A COATING COMPOSITION, COATING AND METHODS OF FORMING THE SAME

Abstract

The present invention relates to a coating composition including polysilazane mixed in a suitable solvent, and nanoparticles dispersed therein, a method of forming the coating composition, a method of forming the coating and a coating.

Claims

1-23. (canceled)

24. A coating composition comprising: polysilazane mixed in a suitable solvent, wherein the polysilazane comprises of a mixture of perhydro-polysilazane and organic polysilazane and wherein the perhydro-polysilazane is no more than 1 part to 3 parts by a mass fraction of the organic polysilazane, and TiO2 nanoparticles and Ag nanoparticles dispersed therein.

25. The coating composition according to claim 24, wherein the coating composition consists of polysilazane mixed in the suitable solvent, and nanoparticles dispersed therein.

26. The coating composition according to claim 24, wherein the mass fraction between perhydro-polysilazane is at least 1 part to 10 parts by mass of the organic polysilazane.

27. The coating composition according to claim 24, wherein a weight percent of polysilazane is any value selected from a range of about 1% to about 10% of the coating composition.

28. The coating composition according to claim 24, wherein a weight percent of polysilazane is any value selected from a range of about 2% to about 3% of the coating composition.

29. The coating composition according to claim 24, further comprising Al.sub.2O.sub.3 nanoparticles having a size.

30. The coating composition according to claim 29, wherein the size of the Al.sub.2O.sub.3 nanoparticles is any value selected from a range of about 1 nm to about 10 nm.

31. The coating composition according to claim 29, wherein the size of the Al.sub.2O.sub.3 nanoparticles is any value selected from a range of about 1 nm to about 5 nm.

32. The coating composition according to any one of claim 29, wherein a weight percent of the Al.sub.2O.sub.3 nanoparticles is at least about 2% and not more than about 5% of the coating composition.

33. The coating composition according to claim 29, wherein a weight percent of the Al.sub.2O.sub.3 nanoparticles is 2% of the coating composition.

34. The coating composition according to claim 24, wherein a size of the TiO.sub.2 nanoparticles and a size of the Ag nanoparticles is any value selected from a range of about 1 nm to about 10 nm.

35. The coating composition according to claim 24, wherein a size of the TiO.sub.2 nanoparticles and a size of the Ag nanoparticles is any value selected from a range of about 1 nm to about 5 nm.

36. The coating composition according to claim 24, wherein a weight percent of the TiO.sub.2 nanoparticles and Ag nanoparticles is at least about 2% and not more than about 5% and at least about 0.1% and not more than about 1% of the coating composition respectively.

37. The coating composition according to claim 24, wherein the suitable solvent is inert.

38. A method of forming a coating composition, the method comprising: mixing polysilazane into a suitable solvent to form a mixture, wherein the polysilazane comprises of a mixture of perhydro-polysilazane and organic polysilazane; and wherein perhydro-polysilazane is no more than 1 part to 3 parts by mass of the organic polysilazane, and mixing TiO2 nanoparticles and Ag nanoparticles into the mixture comprising the organic polysilazane and the suitable solvent.

39. A method of forming a coating, the method comprising: applying the coating composition onto a substrate, and allowing the coating composition to cure to form the coating.

40. The method according to claim 39, wherein the coating composition is cured at about 200 C.

41. The method of claim 39, wherein the coating comprising: polysilazane; and TiO2 nanoparticles and Ag nanoparticles dispersed in the polysilazane, wherein the polysilazane comprises of a mixture of perhydro-polysilazane and organic polysilazane; and wherein the perhydro-polysilazane is no more than 1 part to 3 parts by mass of the organic polysilazane.

42. The method of claim 39, wherein the coating consisting of: polysilazane; and TiO2 nanoparticles and Ag nanoparticles dispersed in the polysilazane, wherein the polysilazane comprises of a mixture of perhydro-polysilazane and organic polysilazane; and wherein the perhydro-polysilazane is no more than 1 part to 3 parts by mass of the organic polysilazane.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0033] FIG. 1 shows a schematic view of an exemplary embodiment of a coating composition.

[0034] FIG. 2 shows a flow diagram of a method of forming a coating composition.

[0035] FIG. 3 shows a flow diagram of an exemplary method of forming a coating.

[0036] FIG. 4 shows a schematic view of an exemplary embodiment of the coating.

DETAILED DESCRIPTION

[0037] FIG. 1 shows a schematic view of an exemplary embodiment of a coating composition 100. Coating composition 100 includes polysilazane 110 mixed in a suitable solvent 120 and nanoparticles 130 dispersed therein. Coating composition 100 may be coated onto a substrate (not shown in FIG. 1), e.g. metal or polymer. Coating composition 100 may consist essentially of polysilazane 110, nanoparticles 130 and the solvent 120.

[0038] Polysilazane 110 may act as a binder to bind the nanoparticles 130. Polysilazane 110 may be composed of organic-polysilazane (OPSZ). Polysilazane 110 may be composed of perhydro-polysilazane (PHPS). Polysilazane 110 may be composed of perhydro-polysilazane and organic-polysilazane. The mass fraction between perhydro-polysilazane and organic polysilazane may be at least 1 to 10. Preferably, the mass fraction may not be more than 1 to 8. Preferably, the mass fraction may not be more than 1 to 5. Preferably, the mass fraction may not be more than 1 to 3.

