Top plate for cooking device

Abstract

A technical object of the present invention is to devise a top plate for a cooking appliance that can suppress proliferation of bacteria or mold. In order to achieve the technical object, the top plate for a cooking appliance of the present invention includes: a crystallized glass substrate having a cooking surface on which a cooking device is placed; and a decorative layer formed on the cooking surface, in which the decorative layer includes 30 vol % to 100 vol % of ZnOB.sub.2O.sub.3-based glass and 0 vol % to 70 vol % of refractory filler powder.

Claims

1. A top plate for a cooking appliance, the top plate comprising: a crystallized glass substrate having a cooking surface on which a cooking device is placed; and a decorative layer formed on the cooking surface, wherein the decorative layer comprises 30 vol % to 100 vol % of ZnO-B.sub.2O.sub.3-based glass and 0 vol % to 70 vol % of refractory filler powder, and wherein the ZnO-B.sub.2O.sub.3-based glass comprises as a glass composition, in terms of mass %, 50% to 70% of ZnO, 10% or more and less than 40% of B.sub.2O.sub.3, 0% to 25% of SiO.sub.2, 0% to 20% of Na.sub.2O, 0.1% to 5% of Al.sub.2O.sub.3, and 0.05% to 5% of Ag.sub.2O, and wherein, in terms of mass %, a content of Al.sub.2O.sub.3is larger than a content of Ag.sub.2O.

2. The top plate for a cooking appliance according to claim 1, wherein the ZnO-B.sub.2O.sub.3-based glass comprises as the glass composition, in terms of mass %, 54% to 64% of ZnO, 15% or more and less than 40% of B.sub.2O.sub.3, 2% to 20% of SiO.sub.2, and 0.05% to 0.9% of Ag.sub.2O, and 0.1% or less is substantially free of an alkali component.

3. The top plate for a cooking appliance according to claim 1, wherein the refractory filler powder comprises one kind or two or more kinds selected from cordierite, willemite, alumina, zirconium phosphate, zircon, zirconia, tin oxide, mullite, silica, -eucryptite, -spodumene, a -quartz solid solution, and zirconium phosphate tungstate.

4. The top plate for a cooking appliance according to claim 1, wherein the decorative layer is formed in a regular dot pattern, and a distance between adjacent dots in the pattern is less than 5 mm.

5. The top plate for a cooking appliance according to claim 1, wherein the decorative layer has a thickness of 10 m or less.

6. The top plate for a cooking appliance according to claim 1, wherein an area of the decorative layer is 5% to 90% of an area of an entirety of the cooking surface when viewed from a direction perpendicular to the cooking surface.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic sectional view for illustrating a top plate for a cooking appliance according to one embodiment of the present invention.

(2) FIG. 2 is a schematic plan view for illustrating a decorative layer in the top plate for a cooking appliance according to the embodiment of the present invention when viewed from a direction perpendicular to a cooking surface.

DESCRIPTION OF EMBODIMENTS

(3) In a top plate for a cooking appliance of the present invention, a decorative layer comprises at least ZnOB.sub.2O.sub.3-based glass, and as required, comprises refractory filler powder, inorganic pigment powder, and the like. The ZnO-B.sub.2O.sub.3-based glass is a component for providing an antimicrobial action. The refractory filler powder is a component for lowering a thermal expansion coefficient, and is also a component for increasing a mechanical strength. The inorganic pigment powder is a component for improving decorative properties through coloration, such as blackening. In addition to the above-mentioned components, metal powder, such as Cu powder, may be added in order to enhance a color developing property.

(4) The decorative layer comprises 30 vol % to 100 vol % of ZnOB.sub.2O.sub.3-based glass and 0 vol % to 70 vol % of refractory filler powder, preferably 50 vol % to 100 vol % of ZnOB.sub.2O.sub.3-based glass and 0 vol % to 50 vol % of refractory filler powder, more preferably 70 vol % to 100 vol % of ZnOB.sub.2O.sub.3-based glass and 0 vol % to 30 vol % of refractory filler powder, particularly preferably 90 vol % to 100 vol % of ZnOB.sub.2O.sub.3-based glass and 0 vol % to 10 vol % of refractory filler powder. When the content of the ZnOB.sub.2O.sub.3-based glass is too small (or when the content of the refractory filler powder is too large), the antimicrobial action is liable to be decreased.

