Discontinuous Hard Base for Deformable Nonstick Cookware
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Solution Overview
Problem
Conventional non-stick coatings on cooking utensils, particularly those based on fluorocarbon resins like PTFE, suffer from low scratch resistance and are sensitive to hydrolysis, making them unsuitable for deformation and multilayer products, and requiring high energy costs for hard enamel bases.
Innovation Solution
A discontinuous ceramic, metallic, or polymer hard base is applied to the inner surface of cooking utensils, specifically at fragile zones, with a coverage rate of 30-80% and drop sizes between 2 μm and 50 μm, allowing for improved scratch and abrasion resistance while enabling deformation and reducing energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard enamel base is used to reinforce the non-stick coating, then scratch and abrasion resistance is improved, but energy cost increases due to high temperature firing requirements
Solution Approach 1:
The patent changes the material composition of the hard base from traditional enamel to a polymer-based composite containing rigid filler particles. This parameter change allows the hard base to achieve adequate hardness and abrasion resistance without requiring high-temperature firing, thus reducing energy consumption in the manufacturing process.
Solution Approach 2:
The patent employs a composite material structure where a polymer matrix is reinforced with rigid filler particles (such as alumina, silica, or titania). This composite approach provides the necessary mechanical strength and abrasion resistance while avoiding the high-energy curing process required for traditional enamel bases.
2Strength
If a continuous hard base layer is applied to improve abrasion resistance, then scratch resistance is enhanced, but deformation of the cooking utensil is prevented
Solution Approach 1:
The patent segments the hard base into discrete particles or filler dispersed within a polymer matrix, rather than forming a continuous rigid layer. This segmentation allows the underlying metal substrate to deform while the dispersed filler particles provide localized abrasion resistance where needed.
Solution Approach 2:
The patent applies local quality by concentrating the rigid filler particles in the hard base at specific locations or orientations, providing enhanced abrasion resistance only where required while maintaining overall flexibility and deformation capability of the cooking utensil.
3Strength
If inorganic hard base materials are used to improve abrasion resistance, then scratch resistance is enhanced, but sensitivity to hydrolysis increases
Solution Approach 1:
The patent creates a composite hard base where inert polymer materials (resistant to hydrolysis) are combined with rigid filler particles (providing abrasion resistance). The polymer matrix protects the inorganic filler from hydrolysis while the filler provides the necessary mechanical strength and scratch resistance.
Solution Approach 2:
The patent uses the polymer matrix as an intermediary between the inorganic filler particles and the environment. This polymer layer acts as a protective barrier that prevents hydrolysis of the inorganic materials while allowing them to maintain their abrasion-resistant properties.
4Strength
If a hard base is applied before shaping the cooking utensil, then abrasion resistance is improved, but manufacturing complexity increases due to additional processing steps
Solution Approach 1:
The patent applies the hard base coating to the metal substrate before shaping operations. This preliminary action allows the hard base to be deposited on a flat, easy-to-handle substrate, and then the entire coated substrate is shaped through drawing or stamping operations, integrating the hard base application into the existing manufacturing flow without requiring additional post-shaping processing steps.
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 solution enhances the non-stick coating's resistance to scratching and abrasion, maintains adhesion, and allows for deformation and energy efficiency, while being compatible with various materials and multilayer products.
Implementation Method 1
a step of producing a hard adherent base on said inner face of the support; said method being characterized in that step d) of producing the hard base comprises thermal spraying, on said inner face, of a ceramic and/or metallic and/or polymer material in powder form
Implementation Method 2
a step of producing a non-stick coating on said hard base; said method being characterized in that said step e) of producing the non-stick coating comprises a step of depositing, on said hard base, at least one composition based on fluorocarbon resin, then a step of sintering at a temperature of between 350°C and 450°C
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a cooking utensil (1) comprising a hollow bowl (2) with a base (21) and a side wall (22) rising from the base (21) and including at least one fragile area (23), said bowl (2) having a concave inner surface (24) for receiving food as well as a convex outer surface (25). The utensil is coated successively, from the bowl (2), with a hard base (3) and a nonstick coating (4) which covers the hard base (3) and includes at least one layer (41) containing at least one fluorocarbon resin. The hard base (3) consists of a layer that is at least broken at the fragile area (23). The invention also relates to a method for producing one such utensil (1).