Cross-linked Emulsion Composition for Hard Coat Adhesion
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Solution Overview
Problem
The existing emulsion compositions used for forming hard coat layers on substrates suffer from low adhesiveness due to permeation of low molecular weight components, leading to a decrease in adhesiveness and appearance deterioration in laminates.
Innovation Solution
An emulsion composition comprising a polymerizable compound with multiple (meth)acryloyl groups, a surfactant, and water as a dispersion medium, with oil droplet diameters less than 1.8 μm, is applied to form a coating film that inhibits the permeation of low molecular weight components, enhancing adhesiveness and preventing bleed-out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a coating film is formed using conventional emulsion composition with non-cross-linked resin, then the coating film can be formed on the substrate, but the coating film has insufficient film compactness and permits permeation of low molecular weight components
Solution Approach 1:
The patent changes the chemical structure parameter of the resin from non-cross-linked to cross-linked, and controls the oil droplet size parameter to D90 < 1.8 μm. These parameter changes result in a coating film with superior compactness that prevents permeation of low molecular weight components while maintaining ease of application.
2Ease of manufacture
If the coating film allows permeation of low molecular weight components, then the coating film can be formed easily, but the low molecular weight components bleed out to the interface between the hard coat layer and coating film, decreasing adhesiveness
Solution Approach 1:
The patent changes the resin structure to cross-linked and controls oil droplet size to D90 < 1.8 μm, creating a coating film that is both easy to form and effective at preventing component permeation, thereby maintaining adhesiveness without compromising ease of manufacture.
3Device complexity
If conventional emulsion composition is used, then the coating process is simple, but the coating film has poor bleed-out preventing properties and deteriorates appearance
Solution Approach 1:
The patent modifies the emulsion composition parameters by using cross-linked resin and controlling oil droplet size to D90 < 1.8 μm. This creates a coating film with excellent bleed-out preventing properties that maintains appearance quality, while the coating process itself remains simple and straightforward.
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 emulsion composition effectively forms a coating film with superior bleed-out preventing properties, maintaining adhesiveness and appearance quality in laminates, enabling reliable production and application.
Implementation Method 1
the coating film formed from the emulsion composition is likely to permit a component having a relatively low molecular weight (relatively low molecular component) such as an oligomer and an additive contained in the substrate to permeate
Data Source
AI summary
An emulsion composition according to the present invention includes: a polymerizable compound comprising two or more (meth)acryloyl groups; a surfactant; and a dispersion medium including water as a principal component, in which an oil droplet diameter D90 corresponding to a diameter at cumulative 90% by volume in the oil droplet size distribution of oil droplets comprising the polymerizable compound and the surfactant, measured according to a laser diffraction and scattering measurement process is less than 1.8 μm. A maximum oil droplet diameter Dmax of the oil droplets, measured according to the laser diffraction and scattering measurement process is preferably less than 4.0 μm. A content of the polymerizable compound in the composition with respect to 100 parts by mass of a total of components other than the dispersion medium is preferably no less than 40 parts by mass. The oil droplets may further comprise an inorganic particle.