Multilayer Metal-Core Pigment Coating Against Cracks and Oxidation
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Solution Overview
Problem
Existing special effect pigments, such as aluminum-based pigments, suffer from defects like cracks and oxidation due to the diffusion of elements through inorganic brittle outerlayers, leading to delamination and corrosion of the metal core.
Innovation Solution
A multilayer encapsulation coating is applied to the pigments, comprising a flexible organic layer sandwiched between rigid inorganic layers, which inhibits the diffusion of elements and prevents crack propagation, using sol-gel and layer-by-layer technologies to form a durable barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid inorganic layer is used to encapsulate the pigment, then the structural stability is improved, but crack propagation and defect formation increase
Solution Approach 1:
The patent applies a composite encapsulation structure combining inorganic layers (providing structural stability and chemical resistance) with organic layers (providing flexibility and crack propagation resistance). This composite approach allows each material to contribute its advantageous properties while mitigating their individual weaknesses.
Solution Approach 2:
The organic layer in the encapsulation structure acts as a flexible shell that can accommodate stress and prevent crack propagation through the rigid inorganic layers. This flexible film component is crucial for maintaining reliability while preserving the structural benefits of the inorganic material.
2Object-affected harmful factors
If an inorganic brittle outer layer is applied to protect the metal core, then oxidation resistance is improved, but element diffusion through the layer increases
Solution Approach 1:
The dual-layer encapsulation structure combines the oxidation resistance of inorganic materials with the diffusion-blocking properties of organic materials. The organic layer specifically targets element diffusion while the inorganic layer provides oxidation protection, creating a synergistic protective system.
3Object-affected harmful factors
If multiple inorganic layers are used to encapsulate the pigment, then protection against elements is improved, but delamination occurs more easily
Solution Approach 1:
The patent uses a composite encapsulation system where the organic layer serves as a flexible bonding medium between inorganic layers. This organic intermediate layer prevents delamination by accommodating thermal expansion differences and mechanical stress, while still allowing the inorganic layers to provide element protection.
Solution Approach 2:
The organic layer acts as a flexible bonding film that maintains adhesion between rigid inorganic layers. This flexible film prevents delamination by absorbing stress and preventing the propagation of cracks through the encapsulation structure.
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 multilayer encapsulation effectively prevents oxidation and delamination, maintaining optical properties and reducing gas production, while providing a stable metal core protection in waterborne applications.
Implementation Method 1
applying a first inorganic layer by a sol-gel process to fully encapsulate the flake
Implementation Method 2
a flexible organic layer that can help minimize at least one of the following: propagation of defects, such as cracks; oxidation of a metal core
Data Source
AI summary
A pigment, including a flake including a metal core having a first surface and a second surface, a first dielectric layer interfacing with a first surface of the metal core, and a second dielectric layer interfacing with a second surface of the metal core; a first inorganic layer encapsulating the flake; and an organic layer encapsulating the first organic layer is disclosed. A colorant composition including the pigment is also disclosed. A method of making the pigment, and a method of making a colorant composition are also disclosed.