(5) The ZnOB.sub.2O.sub.3-based glass preferably comprises as a glass composition, in terms of mass %, 40% to 70% of ZnO, 10% or more and less than 40% of B.sub.2O.sub.3, 0% to 25% of SiO.sub.2, 0% to 20% of Na.sub.2O, and 0% to 5% of Ag.sub.2O. The ZnOB.sub.2O.sub.3-based glass more preferably comprises as a glass composition, in terms of mass %, 54% to 64% of ZnO, 15% or more and less than 40% of B.sub.2O.sub.3, 2% to 20% of SiO.sub.2, 0.1% to 5% of Al.sub.2O.sub.3, and 0.05% to 0.9% of Ag.sub.2O, and is more preferably substantially free of an alkali component. The reasons why the ranges of the contents of the components are restricted as described above are described below. In the descriptions of the ranges of the contents of the components, the expression % represents mass %.

(6) ZnO is a major factor for providing the antimicrobial action as Zn ions. The content of ZnO is preferably from 40% to 70%, from 50% to 66%, from 54% to 64%, or from 55% to 63%, particularly preferably from 57% to 62%. When the content of ZnO is too small, the antimicrobial action is liable to be decreased. In addition, when the content of ZnO is too small, it is necessary to introduce expensive Ag.sub.2O in a large amount in order to increase an antimicrobial power, and a raw material cost is liable to rise. Meanwhile, when the content of ZnO is too large, vitrification becomes difficult.

(7) B.sub.2O.sub.3 is a glass forming component, and is also a component that can adjust antimicrobial persistence. The content of B.sub.2O.sub.3 is preferably 10% or more and less than 40%, from 15% to 38%, or from 15% to 35%, particularly preferably from 18% to 30%. When the content of B.sub.2O.sub.3 is too small, vitrification becomes difficult, and besides the antimicrobial action is liable to be decreased owing to a small elution amount of Zn ions or Ag ions. Meanwhile, when the content of B.sub.2O.sub.3 is too large, the antimicrobial persistence is liable to be decreased owing to an excessively large elution amount of Zn ions or Ag ions.

(8) SiO.sub.2 is a glass forming component, and is also a component that can adjust antimicrobial persistence. The content of SiO.sub.2 is preferably from 0% to 25%, from 1% to 25%, or from 2% to 20%, particularly preferably from 5% to 15%. When the content of SiO.sub.2 is too small, vitrification becomes difficult, and besides the antimicrobial persistence is liable to be decreased owing to an excessively large elution amount of Zn ions or Ag ions. Meanwhile, when the content of SiO.sub.2 is too large, the antimicrobial action is liable to be decreased owing to a small elution amount of Zn ions or Ag ions.

(9) An alkali component is a component that is liable to cause a decrease in water resistance and an outer appearance defect. Therefore, the contents of Li.sub.2O, Na.sub.2O, and K.sub.2O are each preferably 20% or less, 10% or less, or 5% or less, particularly preferably 1% or less. It is desired that the ZnOB.sub.2O.sub.3-based glass be substantially free of those components. The total content of the alkali component is preferably 20% or less, 10% or less, or 5% or less, particularly preferably 1% or less. It is desired that the ZnOB.sub.2O.sub.3-based glass be substantially free of the alkali component.

(10) Ag.sub.2O is a component that increases the antimicrobial action. The content of Ag.sub.2O is preferably from 0% to 5%, from 0% to 3%, from 0.05% to 0.9%, or from 0.1% to 0.9%, particularly preferably from 0.3% to 0.8%. When the content of Ag.sub.2O is too small, it is difficult to exhibit the above-mentioned effect. Meanwhile, when the content of Ag.sub.2O is too large, problems of discoloration through ultraviolet radiation and the like are liable to arise, and besides the raw material cost is liable to rise.

