Aqueous Substrate Coatings Cured by Electron Beam in Air

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Solution Overview

Problem

Electron beam (EB) curing of coatings and inks requires expensive inerting to remove atmospheric oxygen, which is particularly costly for large reaction chambers and three-dimensional objects, and UV curing struggles with thick, pigmented coatings due to poor light penetration.

Innovation Solution

A method involving the application of a radiation curable aqueous composition containing a dispersed polymeric binder, thermally dried to form a dust-free or dry-hard film, allowing electron beam curing in air atmosphere without inertization, using polyurethane or polyacrylate-polyurethane copolymers with unsaturated reactive diluents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If electron beam curing is performed in air atmosphere, then operating costs are reduced by eliminating inert gas, but oxygen inhibition prevents effective curing

Engineering Contradiction:

Improveoperating costsVSAvoidcuring effectiveness

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The coating is pre-dried to remove water before EB curing, creating a dust-free or dry-hard film that protects the adhesive composition from oxygen inhibition during subsequent curing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dried coating film itself creates a protective environment that excludes atmospheric oxygen from the adhesive layer, enabling curing in air without external inert gas

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Speed

If UV light is used for curing, then curing speed is rapid, but penetration capacity is poor for thick or pigmented coatings

Engineering Contradiction:

Improvecuring speedVSAvoidcoating thickness

Core Design Contradiction:

SpeedVSLength of stationary object

Solution Approach 1:

UV light (electromagnetic radiation) is replaced with electron beam (particle radiation), which has superior penetration capacity through thick and pigmented coatings while maintaining rapid curing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If inert gas is used for EB curing, then oxygen inhibition is prevented, but investment and operating costs increase

Engineering Contradiction:

Improvecuring effectivenessVSAvoidinert gas consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The coating composition itself provides the protective function by forming a dust-free film that excludes oxygen, eliminating the need for external inert gas

Inventive Principle:

Principle #25Self-service

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

Enables efficient curing of thick coatings on various substrates in air, reducing operating costs by eliminating the need for inert gas, while achieving coatings with excellent chemical resistance and hardness comparable to those cured in inert atmospheres.

Implementation Method 1

electron beam curing the thermally dried composition

Methodology Applied

Scientific EffectElectron beam curing: Electron Beam

Implementation Method 2

EB coatings are based on the free-radical polymerization of monomers, oligomers and polymers that are typically acrylate-functionalized

Methodology Applied

Scientific EffectFree-radical polymerization: Photopolymerisation

Implementation Method 3

thermally drying the aqueous composition

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12453985B2Method of coating a substrate by electron beam curing

Publication Date: 2025.10.28 LAMBERTI SPA

AI summary

Method of coating a substrate comprising the steps of: i) applying to the substrate a radiation curable aqueous composition comprising a dispersed polymeric binder, ii) thermally drying the aqueous coating composition and iii) electron beam curing the coating composition, the method being characterized by the fact that the aqueous coating composition is a physically drying, film-forming aqueous composition and that the curing is performed in air atmosphere.