Polysilazane Silica Coating for Glass Containers
Solution Overview
Problem
Conventional coatings for glass containers do not adequately enhance surface characteristics such as scratch resistance, strength retention, and ease of cleaning, while also being limited in their application processes.
Innovation Solution
A sol-gel process is used to apply a polysilazane-based inorganic silica coating to glass containers, which is then heated in a water vapor-containing environment to form a non-porous silica coating with a hardness greater than 8.5 GPa, bonded through siloxane bonds, improving abrasion resistance and hydrophilicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal oxide coatings are applied at the hot end or cold end of the annealing lehr, then the glass container gains some protective properties, but the surface characteristics such as scratch resistance, strength retention, and ease of cleaning are not adequately enhanced
Solution Approach 1:
The patent changes the chemical composition parameters of the coating material from conventional metal oxides to polysilazane-based inorganic silica coating. This parameter change enables the coating to achieve superior scratch resistance (hardness greater than 8.5 GPa) and improved surface characteristics while maintaining compatibility with existing manufacturing processes.
Solution Approach 2:
The patent uses a composite coating system consisting of polysilazane precursor material that transforms into inorganic silica coating with siloxane bond formation. This composite approach combines the advantages of organic precursor application ease with inorganic coating durability, achieving both high scratch resistance and manufacturing efficiency.
2Reliability
If conventional protective organic coatings are applied over metal oxide coatings, then some protection is provided, but the coating process becomes more complex and surface characteristics are still not optimally improved
Solution Approach 1:
The patent extracts and eliminates the need for multi-layer coating structures by using a single polysilazane-based coating that provides both protective and functional properties. This single-coating approach replaces the conventional multi-layer system (metal oxide + organic coating), simplifying the manufacturing process while achieving superior strength retention.
Solution Approach 2:
The polysilazane-based inorganic silica coating performs multiple functions simultaneously: it provides scratch resistance, strength retention, stain resistance, and improved ease of cleaning. This multi-functional coating eliminates the need for separate protective and functional coatings, reducing overall system complexity.
3Reliability
If conventional coatings are applied to glass containers, then some surface protection is achieved, but stain resistance and ease of cleaning are not sufficiently improved
Solution Approach 1:
The patent changes the surface energy parameters of the glass container by applying an inorganic silica coating with specific chemical composition. This parameter change creates a surface that is both highly stain-resistant and easy to clean, as the coating's chemical structure prevents stain adhesion while maintaining smooth surface properties that facilitate cleaning.
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 silica coating significantly enhances the glass container's durability, stain resistance, and ease of cleaning, while potentially eliminating the need for conventional hot end coatings, and improving labelability.
Implementation Method 1
applying a sol-gel solution including a polysilazane and an organic solvent to an exterior surface of a glass container to form a sol-gel coating thereon
Implementation Method 2
heating the glass container and the sol-gel coating in a water vapor-containing environment having a temperature between 150 degrees Celsius and 600 degrees Celsius to form an inorganic silica coating
Implementation Method 3
the silica coating has a hardness greater than 8.5 GPa and is bonded to the exterior surface of the glass container through a plurality of siloxane bonds
Implementation Method 4
heating the glass container and the sol-gel coating in a water vapor-containing environment having a temperature between 150 degrees Celsius and 600 degrees Celsius
Data Source
AI summary
A glass container and a process for forming an inorganic silica coating on an exterior surface of the glass container to improve one or more surface characteristics of the glass container. A sol-gel solution including a polysilazane and an organic solvent is applied to the exterior surface of the glass container to form a sol-gel coating thereon. The glass container and the sol-gel coating are then exposed to a water vapor-containing environment and heated at a temperature of between 150 degrees Celsius and 600 degrees Celsius to transform the sol-gel coating into an inorganic silica coating. The as-formed silica coating has a hardness of greater than 8.5 GPa and is bonded to the exterior surface of the glass container through a plurality of siloxane bonds.