(11) Other than the above-mentioned components, the following components may be included.

(12) Al.sub.2O.sub.3 is a component that supports the vitrification, and is also a component that stably retains a Ag component in an ion state. Similar to Si, Al is present in the glass while being coordinated by four oxygen atoms. Al serves as a trivalent cation in the glass, and its valence is lower than that of tetravalent Si by one and therefore Al is present under a state of having a negative ion (1) charge by a charge balance with oxygen ions. Meanwhile, a Ag ion is a monovalent cation, and is stably supported on an Al site having a monovalent negative ion in a charge compensation state. Ag in an ion state has a high antimicrobial action, but has a significantly high reducing property and hence has a property of stripping off an electron from its surroundings to easily change from an ion state into a metal state. When Ag changes into a metal state, the antimicrobial action is significantly decreased. The content of Al.sub.2O.sub.3 is preferably from 0% to 7% or from 0.1% to 5%, particularly preferably from 0.5% to 5%. In addition, it is preferred that the content of Al.sub.2O.sub.3 be larger than the content of Ag.sub.2O. When the content of Al.sub.2O.sub.3 is too small, it becomes difficult to exhibit the above-mentioned effect. Meanwhile, when the content of Al.sub.2O.sub.3 is too large, the antimicrobial action is liable to be decreased owing to a small elution amount of Zn ions or Ag ions.

(13) MgO is a component that lowers a viscosity at high temperature under a state of maintaining water resistance. The content of MgO is preferably from 0% to 10% or from 0.1% to 10%, particularly preferably from 1% to 7%. When the content of MgO is too small, it becomes difficult to exhibit the above-mentioned effect. When the content of MgO is too large, vitrification becomes difficult.

(14) CaO is a component that lowers a viscosity at high temperature under a state of maintaining water resistance. The content of CaO is preferably from 0% to 15%, particularly preferably from 0.1% to 10%. When the content of CaO is too small, it becomes difficult to exhibit the above-mentioned effect. When the content of CaO is too large, vitrification becomes difficult.

(15) P.sub.2O.sub.5 is a glass forming component, and is also a component that can adjust antimicrobial persistence. The content of P.sub.2O.sub.5 is preferably from 0% to 40%, from 0% to 25%, from 0% to 10%, particularly preferably from 0% to 1%. When the content of P.sub.2O.sub.5 is too large, the antimicrobial persistence is liable to be decreased owing to an excessively large elution amount of Zn ions or Ag ions.

(16) Components other than the above-mentioned components may be included. For example, SrO, BaO, TiO.sub.2, ZrO.sub.2, CeO.sub.2, and the like may be introduced up to preferably 5%, particularly preferably 1% as a total content of these components or their respective contents.

(17) Various materials may be used as the refractory filler powder, and cordierite, willemite, alumina, zirconium phosphate, zircon, zirconia, tin oxide, mullite, silica, -eucryptite, -spodumene, a -quartz solid solution, and zirconium phosphate tungstate are preferred, and cordierite and willemite are particularly preferred from the viewpoint of compatibility with the ZnOB.sub.2O.sub.3-based glass.

(18) The content of the inorganic pigment powder is preferably from 0 mass % to 35 mass %, from 0 mass % to 30 mass %, or from 0 mass % to 25 mass %, particularly preferably from 0.1 mass % to 20 mass %. When the content of the inorganic pigment powder is too large, the content of the ZnOB.sub.2O.sub.2-based glass is relatively reduced, and the antimicrobial action is liable to be decreased.

