Component for a cooking appliance
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Solution Overview
Problem
Existing cooking appliance components, particularly hanging grids and telescopic extensions, face issues with high-temperature oxidation and corrosion, which require stainless steel as a starting material, making them costly and difficult to process, and existing coatings do not adequately prevent discoloration and contamination.
Innovation Solution
A multi-layer coating system comprising a chromium or nickel first protective layer and a silicon dioxide second protective layer applied via electrolytic deposition and PECVD, respectively, on a steel base material, providing enhanced protection against high-temperature oxidation and corrosion, with a black chrome layer reducing visible dirt and stains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel is used as base material with silicon oxide coating, then protection against high-temperature oxidation is achieved, but material cost and processing difficulty increase
Solution Approach 1:
The patent applies a multi-layer composite coating system consisting of a first protective layer (chromium or nickel) and a second protective layer (silicon dioxide) on a carbon steel base material. This composite structure provides the oxidation protection of stainless steel while using cheaper carbon steel as the base, thereby reducing material cost and improving ease of manufacture.
Solution Approach 2:
The first protective layer (chromium or nickel) acts as an intermediary between the carbon steel base material and the silicon dioxide coating. This intermediate layer enables the application of silicon oxide coating on carbon steel, which would not otherwise be compatible, thus providing protection against high-temperature oxidation without requiring expensive stainless steel.
2Reliability
If single-layer silicon oxide coating is applied, then protection against oxidation is provided, but adhesion and chemical resistance are insufficient
Solution Approach 1:
The patent uses a composite multi-layer coating structure where a first protective layer (chromium or nickel) is combined with a second protective layer (silicon dioxide). The first layer provides excellent adhesion to the steel substrate and corrosion resistance, while the second layer provides oxidation resistance. This composite structure achieves superior overall performance compared to a single-layer coating.
Solution Approach 2:
The protective coating is segmented into two distinct functional layers: the first protective layer handles adhesion and corrosion protection, while the second protective layer handles oxidation resistance. This segmentation allows each layer to be optimized for its specific function, resulting in improved overall reliability and stability.
3Illumination intensity
If light or glossy surface is used, then aesthetics are maintained, but dirt and stains become highly visible
Solution Approach 1:
The patent applies a black chrome coating to the first protective layer, which provides a dark, matte surface finish. This color change makes accumulated dirt, baked-on residues, and temperature-related discoloration significantly less visible compared to light or glossy surfaces, thereby reducing the aesthetic impact of usage and cleaning requirements.
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 multi-layer coating system effectively prevents discoloration, corrosion, and contamination, offering improved durability and aesthetics by using cost-effective steel instead of stainless steel, while maintaining high-temperature resistance and chemical resistance.
Implementation Method 1
the silicon dioxide layer is applied using a PECVD process. This plasma-assisted vapor deposition under vacuum creates a silicon dioxide layer on the first protective layer.
Implementation Method 2
the silicon dioxide layer is applied using a PECVD process. This plasma-assisted vapor deposition under vacuum creates a silicon dioxide layer on the first protective layer.
Implementation Method 3
The first protective layer has a chromium or nickel surface applied to the metallic base of the component, forming a transfer layer to support the second protective layer. This second protective layer is applied using known methods, such as electrolytic deposition.
Data Source
Figure 1~4
AI summary
A component for a cooking appliance, which is arranged in a cooking chamber, is disclosed, having a first protective layer and a second protective layer applied to the first protective layer.