Sanitary Equipment Part with Zr Colored Layer and Chromium Interlayer
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Solution Overview
Problem
The water-repellent surface layer's functionality deteriorates over time when used with colored layers containing Ti or Zr, due to photocatalytic action, and existing solutions compromise weather resistance and color tone.
Innovation Solution
A sanitary equipment part with a colored layer containing Zr, optionally C and/or N, and a surface layer with a specific Zr oxide to Zr ratio, and a hydrophobic group, forming a thin, transparent layer to prevent photocatalytic activity and maintain water repellency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a colored layer containing Ti or Zr is used to achieve good appearance and corrosion resistance, then the aesthetic quality and protective properties are improved, but the water-repellent surface layer deteriorates over time due to photocatalytic action
Solution Approach 1:
The patent introduces a chromium-containing intermediate layer between the colored layer (containing Ti or Zr) and the water-repellent surface layer. This intermediate layer acts as a mediator that blocks the photocatalytic action from reaching the organic components of the surface layer, thereby preventing decomposition while maintaining the corrosion resistance provided by the colored layer.
Solution Approach 2:
The patent converts the harmful photocatalytic effect into a beneficial structure by allowing controlled oxidation of the chromium intermediate layer. The oxidized chromium layer specifically blocks UV light that causes photocatalysis, while the overall multi-layer structure maintains the desired corrosion protection and aesthetic properties.
2Ease of operation
If a protective layer is provided to prevent scale adhesion, then stain removability is improved, but the appearance of the part is impaired due to color or damage of the protective layer
Solution Approach 1:
The patent uses an ultra-thin water-repellent surface layer (5-20 nm) that is transparent and does not visibly alter the appearance of the underlying colored layer. This thin film provides scale removability while maintaining the aesthetic quality of the original part surface.
Solution Approach 2:
The patent applies different properties to different layers: the colored layer provides appearance and corrosion resistance, the chromium intermediate layer provides photocatalysis blocking, and the ultra-thin surface layer provides water repellency. Each layer has its specific function without compromising the overall appearance.
3Ease of operation
If a thick surface layer is used to ensure water repellency, then stain removability is improved, but the color tone of the colored layer is altered
Solution Approach 1:
The patent employs an ultra-thin surface layer (5-20 nm) that is thin enough to be transparent to visible light, thereby maintaining the original color tone of the colored layer while still providing sufficient water-repellent properties for effective stain removability.
Solution Approach 2:
The patent optimizes the thickness parameter of the surface layer to a specific range (5-20 nm) that balances two requirements: being thick enough to provide water repellency and stain removability, while being thin enough to remain transparent and preserve the color tone of the underlying colored layer.
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 weather resistance and improved stain removability while maintaining the color tone and water-repellent properties of the surface layer.
Implementation Method 1
the surface layer includes a hydrophobic group, and exhibits a water-repellent function
Implementation Method 2
the decomposition of the surface layer mainly containing organic components by the photocatalytic action of an oxide film (passivation film) formed by said metal element
Data Source
AI summary
A part includes a base material, a colored layer on the base material, and a surface layer on the colored layer, wherein the colored layer contains Zr, and optionally, C and/or N, a ratio (HZr oxide/HZr) of a peak height derived from Zr oxide (HZr oxide) to a peak height of Zr (HZr) at an interface of the colored layer on the side of the surface layer is more than 0 and less than 4.5, the interface is a point where Zr is detected by sputtering the part from the side of the surface layer with an XPS depth direction analysis, and the ratio (HZr oxide/HZr) at a point where Ar sputtering is performed for 5 minutes from the interface of the colored layer on the side of the surface layer with the XPS depth direction analysis is 0 to less than 3. The surface layer is water-repellent and exhibits a sputtering time of 5 minutes or less.