Temporary Acrylate Coating Shields Substrates from Scratches
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Solution Overview
Problem
Substrates with functional coatings, particularly those with metallic layers, face issues of low mechanical resistance, high scratchability, and corrosion during transport, storage, and processing stages, especially in humid environments, leading to aesthetic and performance alterations.
Innovation Solution
A temporary protective layer made from (meth)acrylate compounds with a thickness of at least 1 micrometer, applied using a solvent-free liquid composition and hardened by drying, IR baking, or UV irradiation, which provides protection against scratches and corrosion without harming the substrate's optical properties and can be easily removed during heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temporary protective layer is applied to protect the functional coating during transport and storage, then mechanical strength and corrosion resistance are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies a thin film protective layer (1-20 micrometers) composed of polymer compounds to the functional coating. This thin film acts as a flexible protective shell that shields the underlying functional coating from mechanical damage and corrosion during transport and storage, while maintaining optical transparency and not significantly increasing structural complexity.
Solution Approach 2:
The patent creates a composite structure by combining the functional coating (with specific optical and thermal properties) with a protective coating layer (with mechanical strength and corrosion resistance). This composite material system integrates the complementary properties of both layers to achieve simultaneous protection and functionality.
2Strength
If a thick protective layer is applied to ensure adequate protection, then mechanical strength is improved, but the optical properties of the substrate deteriorate
Solution Approach 1:
The patent optimizes the thickness parameter of the protective layer to fall within the range of 1-20 micrometers. This parameter optimization ensures that the layer is thick enough to provide mechanical protection and corrosion resistance, while remaining thin enough to maintain optical transparency and not significantly affect light transmission through the substrate.
3Adaptability or versatility
If multiple processing steps are performed on the substrate, then functionality is improved, but the risk of mechanical damage and corrosion increases
Solution Approach 1:
The protective layer is applied to the functional coating before the substrate undergoes various processing steps such as cutting, washing, edge shaping, assembly, and heat treatments. This preliminary protection ensures that the functional coating is shielded from mechanical damage and corrosion that may occur during these subsequent processing operations.
Solution Approach 2:
The protective layer serves multiple functions simultaneously: it provides mechanical protection against scratches and impacts, prevents corrosion from humidity and chemicals, and allows the substrate to undergo various processing steps including heat treatments up to 800°C. This multi-functionality enables the substrate to be processed and handled without requiring different protective measures for each operation.
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
The temporary protective layer effectively shields the substrates from mechanical damage and corrosion, maintaining the substrate's performance and aesthetics throughout processing stages, and can be completely eliminated without affecting the functional coating's properties, ensuring continuous manufacturing and minimizing scrap rates.
Implementation Method 1
a temporary protective layer obtained from a composition comprising (meth)acrylate compounds deposited on at least part of the functional coating
Implementation Method 2
The temporary protective layer is removed by heat treatment, in particular by combustion
Implementation Method 3
a functional coating deposited by magnetic field-assisted sputtering on at least part of a main surface
Data Source
AI summary
The invention relates to a substrate including two main sides defining two main surfaces separated by edges, said substrate having a functional coating deposited on at least one portion of a main surface and a temporary protection layer deposited on at least one portion of the functional coating. The temporary protection layer, which is hardened by drying, UV radiation or electron beam, has a thickness of at least one micrometre and is not water-soluble. Said temporary protection layer resulting from a liquid composition including (meth)acrylate compositions selected from monomers, oligomers, prepolymers or polymers including at least one (meth)acrylate function.