Low-Temperature Nonstick Coating for Plastic and Metal Substrates
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Solution Overview
Problem
Existing non-stick coatings face challenges in achieving effective adhesion resistance at temperatures below 400°C, particularly for temperature-sensitive substrates and materials like plastics, and are not suitable for a wide range of substrate materials, including elastic substrates and metals.
Innovation Solution
A method involving a primer layer with inclusions in powder or grain form applied to a substrate, followed by a cover layer, which is thermally treated at lower temperatures (120-300°C) to create a non-stick coating with enhanced scratch, abrasion, chemical, and temperature resistance, suitable for various substrate materials, including plastics and metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional non-stick coatings are applied with high sintering temperatures (400-500°C), then the non-stick effect and durability are improved, but temperature-sensitive substrates cannot be coated and energy consumption increases
Solution Approach 1:
The patent changes the chemical composition parameters of the coating material by incorporating specific inclusions (silica, alumina, titania, zirconia) and using alternative binders (silicone, epoxy, polyurethane) that enable sintering at lower temperatures (150-300°C) while maintaining non-stick performance. This parameter change allows the coating to achieve reliable adhesion reduction without requiring high temperatures that would damage temperature-sensitive substrates.
Solution Approach 2:
The patent creates a composite coating material combining multiple components: inclusions (silica, alumina, titania, zirconia), binder (silicone, epoxy, polyurethane), and optional additives. This composite structure enables the coating to achieve both non-stick effect and durability at lower sintering temperatures, resolving the contradiction between reliability and temperature requirements.
2Reliability
If fluorine-containing compounds (PTFE) are used in non-stick coatings, then the non-stick effect is improved, but environmental impact increases and application is limited
Solution Approach 1:
The patent extracts and removes fluorine-containing compounds (PTFE) from the coating formulation while replacing them with alternative materials (silica, alumina, titania, zirconia inclusions combined with silicone, epoxy, or polyurethane binders). This extraction eliminates the harmful environmental factors associated with fluorine compounds while maintaining the non-stick effect through the alternative material combination.
Solution Approach 2:
The patent replaces expensive and environmentally problematic fluorine-containing compounds with more environmentally friendly and potentially biodegradable alternative materials (silica, alumina, titania, zirconia, silicone, epoxy, polyurethane). These alternative materials achieve the same functional effect without the harmful environmental characteristics of PTFE.
3Reliability
If a multi-layer coating structure is applied, then the functional properties (scratch resistance, chemical resistance) are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the coating into distinct functional layers: a primer layer containing inclusions for non-stick effect, and a cover layer providing scratch and chemical resistance. This segmentation allows each layer to be optimized for its specific function while maintaining overall coating performance, reducing the complexity of achieving multiple properties simultaneously.
Solution Approach 2:
The patent applies different material compositions to different layers of the coating structure. The primer layer uses inclusions (silica, alumina, titania, zirconia) for non-stick effect, while the cover layer uses different materials for scratch and chemical resistance. This local quality differentiation allows each layer to perform its specific function optimally without requiring the entire coating to have all properties.
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 method produces a highly effective non-stick coating that is suitable for a broad range of substrates, including temperature-sensitive plastics and metals, with improved adhesion resistance and reduced energy consumption, expanding application areas such as molding tools and medical devices.
Implementation Method 1
The maximum temperature used for all thermal treatments used in the coating is below the specified temperatures or temperature ranges. For example, the maximum treatment temperature is a maximum of 300°C, preferably a maximum of 250°C or 230°C.
Implementation Method 2
At least after the at least one cover layer has been applied, a thermal treatment is carried out to stabilize the non-stick coating or the cover layer. The thermal treatment of the at least one cover layer preferably takes place in a temperature range of 120 to 300 ° C, preferably in the narrower temperature range of 200 to 230 ° C.
Data Source
AI summary
Producing a nonstick coating on a substrate comprises applying a primer coat having inclusions with a particle size of 5-50 mu m, applying a top coat and heat-treating the top coat. Independent claims are also included for: (1) nonstick coating on a substrate, comprising a primer coat having inclusions with a particle size of 5-50 mu m and a top coat comprising silicon- and/or silicate-based components; (2) tool for applying adhesives or adhesive labels, especially for the food sector, with a nonstick coating as above.