Water-Based Coated Glass Containers Abrasion Resistance
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Solution Overview
Problem
Glass pharmaceutical packaging faces challenges with mechanical durability due to breakage and abrasion issues, which can compromise sterility and lead to costly recalls, as conventional tempering techniques are ineffective in enhancing resistance to scratches and abrasions.
Innovation Solution
A water-based coating mixture comprising metal oxide and polymer precursors is applied to glass surfaces, forming a coating that improves mechanical durability and resistance to abrasions, with a high water content reducing environmental impact and maintaining thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermal tempering is used to strengthen glass, then resistance to blunt impacts is improved, but resistance to scratches and abrasions is not improved
Solution Approach 1:
The patent applies a coating composition comprising inorganic material (such as silicon oxide, aluminum oxide, or zirconium oxide) and organic material (such as polymers or resins) to the glass surface. This composite coating structure provides both impact resistance from the tough organic matrix and scratch resistance from the hard inorganic particles, thereby resolving the contradiction between blunt impact resistance and abrasion resistance.
Solution Approach 2:
The patent creates a surface layer with different properties than the bulk glass. The coating is applied specifically to the surface where abrasion occurs, providing localized hardening and scratch resistance while maintaining the original glass properties for impact resistance. This local quality modification allows the glass to exhibit different mechanical properties at different locations.
2Strength
If chemical tempering is used to strengthen glass, then mechanical durability is improved, but resistance to abrasions during manufacturing remains insufficient
Solution Approach 1:
The patent employs a composite coating system where inorganic particles (providing hardness and abrasion resistance) are dispersed within an organic binder matrix. This combination creates a surface layer that is highly resistant to both chemical attacks and mechanical abrasions during manufacturing processes, while the glass substrate retains its chemically tempered strength.
Solution Approach 2:
The coating is applied to the glass surface before the glass undergoes chemical tempering or other manufacturing processes. This preliminary protective layer prevents abrasions and mechanical damage from occurring during subsequent handling and processing steps, addressing the harmful effects before they can damage the glass.
3Productivity
If glass packages are subjected to high processing speeds, then productivity is improved, but mechanical damage on the surface increases
Solution Approach 1:
The coating is applied to the glass surface in advance, before the high-speed processing operations. This pre-applied protective layer acts as a sacrificial barrier that absorbs mechanical stresses and prevents direct contact between the glass surface and processing equipment, thereby preventing abrasions and mechanical damage during high-speed manufacturing.
Solution Approach 2:
The coating composition creates a cushioning layer on the glass surface that absorbs and dissipates mechanical impacts and friction forces generated during high-speed processing. This beforehand cushioning protects the underlying glass from developing cracks or surface damage that would compromise product integrity.
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 coated glass articles exhibit enhanced mechanical properties, including reduced coefficient of friction and improved strength, maintaining performance through thermal treatments and handling processes without significant color change or degradation.
Implementation Method 1
heating the water-based coating mixture to form a coating on the first surface of the glass article
Implementation Method 2
a metal oxide precursor wherein the metal oxide precursor is miscible in the water or may form an emulsion with the water
Implementation Method 3
heating the water-based coating mixture to form a coating
Data Source
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AI summary
According to one or more embodiments disclosed herein, a coated glass article may be made by a method that includes applying a water-based coating mixture onto at least a portion of a first surface of a glass article, and heating the water-based coating mixture to form a coating on the first surface of the glass article, where the coating includes metal oxide and polymer. The water-based coating mixture may include comprise water in an amount of at least 50% by weight of the water-based coating mixture, a polymer or polymer precursor, and a metal oxide precursor. The polymer or polymer precursor may be miscible in the water or may form an emulsion with the water. The metal oxide precursor may be miscible in the water or may form an emulsion with the water.