(19) Various materials may be used as the inorganic pigment powder, and examples thereof include: colored oxides, such as NiO (green), MnO.sub.2 (black), CoO (black), Fe.sub.2O.sub.3 (brownish-red), Cr.sub.2O.sub.3 (green), and TiO.sub.2 (white); oxides, such as CrAl-based spinel (pink), SnSbV-based rutile (gray), TiSbNi-based rutile (yellow), and ZrV-based baddeleyite (yellow); composite oxides, such as CoZnAl-based spinel (blue), ZnFeCr-based spinel (brown), and CrCuMn-based spinel; and silicates, such as CaCrSi-based garnet (Victoria green), CaSnSiCr-based sphene (pink), ZrSiFe-based zircon (salmon pink), CoZnSi-based willemite (dark blue), and CoSi-based olivine (dark blue). Those materials may be mixed at the above-mentioned ratio so that a desired color may be obtained. In addition, other than the above-mentioned inorganic pigment powders, for example, ZrSiO.sub.4, talc, or the like may be mixed in an appropriate amount in order to improve concealing properties and abrasion resistance of the decorative layer.

(20) The inorganic pigment powder has an average particle diameter D.sub.50 of preferably 9 m or less, particularly preferably from 0.5 m to 4 m. The inorganic pigment powder has a maximum particle diameter D.sub.max of preferably 10 m or less, particularly preferably from 2 m to 8 m. When the particle size of the inorganic pigment powder is too large, screen printability is liable to be decreased. In addition, the color developing property of the decorative layer is liable to be decreased.

(21) In the top plate for a cooking appliance of the present invention, the decorative layer is formed on a cooking surface of a crystallized glass substrate. For example, a dot (substantially circle) pattern, a rectangular pattern, or a line pattern may be utilized as the decorative layer, and from the viewpoint of improving the aesthetic appearance, a regular dot pattern is preferred. Concerning the size of the pattern, when the decorative layer has a dot form when viewed from a cooking surface side, each dot has a diameter of preferably from 0.5 mm to 5 mm. When the decorative layer has a rectangular form, each rectangle has a side length of preferably from 0.2 mm to 4 mm. Alternatively, when the decorative layer has a lattice form or a line form, a line constituting a lattice or a line in the line pattern has a width of preferably from 0.2 mm to 5.0 mm.

(22) In the case of the regular dot pattern, a distance between adjacent dots is preferably less than 5 mm or less than 3 mm, particularly preferably less than 2 mm. When the distance between adjacent dots is too large, there is a risk in that water or droplet food adhering to the cooking surface is prevented from being brought into contact with the decorative layer, and it becomes difficult to prevent the generation of bacteria, mold, or the like.

(23) In the present invention, the area of the decorative layer is preferably 5% to 90% of the area of the entirety of the cooking surface when viewed from a direction perpendicular to the cooking surface. The area of the decorative layer falls within a range of more preferably from 15% to 80%, still more preferably from 17% to 70%, particularly preferably from 20% to 60%. When the area of the decorative layer is too small, an aesthetic action and the antimicrobial action are liable to be insufficient. In addition, there is a risk in that sliding of a cooking device cannot be suppressed sufficiently.

(24) The decorative layer has a thickness of preferably 10 m or less, particularly preferably 6 m or less. In addition, the decorative layer has a thickness of preferably 1 m or more, particularly preferably 1.5 m or more. When the thickness of the decorative layer is too large, the decorative layer may be peeled off in some cases. When the thickness of the decorative layer is too small, the aesthetic action and the antimicrobial action may be insufficient in some cases.

(25) For example, the decorative layer according to the present invention is produced as described below. First, glass powder formed of the ZnOB.sub.2O.sub.3-based glass (having added thereto the refractory filler powder, the inorganic pigment powder, or the like as required) and a vehicle are kneaded homogeneously with a triple roll mill to produce a powder paste. The vehicle is formed mainly of a solvent and a resin. The solvent is added for the purpose of uniformly dispersing the glass powder or the like while dissolving the resin. The resin is added for the purpose of adjusting the viscosity of the paste. In addition, a surfactant, a thickener, or the like may be added as required.

(26) The following resins may be used as the resin: an acrylic acid ester (acrylic resin), ethylcellulose, a polyethylene glycol derivative, nitrocellulose, polymethylstyrene, polyethylene carbonate, a methacrylic acid ester, and the like. In particular, an acrylic acid ester or ethylcellulose is preferred from the viewpoint of its satisfactory heat decomposability.

