free dispersion system where fluoropolymer particles are suspended in water without requiring organic solvents for dissolution. This extraction of harmful components maintains ease of manufacture while significantly improving environmental friendliness
Solution Approach 2:
The patent changes the physical-chemical parameters of the coating system by using aqueous dispersions instead of solvent-based systems, and by controlling particle size, concentration, and surface charge of fluoropolymer particles to enable stable suspension and uniform coating without traditional solvents and binders
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 approach results in a durable release coating with excellent adhesion to the metal substrate, as demonstrated by the cross hatch test, and eliminates the need for solvents and binders, making the process more environmentally friendly and cost-effective.
Implementation Method 1
delivering particles comprising a silicon compound from at least one fluid jet to a metal surface to embed the metal surface with the silicon compound
Implementation Method 2
embed the metal surface with the silicon compound to form a silicon compound layer
Implementation Method 3
coating the silicon compound layer with an aqueous fluoropolymer dispersion to form a fluoropolymer layer
Implementation Method 4
sintering the multilayered article to form the release surface coated substrate
Data Source
Figure 1
AI summary
Described herein is multilayer article made by the process comprising: delivering particles comprising a silicon compound from at least one fluid jet to a metal surface to embed the metal surface with the silicon compound to form a silicon compound layer; coating the silicon compound layer with an aqueous fluoropolymer dispersion to form a fluoropolymer layer and thereby forming a multilayered article, wherein the aqueous fluoropolymer dispersion comprises (i) a modifying agent; and (ii) a fluorinated polymer, wherein the fluorinated polymer comprises at least one of (a) a partially fluorinated polymer capable of forming a carbon-carbon double bond, (b) a functionalized fluorinated polymer, and (c) combinations thereof; and sintering the multilayered article to form the release surface coated substrate.