High-Gloss ABS Sheet via PEDOT-PSS and PVDF-TE Coating

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Solution Overview

Problem

Conventional methods for improving the gloss of acrylonitrile butadiene styrene (ABS) materials, such as double coating with polyurethane or fluorinated resins, often result in surface roughness issues due to the use of polar solvents and high-temperature processes like UV ozonization, which are not suitable for high-gloss coatings.

Innovation Solution

A method involving the sequential lamination of a hydrophilic intermediate film of poly(3,4-ethylenedioxythiophen)-polystyrene sulfonate and a fluorinated resin film of poly(vinylidene fluoride-trifluoroethylene) on a hydrophilized ABS substrate, using a surfactant solution and water-soluble polymers to enhance surface properties without causing scratches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If UV ozonization is used to prepare the ABS surface for coating, then the surface can be activated for coating, but scratches are formed on the surface which worsens surface roughness

Engineering Contradiction:

Improvecoating adhesionVSAvoidsurface roughness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A hydrophilic intermediate layer is introduced between the ABS substrate and the fluorinated resin coating. This intermediate layer serves as a mediator that provides both coating activation and surface smoothing functions, eliminating the need for UV ozonization that causes scratches.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical/chemical action of UV ozonization is replaced by a chemical coating process using a hydrophilic polymer solution. The intermediate layer is applied through coating and drying processes rather than high-energy UV treatment, avoiding surface damage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Illumination intensity

If powder coating method is used to apply fluorinated resin, then high gloss can be achieved, but high temperature heating is required which exceeds the melting point of ABS

Engineering Contradiction:

ImproveglossVSAvoidheating temperature

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The coating method is changed from powder coating requiring high temperature sintering to solution coating followed by low-temperature drying. The fluorinated resin is applied as a solution and dried at temperatures below the ABS melting point, preventing substrate damage while achieving high gloss.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The thermal sintering process is replaced by a solvent evaporation process. Instead of using heat to melt and fuse powder particles, the coating is applied as a solution and the solvent is evaporated at low temperature, leaving a solid fluorinated resin film.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If solution coating method is used to apply fluorinated resin, then low temperature processing is possible, but polar solvents dissolve the ABS substrate

Engineering Contradiction:

Improveprocessing temperatureVSAvoidsubstrate integrity

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The hydrophilic intermediate layer acts as a protective barrier between the polar solvent and the ABS substrate. It prevents the solvent from attacking and dissolving the substrate while allowing the fluorinated resin to be applied and dried at low temperatures.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface properties are modified locally by introducing a hydrophilic intermediate layer with specific chemical characteristics. This layer has affinity for both the polar solvent and the substrate, creating a localized protective zone that prevents solvent-substrate interaction.

Inventive Principle:

Principle #3Local quality

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

This approach significantly improves surface roughness and gloss of ABS sheets, achieving a high-gloss finish suitable for vehicle interiors while maintaining a smooth, scratch-free surface.

Implementation Method 1

coating a surfactant solution on the substrate

Methodology Applied

Scientific EffectSurfactant action: Surfactant

Implementation Method 2

drying surfactant-coated ABS substrate

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

coating a fluorinated polymer solution of poly(vinylidene fluoride-trifluoroethylene) on top of the intermediate film

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS10370512B2Process for preparing coated ABS sheet

Publication Date: 2019.08.06 HYUNDAI MOTOR CO LTD

AI summary

A method of preparing an acrylonitrile butadiene styrene (ABS) sheet includes: a first step of hydrophilizing the surface of an ABS substrate by coating a surfactant solution on the substrate; a second step of washing the surfactant-coated ABS substrate with distilled water and drying the surfactant-coated ABS substrate; a third step of forming an intermediate film by coating poly(3,4-ethylenedioxythiophen)-polystyrene sulfonate (PEDOT-PSS) on top of the dried ABS substrate; and a fourth step of coating a fluorinated polymer solution of poly(vinylidene fluoride-trifluoroethylene) on top of the intermediate film.