Stone Substrate Vacuum Pre-Treatment for Durable Protective Coatings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coatings for stone materials suffer from adhesion issues, high porosity, and thermal expansion coefficient differences, leading to cracks and breaks, and lack effective barrier properties against corrosion.
Innovation Solution
A pre-treatment process involving vacuum treatment inside an autoclave to remove pollutants and porosity, followed by application of silicon-based coatings like sol-gel formulations or polysilazane compounds to enhance adhesion and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coatings are applied to stone material substrates to protect from corrosion, then corrosion resistance is improved, but adhesion between coating and substrate deteriorates
Solution Approach 1:
The patent applies preliminary action by performing surface pre-treatment (polishing, cleaning with solvent, drying) before coating application. This prepares the stone substrate surface to optimize coating adhesion, preventing the adhesion problems that would otherwise occur with direct coating application.
Solution Approach 2:
The patent introduces an intermediary substance (silicon-based coating material such as sol-gel formulations or polysilazane compounds) that acts as a mediator between the stone substrate and the protective coating. This intermediary material is specifically selected to ensure optimal adhesion to the stone surface while providing the required corrosion protection.
2Reliability
If conventional coatings are applied to stone substrates, then corrosion protection is provided, but porosity of the coating increases leading to cracks and breaks
Solution Approach 1:
The patent applies parameter changes by carefully controlling the porosity level of the coating during the coating formation process. The porosity is maintained within a specific range (3-15%) to prevent crack formation while still providing effective corrosion protection, optimizing both coating integrity and protective function.
3Reliability
If coatings with different thermal expansion coefficients are applied to stone substrates, then coating properties are improved, but thermal expansion mismatch causes cracks and breaks
Solution Approach 1:
The patent applies parameter changes by selecting coating materials with thermal expansion coefficients specifically matched to the stone substrate. This parameter matching prevents thermal expansion mismatch, eliminating the cause of cracks and breaks that would otherwise occur during temperature variations.
4Strength
If surface pre-treatment is performed to improve coating adhesion, then adhesion is improved, but treatment time and process complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the surface pre-treatment process into distinct sequential steps: polishing, cleaning with solvent, and drying. This segmented approach allows each step to be optimized independently and enables efficient process execution, reducing overall treatment time while ensuring optimal 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
The process improves mechanical, thermal, and catalytic properties, particularly corrosion resistance, by ensuring optimal coating adhesion and reducing porosity, without compromising the substrate's aesthetics.
Implementation Method 1
one or more steps of pre-treating the substrate made of stone material to be coated, in particular by carrying out one or more steps of treatment under vacuum conditions inside an autoclave
Implementation Method 2
titanium dioxide is a substance which is highly reactive to UV rays present in normal solar radiation and, when it is hit by UV rays, it can convert pollutants such as sulfur oxides (SOx), nitrogen oxides (NOx), benzene, bacteria and moulds into sodium and calcium nitrate salts and CO2
Data Source
AI summary
This invention relates to a process for treating a substrate made of stone material, preferably in the form of slabs, which process is intended to improve the mechanical, thermal and catalytic properties of said substrate. The process according to the invention provides for applying a protective coating to the outer surface of the substrate made of stone material and, in order to improve the adhesion of said protective coating to the outer surface of said substrate, it further provides for preliminarily subjecting the substrate made of stone material to be coated to one or more "pre-treatment" steps that allow to eliminate - or at least reduce - the presence of pollutants and porosity on the surface of said substrate. According to the invention, said "pre-treatment" of the substrate made of stone material comprises at least one step of treatment under vacuum conditions inside an autoclave, preferably under pressure conditions lower than 10-2 mbar. Then, after having brought said substrate back to ambient pressure, it is possible to apply and effectively adhere the protective coating to the surface of the stone material.