Inorganic-Organic Hybrid Coating for Metallic Substrates
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Solution Overview
Problem
Existing corrosion protection methods for metallic substrates are either expensive, toxic, or environmentally hazardous, and often result in coatings with limited adhesion, leading to delamination and exposure to corrosive environments.
Innovation Solution
A cross-linked inorganic-organic hybrid coating with functional groups such as C1-C20 alkyl, amide, and halogen atoms, covalently bonded to the substrate using silicon or titanium, applied through a sol-gel process that allows for moderate temperature and non-toxic processing, providing excellent adhesion and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional corrosion inhibitors are used to protect metallic substrates, then corrosion protection is achieved, but the coating becomes toxic and environmentally hazardous
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using inorganic-organic hybrid materials (ORMOCER®) with specific functional groups (alkyl, amide, carboxyl, phosphonic, or silane groups) instead of traditional toxic corrosion inhibitors. This parameter change maintains corrosion protection while eliminating toxicity and environmental hazards.
Solution Approach 2:
The patent employs composite inorganic-organic hybrid materials that combine the corrosion resistance of inorganic materials with the protective and adhesive properties of organic materials. This composite approach provides effective corrosion protection without the toxic effects of traditional inhibitors.
2Reliability
If protective coatings are deposited on substrate surfaces, then corrosion protection is provided, but the coating adhesion is limited leading to delamination
Solution Approach 1:
The patent modifies the chemical parameters of the coating by incorporating specific functional groups (alkyl, amide, carboxyl, phosphonic, or silane groups) that enhance chemical bonding to the substrate. This improves coating adhesion strength and prevents delamination while maintaining corrosion protection.
Solution Approach 2:
The inorganic-organic hybrid coating acts as an intermediary layer that chemically bonds to both the metallic substrate and the environment, providing strong adhesion through covalent bonding mechanisms while simultaneously offering corrosion protection.
3Reliability
If expensive traditional corrosion inhibitors are used, then effective corrosion protection is achieved, but the cost increases
Solution Approach 1:
The patent uses cost-effective inorganic-organic hybrid materials that can be applied as thin, single-layer coatings without requiring expensive traditional corrosion inhibitors. The coating provides durable protection at lower material and processing costs.
Solution Approach 2:
The patent changes the material composition to use economically viable inorganic-organic hybrids with specific functional groups, replacing expensive traditional inhibitors while maintaining effective corrosion protection through the coating's inherent properties.
4Object-affected harmful factors
If sol-gel process is used to create inorganic-organic hybrid coatings, then environmental friendliness and high performance are achieved, but the coating requires precise control of inorganic and organic structural units
Solution Approach 1:
The patent specifies precise compositional parameters for the inorganic-organic hybrid coating, including the types of functional groups (alkyl, amide, carboxyl, phosphonic, or silane groups) and their ratios, to achieve optimal balance between environmental friendliness, adhesion, and corrosion protection while managing formulation complexity.
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 effectively inhibits corrosion on metallic substrates by forming a stable, non-toxic, and environmentally friendly coating that maintains adhesion, reducing corrosion risk and energy consumption, while being suitable for use in various applications including watch components.
Implementation Method 1
The sol-gel process is a method for producing solid materials from small molecules, and is considered a sustainable and non-toxic technique. The process involves conversion of monomers into a colloidal solution (sol) that acts as a precursor for an integrated network (or gel) of either discrete particles or network polymers (cross-linked polymers).
Implementation Method 2
The method comprises providing a first compound according to formula (I): wherein M is silicon or titanium
Implementation Method 3
The pre-polymer applied to at least part of a surface of the substrate is cross-linked. Advantageously, the cross-linking of the pre-polymer is realised by cross-linking of the cross-linkable functional group R5.
Implementation Method 4
These coatings provide a protective barrier against the corrosive environment.
Data Source
AI summary
An article including a substrate and a corrosion inhibiting coating present on at least part of a surface of the substrate, wherein the corrosion inhibiting coating is a cross-linked inorganic organic hybrid coating comprising at least one functional group R1, wherein R1 comprises one or more functional groups selected from the group consisting of C1-C20 alkyl, C1-C20 cycloalkyl, C1-C10 aryl, amide, amine, mercapto, and epoxy, and substituted with at least one halogen atom, wherein the coating comprises silicon and/or titanium, and is covalently bonded to the metallic element or the alloy thereof by oxygen-silicon bonds or oxygen-titanium bonds, respectively. Also, a method for producing such an article.