Ceramic composite wall covering

Abstract

Disclosed is a wallcovering assembly consisting of a base material and at least one ceramic coating/topcoat with or without an optional ceramic interlayer.

1 - 25 . (canceled) 
     
     
         26 . A process for forming a wallcovering assembly comprising a base layer, one or more ceramic interlayers present on the base layer and a ceramic coating covering the base layer and the ceramic interlayers, wherein the process comprises:
 applying a suspension to the ceramic interlayers present on the base layer, and   solidifying the suspension to form the ceramic coating,   wherein the ceramic coating comprises ceramic particles selected from the group consisting of oxides of metals, oxides of semimetals, nitrides of metals, nitrides of semimetals, borides of metals, borides of semimetals, carbides of metals and carbides of semimetals embedded in a matrix consisting of a silicon network linked together by Si—O—Si bridges,   wherein the ceramic interlayer comprises particles selected from the group consisting of at least one metal, at least one semimetal and at least one mixed metal with at least one element of the third to seventh main group, wherein the particles are bonded to each other and to the layer present underneath the ceramic interlayer by at least one inorganic adhesive, and   wherein at least one of the ceramic coating and the ceramic interlayer comprise an inorganic-organic silicon network including an organic component covalently bonded between silicon atoms, and wherein the organic component has a hydroxyl group and an amine group and a structural unit of the following formula (II):   
       
         
           
           
               
               
           
         
         wherein R 10  is an organic radical. 
       
     
     
         27 . The process of  claim 26 , wherein the ceramic coating comprises POSS clusters or hydrophobicized silicas as particles. 
     
     
         28 . The process of  claim 26 , wherein the ceramic coating is transparent to electromagnetic radiation having a wavelength in the region of visible light. 
     
     
         29 . The process of  claim 26 , wherein the ceramic interlayer comprises particles of oxides selected from the group consisting of Al 2 O 3 , ZrO 2 , TiO 2  and SiO 2  having an average particle size from 200 nm to 5 μm, and a silicon network,
 wherein the silicon of the network is bonded via oxygen atoms to the oxides of the ceramic coating, via organic radicals to the layer underneath the ceramic coating and via at least one chain of carbon atoms to a further silicon. 
 
     
     
         30 . The process of  claim 26 , wherein R 10  is a substituted or unsubstituted alkyl, aryl, acyl or alkylaryl radical. 
     
     
         31 . The process of  claim 26 , wherein R 10  is a dimethylmethylene radical. 
     
     
         32 . The process of  claim 26 , wherein the wallcovering consists of the base material, the ceramic coating and the ceramic interlayer. 
     
     
         33 . A process for producing a wallcovering assembly comprising a base material, at least one ceramic interlayer and at least one ceramic coating comprising ceramic particles, wherein the ceramic interlayer is present between the base material and the ceramic coating and the ceramic interlayer contains ceramic particles of an inorganic component selected from the group consisting of at least one metal, at least one semimetal and at least one mixed metal with at least one element of the third to seventh main group, wherein the particles are bonded to each other and to an adjacent layer underneath the ceramic interlayer by at least one inorganic adhesive, wherein the process comprises:
 producing the ceramic coating by applying a suspension comprising the ceramic particles and a polymeric sol, wherein the polymeric sol is produced by mixing at least one silane with an alcohol and an acid, onto at least one of the base material and the ceramic interlayer, and   solidifying the suspension after the applying.   
     
     
         34 . The process of  claim 33 , wherein the ceramic particles are selected from the group consisting of an oxide, a nitride, a boride and a carbide, of at least one of a metal and a semimetal, and the ceramic particles are embedded in a silicon network matrix linked by Si—O—Si bridges. 
     
     
         35 . The process of  claim 33 , wherein the suspension is solidified by heating and the polymeric sol comprises at least one selected from the group consisting of tetraethoxysilane, 3-glycidyloxytrimethoxysilane, 3-glycidyloxytriethoxysilane and 3-methacryloyloxypropyltrimethoxysilane. 
     
     
         36 . The process of  claim 33 , wherein the suspension comprises at least one of a diol and a polyol. 
     
     
         37 . The process of  claim 33 , further comprising:
 producing the suspension in two steps:
 first—producing a mixture of a first silane, an alcohol and an acid, and stirring in the ceramic particles are stirred, 
 second—adding selected from the group consisting of a further silane, a diol and a polyol before heating the suspension. 
   
     
     
         38 . The process of  claim 37 , wherein in the first step the mixture comprises GLYEO, an alcohol and an acid, and in the second step at least one of AMEO and bisphenol A is added. 
     
     
         39 . The process of  claim 33 , wherein the heating takes 1 second to 2 hours at temperatures from 50 to 650° C. 
     
     
         40 . The process of  claim 33 , wherein the suspension is solidified by treatment with UV rays and the sol comprises methacryloyloxypropyltrimethoxysilane. 
     
     
         41 . The process of  claim 33 , further comprising:
 applying the ceramic interlayer comprising at least one selected from the group consisting of an adhesive, an adhesion promoter, a dye, a printing ink and a binder.   
     
     
         42 . The process of  claim 33 , wherein each layer is applied to the base material in a roll-to-roll process.