(27) The following solvents may be used as the solvent: pine oil, N,N-dimethylformamide (DMF), -terpineol, a higher alcohol, -butyrolactone (-BL), tetralin, butylcarbitol acetate, ethyl acetate, isoamyl acetate, diethylene glycol monoethyl ether, diethylene glycol monoethyl ether acetate, benzyl alcohol, toluene, 3-methoxy-3-methylbutanol, triethylene glycol monomethyl ether, triethylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monomethyl ether, tripropylene glycol monobutyl ether, propylene carbonate, N-methyl-2-pyrrolidone, and the like. In particular, -terpineol is preferred from the viewpoints of its high viscosity and satisfactory solubility of a resin or the like therein.

(28) Next, the powder paste is applied onto the cooking surface of the crystallized glass substrate with an applicator, such as a screen printer, and then subjected to a drying step and a firing step. With this, the decorative layer can be formed on the cooking surface of the crystallized glass substrate. The conditions of the drying step are generally as follows: at from 70 C. to 150 C. for from 10 minutes to 60 minutes. The firing step is a step of sintering the glass powder while decomposing and volatilizing the resin, to fix the decorative layer onto the surface of the crystallized glass substrate. The conditions of the firing step are generally as follows: at from 650 C. to 850 C. for from 5 minutes to 30 minutes. As the firing temperature in the firing step is lower, firing efficiency is improved more, but fixability between the decorative layer and the crystallized glass substrate lowers more.

(29) In the top plate for a cooking appliance of the present invention, the crystallized glass substrate has a softening temperature of preferably 700 C. or more, particularly preferably 750 C. or more from the viewpoint of preventing breakage caused by thermal shock. In addition, the crystallized glass substrate has an average linear thermal expansion coefficient in a range of from 30 C. to 750 C. of preferably from 1010.sup.7/ C. to +3010.sup.7/ C., particularly preferably from 1010.sup.7/ C. to +2010.sup.7/ C. from the viewpoint of preventing the breakage caused by thermal shock.

(30) The crystallized glass substrate has a thickness of preferably 6 mm or less, particularly preferably 4.5 mm or less. In addition, the crystallized glass substrate has a thickness of preferably 2 mm or more, particularly preferably 2.5 mm or more. When the thickness of the crystallized glass substrate is too large, a distance between a heating source and a cooking device, such as a pot, becomes large in use as a top plate for a cooking appliance of an infrared heating mode or an electromagnetic heating (IH) mode, and heating efficiency tends to be decreased. Meanwhile, the thickness of the crystallized glass substrate is too small, the glass substrate is liable to be broken at the time of cooking owing to an excessively low mechanical strength.

(31) A painted layer having a color tone, such as a pearl tone, or a luster layer formed of Lusterware may be formed on a surface of the crystallized glass substrate opposite to the cooking surface.

EXAMPLES

(32) Now, the present invention is described by way of Examples. The following Examples are merely illustrative. The present invention is by no means limited to the following Examples.

(33) Examples (Sample Nos. 1 to 11) of the present invention are shown in Table 1.

(34) TABLE-US-00001 TABLE 1 Glass composition Example (wt %) No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 ZnO 60.0 46.2 58.8 61.8 55.0 59.4 56.1 60.9 64.8 57.5 58.7 B.sub.2O.sub.3 15.0 27.1 23.9 31.5 25.0 30.2 22.8 33.1 12.9 28.5 23.9 SiO.sub.2 15.0 0.0 11.8 2.6 10.0 4.6 17.4 5.1 11.3 7.3 10.9 Ag.sub.2O 0.0 0.0 0.3 0.1 0.0 0.5 0.9 0.2 0.0 0.7 0.5 Na.sub.2O 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 MgO 5.0 1.8 5.0 3.5 5.0 4.2 2.5 0.5 0.0 3.5 5.0 CaO 5.0 8.9 0.0 0.0 5.0 0.0 0.0 0.0 0.0 0.0 0.0 Al.sub.2O.sub.3 0.0 0.0 0.2 0.5 0.0 1.1 0.3 0.2 0.0 2.5 1.0 P.sub.2O.sub.5 0.0 16.1 0.0 0.0 0.0 0.0 0.0 0.0 12.8 0.0 0.0 Refractory filler None Willemite None CDR Quartz CDR None CDR Willemite CDR None powder 50 vol % 30 vol % 20 vol % 30 vol % 30 vol % 20 vol % 20 vol % Presence or absence of cracks Abrasion resistance Antimicrobial activity Escherichia coli After treatment at 50 C. for 16 hr. Water resistance

