Aqueous Coating for Vehicle Interior Plastic Sheets
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Solution Overview
Problem
Conventional coating methods for vehicle interior plastic sheets using TPO materials result in inferior adhesion due to non-polarization and high crystallization, leading to health concerns from volatile organic compounds and complex processes.
Innovation Solution
A two-step aqueous coating process using a primary composition of chlorinated aqueous olefin resin and a secondary composition of aliphatic urethane, with specific weight percentages and baking temperatures, to form a coated film with excellent light resistance, scratch resistance, and thermoforming properties, eliminating volatile organic compounds and simplifying the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional three-step coating process (pretreatment, base coating, top coating) is used on TPO sheets, then adhesion property is improved, but process complexity increases and volatile organic compounds are released
Solution Approach 1:
The invention combines the pretreatment and base coating steps into a single primary coating composition containing chlorinated polyolefin resin. This merging eliminates the need for separate pretreatment processes (flame, ozone, or plasma treatment) while maintaining adhesion performance, thereby simplifying the overall coating process from three steps to two steps.
Solution Approach 2:
The primary coating composition serves multiple functions simultaneously: it acts as both a pretreatment agent (improving surface adhesion through chlorinated polyolefin resin) and a base coating layer (提供附着力 and 打底功能). This multi-functionality reduces the number of required coating steps while ensuring reliable adhesion on TPO sheets.
2Reliability
If conventional coating materials containing organic solvents are used, then coating performance is achieved, but health concerns and environmental pollution increase due to volatile organic compounds
Solution Approach 1:
The invention changes the solvent parameter from organic solvents to water as the continuous phase in aqueous resin compositions. Both the primary coating (chlorinated polyolefin resin) and secondary coating (polyester urethane resin) use water-based systems, eliminating volatile organic compounds while maintaining coating performance through controlled water evaporation and resin curing.
Solution Approach 2:
The invention converts the traditionally harmful organic solvent system into a beneficial aqueous system. By using water-based resin compositions, the harmful volatile organic compounds are eliminated, and the coating process becomes environmentally friendly while still achieving the required adhesion, light resistance, and durability properties.
3Object-generated harmful factors
If TPO sheets are used instead of PVC/ABS sheets, then environmental friendliness and odor resistance are improved, but adhesion property deteriorates due to non-polarization and high crystallization
Solution Approach 1:
The chlorinated polyolefin resin in the primary coating composition acts as an intermediary substance that bridges the TPO sheet surface and the polyester urethane resin coating. The chlorinated polyolefin resin has affinity for both the non-polar TPO surface and the polar polyester urethane resin, enabling effective adhesion despite the non-polarization and high crystallization characteristics of TPO sheets.
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 method produces coated sheets with superior light resistance, scratch resistance, and high elongation, while preventing environmental contamination and improving user satisfaction by eliminating new car odors, with a simplified coating process compared to conventional three-step methods.
Implementation Method 1
coating the plastic sheet with a primary composition, the primary (or primer) composition comprising chlorinated aqueous olefin resin
Implementation Method 2
baking the resulting plastic sheet
Implementation Method 3
baking the resulting plastic sheet
Implementation Method 4
coating the baked sheet with a secondary composition, the secondary composition comprising aliphatic urethane
Data Source
AI summary
The present invention relates to methods of forming an aqueous coating on a plastic sheet surface for vehicle interior equipment, comprising the steps of: coating the plastic sheet with a primary composition, the primary composition comprising chlorinated aqueous olefin resin; baking the resulting plastic sheet; coating the baked sheet with a secondary composition, the secondary composition comprising aliphatic urethane; and baking the resulting plastic sheet.