IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0190957
(2002-07-08)
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등록번호 |
US-7410672
(2008-08-12)
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발명자
/ 주소 |
- Waters,James D
- Knoeppel,Ray O.
- Pfendt,Glenn
|
출원인 / 주소 |
|
대리인 / 주소 |
Michael Best & Friedrich LLP
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인용정보 |
피인용 횟수 :
1 인용 특허 :
16 |
초록
▼
A water-resistant porcelain enamel coating and method of making the same is provided. The porcelain enamel coating is prepared using a borosilicate glass frit, and mill additions of silica and a zirconia compound. The mixture is applied to a metal substrate and fired, resulting in a water-resistant
A water-resistant porcelain enamel coating and method of making the same is provided. The porcelain enamel coating is prepared using a borosilicate glass frit, and mill additions of silica and a zirconia compound. The mixture is applied to a metal substrate and fired, resulting in a water-resistant coating that resists cracking and crazing. The coating is particularly useful in water heaters. In one embodiment, the coating comprises a fine zirconia compound having a median particle size of less than 10 microns.
대표청구항
▼
What is claimed is: 1. A method of manufacturing water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: providing ground glass; adding mill additions to the ground glass to form a mixture, wherein the mill additions comprise silica and a zirconia compoun
What is claimed is: 1. A method of manufacturing water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: providing ground glass; adding mill additions to the ground glass to form a mixture, wherein the mill additions comprise silica and a zirconia compound; applying the mixture to a water heater; and firing the water heater to form the water-resistant porcelain enamel coating, wherein the silica and zirconia compound mill additions comprise at least about 25 and less than about 70 parts by weight per hundred parts by weight ground glass sufficient that the water-resistant coating resists cracking. 2. The method of claim 1 wherein the ground glass is provided by grinding a glass system. 3. The method of claim 1 wherein the ground glass comprises a sodium borosilicate glass. 4. The method of claim 1 wherein the zirconia compound comprises zircon (ZrO2.SiO2) or zirconia (ZrO2). 5. The method of claim 1 wherein the mixture comprises from about 15 to about 50 parts by weight of the silica mill addition per hundred parts by weight of the ground glass. 6. The method of claim 1 wherein the mixture comprises at least about 10 parts by weight of the zirconia compound mill addition per hundred parts by weight of the ground glass. 7. The method of claim 1 wherein the mill additions further comprise a clay. 8. The method of claim 1 wherein the coated substrate is fired at a temperature of about 1000 to about 1700�� F. (538-927�� C.). 9. The method of claim 1 wherein the coated substrate is fired at a temperature of about 1550 to about 1600�� F. (843-899�� C.). 10. The method of claim 1 wherein the ground glass comprises: about 52 weight percent SiO2, about 17 weight percent Na2O, about 10 weight percent ZrO2, less than about 4.1 weight percent F2, less than about 0.005 weight percent CaO, and greater than about 4.1 weight percent Li2O. 11. The method of claim 1, wherein the zirconia compound has a median particle size, and the median particle size is less than about 10 microns. 12. A method of manufacturing a water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: providing a ground borosilicate glass; adding mill additions to the ground glass to form a mixture, wherein the mill additions comprise (a) a zirconia compound constituting at least about 10 parts by weight per hundred parts by weight ground glass and (b) a silica compound; applying the mixture to a water heater; and firing the water heater at a temperature of about 1000�� F. to about 1700�� F. to form the water-resistant porcelain enamel coating. 13. The method of claim 12 wherein the zirconia compound comprises zircon (ZrO2.SiO2) or zirconia (ZrO2). 14. The method of claim 12 wherein the mixture comprises from about 15 to about 50 parts by weight of the silica compound mill addition and from about 10 to about 30 parts by weight of the zirconia compound mill addition per 100 parts by weight of the ground glass. 15. A method of manufacturing a water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: providing ground glass; adding mill additions to the ground glass to form a mixture, wherein the mill additions comprise silica and a zirconia compound and wherein the mixture comprises at least about 15 parts and less than about 60 parts by weight of the silica mill addition per hundred parts by weight of the ground glass; applying the mixture to a water heater; and firing the water heater at a temperature of about 1000 to 1700�� F. (538-927�� C.) to form the water-resistant porcelain enamel coating that resists cracking. 16. The method of claim 15, wherein the zirconia compound has a median particle size, and the median particle size is less than about 10 microns. 