(35) Each sample was produced as described below. First, glass raw materials were blended and mixed sufficiently so as to achieve a glass composition shown in Table 1, and then put into a crucible made of a platinum-rhodium alloy and melted at from 1,100 C. to 1,300 C. for 3 hours. After the melting, the resultant was formed into a film having a thickness of about 0.7 mm. The resultant glass film was pulverized with a ball mill, allowed to pass through a sieve having an opening of 75 microns, and further subjected to air classification, to thereby provide glass powder having an average particle diameter D.sub.50 of 3 m. The particle size of the glass powder refers to a value measured with a laser diffractometer manufactured by Shimadzu Corporation.

(36) Next, the resultant glass powder (or composite powder of glass powder and refractory filler powder) and a vehicle were mixed, and then uniformly kneaded with a three roll mill, to yield a powder paste. A vehicle obtained by dissolving ethylcellulose in -terpineol was used as the vehicle, and the mass ratio of composite powder/vehicle was adjusted to from 1 to 2. The CDR and Quartz in Table 1 represent cordierite and -quartz solid solution, respectively.

(37) Next, the powder paste was screen printed on the entirety of one surface (assumed to be a cooking surface) of a transparent crystallized glass substrate (N-0 manufactured by Nippon Electric Glass Co., Ltd., main crystal: -quartz solid solution, thickness: 4.0 mm, dimensions: 600400 mm) so that a regular dot pattern was obtained. After that, the resultant was dried at 120 C. for 20 minutes, and then loaded in an electric furnace at 720 C. and fired for 10 minutes, and naturally cooled to room temperature, to thereby form a decorative layer having a thickness of 5 m. A distance between adjacent dots was set to 1.8 mm, and the area of the decorative layer when viewed from a direction perpendicular to the cooking surface was set to 25% of the area of the entirety of the cooking surface. The decorative layer was subjected to various evaluations.

(38) The presence or absence of cracks was evaluated by observing the decorative layer, and the case in which no cracks were observed was evaluated as o, and the case in which cracks were observed was evaluated as x.

(39) The abrasion resistance was evaluated as follows: #1000 sandpaper was used to be reciprocated on the decorative layer 100 times at a load of 1.3 kg and a one-way speed of 100 mm/sec, and the case in which the decorative layer was not peeled off was evaluated as o, and the case in which the decorative layer was peeled off was evaluated as x.

(40) An antimicrobial test was performed in accordance with Film contact method as Test method I for antimicrobial power of antimicrobial products (1998 version): JIS Z2801 from Society of International sustaining growth for Antimicrobial Articles. When test microbes were Escherichia coli, the case of an antimicrobial activity of 2.0 or more was evaluated as o, and the case of an antimicrobial activity of less than 2.0 was evaluated as x. In addition, the decorative layer was immersed in warm water at 50 C. for 16 hours, and the outer appearance of the decorative layer was visually observed.

(41) As is apparent from Table 1, in Sample Nos. 1 to 11, the decorative layer had a good fixation strength, a good antimicrobial action, and good water resistance.

INDUSTRIAL APPLICABILITY

(42) The top plate for a cooking appliance of the present invention is suitably applicable to a cooking appliance, such as an electromagnetic cooking appliance or a gas cooking appliance. In addition, while the top plate for a cooking appliance of the present invention comprises the crystallized glass substrate, an amorphous glass substrate may be used instead of the crystallized glass substrate when the standard for heat resistance requirement is low.

REFERENCE SIGNS LIST

(43) 1 . . . top plate for cooking appliance 10 . . . crystallized glass substrate 11 . . . cooking surface 20 . . . decorative layer