Interpenetrating Polymer Network Coating for Translucent Glass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The handling and disposal of hydrofluoric acid in acid etching processes for fabricating translucent glass pose environmental and safety concerns, and existing techniques for forming translucent enamel coatings often result in coatings with inadequate strength, adhesion, and chemical resistance.
Innovation Solution
A glass article with a coating comprising a glass frit material and a binder material that forms an interpenetrating network of cross-linked and linear or branched polymer chains, including carbon-backbone and silicon-backbone polymers, with a low binder content and optional silicon-containing nanoparticles, providing enhanced strength, adhesion, and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If acid etching with hydrofluoric acid is used to achieve good optical performance, then optical performance is improved, but handling and disposal of acid becomes problematic
Solution Approach 1:
The patent extracts and eliminates the hydrofluoric acid from the translucent glass fabrication process. Instead of using acid etching, the invention applies a translucent enamel coating that achieves the desired optical performance without requiring harmful chemicals, thereby removing the acid handling and disposal problems entirely
Solution Approach 2:
The patent replaces the reusable but hazardous acid etching process with a disposable coating system. The translucent enamel coating is applied as a surface layer that can be processed and removed or replaced without contaminating the environment, effectively substituting a permanent chemical process with a temporary, cleanable surface treatment
2Ease of manufacture
If a translucent enamel coating is formed with traditional binder materials, then the coating can be applied to glass, but the coating has inadequate strength, adhesion, and chemical resistance
Solution Approach 1:
The patent employs a composite binder material consisting of multiple polymer components with different functions. The binder includes polymers providing adhesion, flexibility, and chemical resistance, combined in a formulation that achieves both ease of application and superior coating performance. This multi-component composite approach allows each polymer to contribute specific properties that compensate for the weaknesses of individual materials
Solution Approach 2:
The patent modifies the chemical and physical parameters of the binder material to optimize coating performance. By adjusting polymer molecular weights, cross-linking densities, and compositional ratios, the formulation achieves enhanced strength, adhesion, and chemical resistance while maintaining applicability. The thermal treatment parameters are also optimized to control polymer decomposition and frit sintering for maximum coating durability
3Strength
If high binder content is used in the coating to improve adhesion and strength, then coating durability is improved, but the amount of glass frit material decreases
Solution Approach 1:
The patent optimizes the binder content parameter within a specific range (5-20 wt%) to achieve the desired balance between coating durability and frit content. By precisely controlling the binder formulation and cross-linking density, the coating achieves maximum adhesion and strength with minimal binder, thereby preserving high glass frit content for optimal optical and mechanical properties
Solution Approach 2:
The patent uses a composite binder system where multiple polymers work synergistically to provide enhanced binding power at lower concentrations. The combination of different polymer types allows the coating to achieve superior adhesion and flexibility with reduced overall binder content, maintaining high glass frit content while ensuring coating durability through the complementary actions of the polymer components
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 high adhesion, strength, and chemical resistance, allowing for safe handling and processing before thermal treatment, and results in a durable translucent enamel coating with improved optical and mechanical properties.
Implementation Method 1
The binder material includes a first polymer that has cross-linked first polymer chains and a second polymer that has second polymer chains that are linear, branched, or cross-linked. The cross-linked first polymer chains and the second polymer chains form an interpenetrating network
Implementation Method 2
The mixture is thermally treated to remove the carrier medium, leaving an 'intermediate' or 'green' coating of the binder and frit on the surface of the glass. A further thermal treatment then removes the binder and sinters the frit to form the final translucent enamel coating
Implementation Method 3
A further thermal treatment then removes the binder and sinters the frit to form the final translucent enamel coating on the glass
Data Source
AI summary
A glass article includes a glass substrate and a coating disposed on the glass substrate. The coating includes a glass frit material and a binder material. The binder material includes a first polymer that has cross-linked first polymer chains and a second polymer that has second polymer chains that are linear, branched, or cross-linked. The cross-linked first polymer chains and the second polymer chains form an interpenetrating network in which the second polymer chains are intertwined on a molecular scale with the cross-linked first polymer chains.