17. A method of manufacturing a water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: adding mill additions to ground glass to form a mixture, wherein the mill additions comprise a zirconia compound; applying the mixture to a water heater; and firing the water heater to form the water-resistant porcelain enamel coating. 18. The method of claim 17, wherein the zirconia compound has a median particle size of less than about 100 microns. 19. The method of claim 17, wherein the zirconia compound has a median particle size of less than about 10 microns. 20. The method of claim 17, wherein the zirconia compound has a median particle size of about 0.1 to 10 microns. 21. The method of claim 17, wherein the zirconia compound has a median particle size of about 0.1 to 5 microns. 22. The method of claim 17, wherein the zirconia compound has a median particle size of about 0.3 to 4 microns. 23. The method of claim 17, wherein the zirconia compound mill additions comprise a fine zirconia up to about 60 parts by weight per 100 parts ground glass. 24. The method of claim 17, wherein the zirconia compound mill additions comprise a fine zirconia at about 10 to about 60 parts by weight per 100 parts ground glass. 25. The method of claim 17, wherein the zirconia compound mill additions comprise a fine zirconia up to about 90 parts by weight per 100 parts ground glass. 26. The method of claim 25, wherein the zirconia compound mill additions comprise a fine zirconia at about 35 to 75 parts by weight per 100 parts ground glass. 27. The method of claim 17, wherein zirconia compound mill additions comprise a fine zirconia up to about 120 parts by weight per 100 parts by weight ground glass. 28. The method of claim 27, wherein the zirconia compound mill additions comprise a fine zirconia at about 30 to 100 parts by weight per 100 parts by weight ground glass. 29. The method of claim 17, wherein the substrate is at least a portion of a water heater. 30. The method of claim 17, wherein the portion of the water heater is an internal portion of the water heater, and the coating contacts water in the water heater. 31. The method of claim 17, wherein the mixture comprises up to about 120 parts by weight fine zirconia compound per about 100 parts by weight ground glass. 32. The method of claim 17, wherein the mixture comprises about 10 to about 80 parts by weight fine zirconia compound per about 100 parts by weight ground glass. 33. The method of claim 17, wherein the mill additions further comprise silica. 34. The method of claim 33, wherein the mixture comprises at least about 20 and less than about 120 parts by weight of a fine zirconia compound and silica per hundred parts by weight ground glass. 35. The method of claim 23, wherein the firing occurs at a temperature from about 1000�� F. to about 1700�� F. 36. The method of claim 17, wherein the zirconia compound comprises at least one of zircon (ZrO2.SiO2), zirconia (ZrO2), and a combination thereof. 37. The method of claim 17, wherein the firing occurs at a temperature from about 1000�� F. to about 1700�� F. 38. The method of claim 17, wherein the zirconia compound mill additions comprise at least about 30 parts by weight of a fine zirconia compound per about 100 parts of ground glass. 39. The method of claim 17, wherein the zirconia compound mill additions comprise at least about 10 parts by weight of zirconia per about 100 parts of ground glass. 40. A method of manufacturing a water-resistant porcelain enamel coating suitable for use on a water heater, the method comprising: adding a zirconia compound and silica to ground glass to form a mixture; applying the mixture to a water heater; and firing the water heater to form the water-resistant porcelain enamel coating, wherein the mixture comprises at least about 10 parts by weight zirconia compound per hundred parts by weight ground glass, and wherein the water-resistance of the coating is improved compared to a similar coating not comprising silica and at least about 10 parts by weight zirconia compound. 41. The method of claim 40, wherein the zirconia compound has a median particle size, and the median particle size is less than about 10 microns. 42. The method of claim 40, wherein the mixture comprises at least about 20 and less than about 100 parts by weight of fine zirconia compound and silica per hundred parts by weight ground glass. 43. The method of claim 40, wherein the firing occurs at a temperature from about 1000�� F. to about 1700�� F. 44. The method of claim 40, wherein fine zirconia compound comprises at least one of zircon (ZrO2.SiO2), zirconia (ZrO2), and a combination thereof. 45. The method of claim 40, wherein the substrate is steel. 46. The method of claim 40, wherein the substrate is at least a portion of a water heater. 47. The method of claim 46, wherein the portion of the water heater is an internal portion of the water heater and the coating contacts water in the water heater. 48. The method of claim 40, wherein the zirconia compound mill additions comprise a fine zirconia at at least about 10 and less than about 120 parts by weight per hundred parts by weight ground glass. 49. The method of claim 48, wherein the zirconia compound mill additions comprise a fine zirconia at at least about 20 and less than about 100 parts by weight per hundred parts by weight ground glass.
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