Solventless Fluoropolymer Coating Process for Metal Release Surfaces
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Solution Overview
Problem
Existing methods for forming primer layers in multilayer articles with release surfaces often require solvents, which are costly and inefficient, and result in thicker coatings than desired.
Innovation Solution
A solventless process involving the delivery of abrasive particles, a first fluoropolymer, and a binder to a metal surface using a fluid jet to form a thin, strong adhesion layer, followed by sintering and application of a second fluoropolymer layer to create a durable release surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a primer composition including fluorinated polymer is applied to improve adhesion, then adhesion strength is improved, but coating thickness increases and production cost increases
Solution Approach 1:
The patent extracts the solvent component from the traditional primer composition, creating a solvent-free system. This allows the fluorinated polymer to be applied in much thinner layers (reducing quantity) while the abrasive particles provide mechanical anchoring that maintains strong adhesion without requiring thick coatings.
Solution Approach 2:
The invention creates a composite primer composition combining fluorinated polymer with abrasive particles (such as aluminum oxide or silicon carbide). This composite structure provides dual functionality: the fluorinated polymer ensures chemical adhesion to the metal substrate, while the abrasive particles create mechanical interlocking through surface roughening, achieving strong adhesion with minimal material thickness.
2Quantity of substance
If solvent-based dispersion coating is used to achieve thin coating layers, then coating thickness is reduced, but production cost increases due to solvent removal requirements
Solution Approach 1:
The patent removes the solvent component entirely from the coating system, using a solvent-free fluorinated polymer composition delivered with abrasive particles. This eliminates all costs and process steps related to solvent evaporation, drying, and environmental compliance, while still achieving thin coating layers through the abrasive delivery mechanism.
Solution Approach 2:
The invention uses a fluid jet (pneumatic or hydraulic) to deliver the abrasive particles coated with fluorinated polymer directly to the substrate surface. This jet delivery system applies the coating in a controlled, thin layer without requiring solvent-based dispersion, eliminating solvent removal steps and reducing manufacturing complexity and cost.
3Strength
If traditional primer coating methods are used, then adhesion is improved, but the process complexity increases due to solvent handling and removal
Solution Approach 1:
The patent extracts and eliminates the solvent handling portion of the traditional coating process. By using a solvent-free fluorinated polymer composition delivered with abrasive particles through a jet system, the process eliminates drying ovens, ventilation requirements, and solvent recovery systems, significantly reducing device and process complexity while maintaining strong adhesion.
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
This method allows for the formation of thin, solvent-free primer layers with strong adhesion to metal substrates, enabling the creation of durable release surfaces without the need for additional adhesives and reducing production costs.
Implementation Method 1
delivering particles from at least one fluid jet to a metal surface to impregnate the metal surface with a fluoropolymer
Implementation Method 2
sintering the multilayered article to from the release surface coated substrate
Data Source
Figure 1
AI summary
Described herein is multilayer article made by the process comprising: delivering particles from at least one fluid jet to a metal surface to impregnate the metal surface with a fluoropolymer to form a first fluoropolymer layer, wherein the particles comprise an abrasive particle, a binder, and a first fluoropolymer; coating the first fluoropolymer layer with a second fluoropolymer to form a second fluoropolymer layer and thereby forming a multilayered article; and sintering the multilayered article to form the release surface coated substrate.