Laminate Primer Layer Inorganic Particles Adhesion
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Solution Overview
Problem
Existing laminates face limitations in abrasion resistance, hardness, and adhesion between layers, particularly between the substrate and primer layers, and between intermediate and top coat layers, due to the inherent properties of fluororesins and the use of fillers.
Innovation Solution
A laminate configuration featuring a substrate with a primer layer containing heat-resistant resin and inorganic particles, an intermediate layer with fluororesin and heat-resistant resin, and a top coat layer with fluororesin and inorganic particles, where the inorganic particles have specific sizes and hardness, enhancing adhesion and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluororesin is used for surface treatment to achieve low coefficient of friction and non-adhesiveness, then chemical resistance and heat resistance are improved, but adhesiveness to substrate deteriorates
Solution Approach 1:
The coating is divided into multiple functional layers: a primer layer containing heat-resistant resin and inorganic particles for substrate adhesion, and a fluororesin top layer for non-adhesive properties. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The primer layer acts as an intermediary between the substrate and the fluororesin top layer. It provides a bonding interface that adheres to the substrate while allowing the fluororesin layer to maintain its non-adhesive properties for cooking applications.
2Strength
If filler is added to improve abrasion resistance and strength, then mechanical properties are enhanced, but filler easily falls due to soft fluororesin matrix
Solution Approach 1:
Inorganic particles are concentrated in the primer layer rather than distributed throughout the fluororesin layer. This segmentation ensures that the hard particles are embedded in a rigid heat-resistant resin matrix that can securely hold them, preventing filler fallout while maintaining abrasion resistance.
Solution Approach 2:
The primer layer is designed with local quality characteristics - it contains high concentrations of inorganic particles and heat-resistant resin specifically where mechanical strength and filler retention are needed, while the fluororesin top layer maintains its soft, non-adhesive properties where cooking performance is required.
3Strength
If multi-layer structure is created to improve adhesion between substrate and primer layer, then interlayer adhesion is enhanced, but device complexity increases
Solution Approach 1:
The coating system is segmented into two main layers with distinct compositions and functions. The primer layer handles adhesion and mechanical strength, while the fluororesin layer handles non-adhesive cooking properties. This functional segmentation achieves excellent interlayer adhesion without requiring excessive complexity.
Data Source
AI summary
The present invention provides a laminate excellent in abrasion resistance, high in hardness, and excellent in adhesion between a substrate and a primer layer and adhesion between an intermediate layer and a top coat layer. The laminate includes: a substrate; a primer layer disposed on the substrate, the primer layer containing inorganic particles (a) having an average particle size of 3 µm or greater and a heat-resistant resin (a), but not containing a fluororesin; an intermediate layer disposed on the primer layer and containing a fluororesin (b) and a heat-resistant resin (b); and a top coat layer disposed on the intermediate layer and containing a fluororesin (c).