Cooking Element Coated With A Peelable Non-Stick Fluorinated Polymeric Film
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Solution Overview
Problem
Existing non-stick coatings for culinary items face challenges with mechanical durability and ease of disassembly for recycling, as conventional methods like liquid-spraying and powder coating processes result in coatings that are either too thin for durability or difficult to disassemble without damaging the film.
Innovation Solution
A metal substrate coated with a peelable, non-stick fluorinated polymeric film reinforced by a mechanical layer and a hotmelt polymer layer with a melting point above 250°C, allowing for easy disassembly by peeling when worn, enabling recycling and prolonged service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If liquid-spraying coating process is used, then coating can be applied to curved surfaces, but coating thickness is limited and uniformity is difficult to achieve
Solution Approach 1:
The coating system is segmented into multiple functional layers: a primer layer for adhesion, intermediate layers for thickness and uniformity control, and a top fluorinated resin layer for non-stick properties. This segmentation allows each layer to be optimized independently for its specific function.
Solution Approach 2:
The patent uses composite material structure combining different resin types (epoxy, polyester, polyurethane in primer; calcium carbonate, barium sulfate fillers; fluorinated resins like PTFE, PFA, FEP in top layer) to achieve both uniform thickness application and superior non-stick performance with enhanced durability.
2Strength
If powder coating process is used, then coating can provide good adhesion, but pinhead defects appear reducing non-stick character
Solution Approach 1:
Different regions of the coating have different compositions optimized for their specific functions: the primer layer contains adhesion-promoting resins and fillers for strong bonding, while the top fluorinated resin layer provides smooth non-stick surface without pinhead defects, as each layer's composition is locally optimized.
3Duration of action of stationary object
If coating thickness is increased to improve durability, then wear resistance improves, but cracks appear and mechanical properties deteriorate
Solution Approach 1:
The thick coating is segmented into multiple thinner functional layers, each with appropriate thickness optimized for its function. This prevents cracking while maintaining total thickness for durability, as each layer can flex independently without stress concentration.
Solution Approach 2:
The composite structure combines flexible primer layers with filler materials (calcium carbonate, barium sulfate) and fluorinated resins in controlled ratios, creating a multi-layer composite that maintains mechanical integrity at increased total thickness while preventing crack formation through material flexibility and stress distribution.
4Duration of action of stationary object
If fluorinated film is laminated to provide thicker coating, then wear resistance improves, but disassembly by peeling becomes difficult and film damage occurs
Solution Approach 1:
The coating system is segmented with the fluorinated non-stick layer as a separate removable top layer over a permanent primer-substrate structure. This allows the durable thick coating to be peeled off in one piece when needed, as the layered structure maintains integrity during removal.
Solution Approach 2:
The fluorinated top layer is designed to be removable and replaceable, allowing it to be peeled off and discarded when worn, while the primer layer remains on the substrate for potential reuse or re-coating, enabling recovery and recycling of the substrate.
5Reliability
If conventional coating methods are used, then initial non-stick properties are achieved, but mechanical durability and wear resistance are insufficient
Solution Approach 1:
The patent creates a composite coating system where the primer layer provides strong adhesion and flexibility, filler materials (calcium carbonate, barium sulfate) enhance wear resistance and mechanical strength, and the top fluorinated resin layer maintains excellent non-stick properties. This composite structure ensures both initial performance and long-term durability.
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 solution provides enhanced durability and wear resistance while allowing for easy disassembly and recycling of the coating, addressing the limitations of previous methods by maintaining mechanical strength at ambient temperatures and facilitating peeling at higher temperatures.
Implementation Method 1
a layer of hotmelt polymer(s) (4) arranged on the opposite side to the cooking face (5) and having a melting point higher than 250° C.
Data Source
AI summary
The invention relates to a coated cooking element for a kitchen item or electrical cooking apparatus, comprising a metal substrate coated on one side with a peelable film, forming a cooking face, the peelable film comprising one or several layers of fluorinated polymer, a mechanical reinforcing layer and a hotmelt polymer layer arranged on the opposite side to the cooking face and having a melting point higher than 250° C. and lower than or equal to that of at least one of the other layers of the peelable film, the peelable film being assembled with the metal substrate, the hotmelt polymer layer being in contact with the face of the metal substrate. The invention also relates to a method for manufacturing such a coated cooking element and to a cooking article or an electrical cooking appliance having said coated cooking element.