Polymeric Sublayer-Formulation Based On Resins Having High Thermomechanical Properties (PEEK, PES, PAI, PBI, ETC) For Reinforcing The Mechanical Resistance, In Particular To Heat, Of Fluorinated Coatings
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Solution Overview
Problem
Existing non-stick coatings for culinary articles and electrical cooking appliances suffer from low mechanical resistance, particularly when exposed to heat, and require multiple baking or sintering steps, which are costly in terms of time and energy.
Innovation Solution
A tie sublayer formulation comprising polyaryletherketones, polyethersulfones, and inorganic fillers, with a single sintering step at 420-430°C, enhances mechanical resistance while maintaining non-stick properties and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard fillers or hard sublayers are used to reinforce mechanical resistance, then abrasion resistance is improved, but impact resistance deteriorates and metal surface damage occurs
Solution Approach 1:
The patent uses a composite sublayer formulation combining PEEK polymer (provides toughness and impact resistance), PAI polymer (enhances mechanical strength), and PES polymer (improves thermal stability), along with inorganic fillers like alumina and silica (provide abrasion resistance). This composite approach allows the sublayer to simultaneously achieve high abrasion resistance while maintaining impact resistance and protecting the metal substrate from damage.
2Reliability
If double baking is performed to ensure proper adhesion and sintering, then coating quality is improved, but production time and energy consumption increase
Solution Approach 1:
The patent combines the adhesion promotion function and the sintering function into a single baking step performed at 420-430°C. The sublayer formulation is specifically designed to achieve both proper adhesion to the metal substrate and complete sintering of the fluorinated coating layers during this one high-temperature treatment, eliminating the need for separate baking operations and reducing production time and energy consumption.
3Reliability
If high sintering temperature is used to ensure proper coating formation, then coating quality is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes the sintering temperature parameter to a specific range of 420-430°C, which is sufficiently high to ensure complete sintering of the fluorinated coating layers and proper adhesion, but not excessively high to waste energy. The sublayer formulation is specifically designed to achieve optimal coating formation within this temperature window, balancing coating quality with energy efficiency.
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 excellent anti-scratch performance at both room and high temperatures, minimizing costs and maintaining adhesion and release properties, with a single sintering step.
Implementation Method 1
The sublayer is deposited by spray, by coating, by screen printing or by roller
Implementation Method 2
characterized in that it comprises in overall only a single sintering step (vi) at T° C.>400° C., after the deposition of the various layers
Data Source
AI summary
A tie sub layer of a release coating on a metal support includes between 20% and 80% by weight of the total weight of the sub layer of one or more polymers selected from the group consisting of polyaryletherketones (PAEK), polyethyleneimines (PEI), polyimides (PI), polyamide imides (PAI) and polybenzymidazoles (PBI), with a weight ratio PAEK:(PEI+PI+PAI+PBI) of between 1:1 and 15:I; at least 20%, preferably at least 25%, by weight of the total weight of the sublayer of one or more polymers selected from the group consisting of phenylene polysulfides (PPS) and polyethersulfones (PES); less than 40%, preferably less than 30%, by weight of the total weight of the sub layer of reinforcing inorganic fillers, preferably between 5% and 25% by weight; between 0% and 5% by weight of the total weight of the sub layer of one or more fluorocarbon or acrylic resins; and optionally one or more pigments.