[0039] Coating composition 100 may be composed of polysilazane 110, the nanoparticles 130, and a solvent 120. For example, the coating composition 100 may include a mixture of perhydro-polysilazane and organic-polysilazane in the solvent 120 with the nanoparticles 130 blended and dispersed therein. The weight percent (wt %) of the polysilazane 110 may be any value selected from the range of about 1% to about 10% of the coating composition 100, e.g. about 1% to about 8%, about 1% to 5%. Preferably, the weight percent of the polysilazane 110 may be any value selected from the range of about 2% to about 3% of the coating composition 100 so that the desired thickness of the cured coating may be achieved, e.g. between about 1 m to about 5 m. The solvent weight may be at least about 80% of the coating composition 100. Preferably, the solvent weight may be not more than about 99%. Solvent weight may be not more than 90%. Solvent 120 may be inert and may include, but not limited to, di-n-butyl ether, petroleum distillates, and/or alcohols.

[0040] Nanoparticles 130 may be Al.sub.2O.sub.3 nanoparticles. Coating of polysilazane 110 with Al.sub.2O.sub.3 nanoparticles dispersed therein has good electrical insulating property and is suitable for electrical insulation for wire and strips, etc. Nanoparticles 130 may be TiO2 and Ag nanoparticles. Coating of polysilazane 110 and TiO2 and Ag nanoparticles dispersed therein has anti-microbial property. Nanoparticles 130 may be of the size of any value selected from a range of about 1 nm to about 10 nm, e.g. 2 nm, 4 nm, 6 nm, 8 nm. Preferably, the size of the nanoparticles 130 may be selected from a range of about 1 nm to 8 nm. Preferably, the size of the nanoparticles 130 may be selected from a range of about 4 nm to 6 nm. Preferably, the size of the nanoparticles 130 may be in the range of 1-5 nm. At this range, it is possible to obtain the coating with a smooth surface. Coating composition 100 may consist of Al.sub.2O.sub.3 nanoparticles and TiO2 and Ag nanoparticles.

[0041] The weight percent of the Al.sub.2O.sub.3 nanoparticles may be at least about 2% and not more than about 5% of the coating composition 100, e.g. about 3% to about 4%. Preferably, the weight percent may be about 2% to achieve the desired effect. Coating may be of a thickness of any value selected between about 2 m to about 10 m. Coating with the Al.sub.2O.sub.3 nanoparticles may achieve a DC breakdown voltage of up to 40 MV/m. Coating with the Al.sub.2O.sub.3 nanoparticles may withstand a temperature of up to 500 C.

[0042] The weight percent of the TiO.sub.2 and Ag nanoparticles may be at least about 2% and not more than about 5% and at least about 0.1% and not more than about 1% of the coating composition 100 respectively. Preferably, the weight percent may be a value selected from a range of about 2% to about 3% to achieve the desired effect. Coating may be of a thickness of any value selected between 2 m and 10 m. Coating with TiO.sub.2 and Ag nanoparticles has photocatalytic characteristic under the UV and visible light respectively. Further, the coating is effective in eradicating virus and bacteria, thus achieving anti-microbial effect.

[0043] When the Al.sub.2O.sub.3 nanoparticles and TiO.sub.2 and Ag nanoparticles are mixed into the solvent, the abovementioned weight percent of the Al.sub.2O.sub.3 nanoparticles and TiO.sub.2 and Ag nanoparticles may be applicable.

[0044] FIG. 2 shows a flow diagram of a method 2000 of forming a coating composition 100. Method 2000 includes mixing polysilazane 110 into a suitable solvent 120 in block 2010 and mixing nanoparticles 130 into the solvent 120 in block 2020. Method 2000 may include mixing perhydro-polysilazane and organic-polysilazane into the solvent 120 to obtain a mixture, blending the nanoparticles 130 into the mixture to obtain the coating composition 100. Blending the nanoparticles 130 may include shaking or mixing the mixture with the nanoparticles 130 vigorously for a duration of any value selected from a range of at least about 30 minutes and not more than about 60 minutes, e.g. 45 minutes. Method may include blending Al.sub.2O.sub.3 nanoparticles and TiO.sub.2 and Ag nanoparticles into the mixture.

[0045] FIG. 3 shows a flow diagram of an exemplary method 300 of forming a coating. Method 3000 includes applying the coating composition 100 onto the substrate, allowing the coating composition 100 to cure to form the coating. Coating composition 100 may be cured at an ambient temperature, e.g. about 25 C. to about 30 C. Coating composition 100 may be cured for a duration of any value in the range of about 6 hours to about 8 hours. Curing may take place at an elevated temperature in a range of about 150 C. to about 250 C., e.g. 200 C. At such a temperature, curing may take place for a duration of about 2-3 minutes.

[0046] FIG. 4 shows a schematic view of an exemplary embodiment of the coating 400. Coating 400 may be formed by the abovementioned method 3000 of forming a coating. Coating may include polysilazane 410 and nanoparticles 430. Coating may include essentially of polysilazane 410 and nanoparticles 420. Polysilazane 410 may include perhydro-polysilazane and organic-polysilazane. Nanoparticles 430 may be Al.sub.2O.sub.3 nanoparticles. Nanoparticles 130 may be TiO.sub.2 and Ag nanoparticles. Nanoparticles 430 may be of the size of any value selected from a range of about 1 nm to about 10 nm, e.g. 2 nm, 4 nm, 6 nm, 8 nm. Preferably, the size of the nanoparticles 130 may be selected from a range of about 1 nm to 8 nm. Preferably, the size of the nanoparticles 130 may be selected from a range of about 4 nm to 6 nm. Preferably, the size of the nanoparticles 130 may be in the range of 1-5 nm. Coating may consist of Al.sub.2O.sub.3 nanoparticles and TiO.sub.2 and Ag nanoparticles.