Cure-in-Place Prepregs for Seamless Solid Surfaces

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Solution Overview

Problem

Decorative laminate composites face issues with delamination and surface degradation due to moisture, leading to an unpleasant appearance over time, and existing solid surface synthetics lack seamless integration and flexibility in application.

Innovation Solution

Development of cure-in-place prepregs composed of a polymerizable component, catalyst, and filler, which can be cured using ambient light, pressure, or heat to form flexible, print-free sheets that can be applied seamlessly to substrates, offering enhanced abrasion resistance and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If decorative laminate composite construction is used, then cost-effectiveness and ease of installation are improved, but delamination and surface degradation occur due to moisture exposure

Engineering Contradiction:

Improveease of installationVSAvoidresistance to delamination and surface degradation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite material system consisting of a radiation-curable resin matrix combined with inorganic fillers (such as aluminum trihydrate, silica, or calcium carbonate). This composite structure provides both the ease of installation characteristics of laminates and the moisture resistance of inorganic-filled composites, eliminating delamination and surface degradation while maintaining cost-effectiveness

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical and physical parameters of the resin system by incorporating radiation-curable functionality and specific filler loadings. The resin composition is designed with controlled viscosity, crosslinking density, and filler content to achieve optimal balance between ease of installation and moisture resistance, transforming the traditional laminate structure into a superior solid surface material

Inventive Principle:

Principle #35Parameter changes

2Reliability

If solid surface synthetics are used, then abrasion resistance and durability are improved, but seamless integration and flexibility in application are compromised

Engineering Contradiction:

Improveabrasion resistance and durabilityVSAvoidseamless integration and flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible resin-based prepreg material that can be applied as a thin film or sheet directly to substrates of various shapes and sizes. The radiation-curable resin system provides the durability and abrasion resistance of solid surfaces while maintaining the flexibility and conformability needed for seamless integration on complex geometries, eliminating the need for rigid cast-cured blocks

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent replaces the traditional mechanical casting and machining process with a radiation-curing system. Instead of mechanically forming and machining solid surface synthetics from rigid blocks, the material is applied in a flexible, uncured state and then cured in place through radiation exposure, enabling seamless integration while maintaining durability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional solid surface synthetics are used, then durability is improved, but machinability and repairability are reduced

Engineering Contradiction:

ImprovedurabilityVSAvoidmachinability and repairability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent creates a dynamic material system that transitions from a flexible, workable uncured state to a rigid, durable cured state. The radiation-curable resin allows the material to be applied and shaped while flexible, then transformed into a hard, durable solid surface through radiation curing, enabling both ease of repair and long-term durability

Inventive Principle:

Principle #15Dynamics

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 solution provides a durable, abrasion-resistant solid surface that maintains its appearance and can be seamlessly applied to various substrates, including complex curvatures, with improved shelf life and ease of installation.

Implementation Method 1

a photoinitiator; peroxide or both

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

It is believed the reactive mixture is cured via a free radical mechanism using hemi-perester of maleic acid

Methodology Applied

Scientific EffectFree radical mechanism:

Implementation Method 3

cured using ambient light sources, pressure, heat, incident radiation, or combinations thereof

Methodology Applied

Scientific EffectThermal curing:

Implementation Method 4

cured using ambient light sources, pressure, heat, incident radiation, or combinations thereof

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP1954748B1Prepregs and cured in place solid surfaces prepared therefrom

Publication Date: 2018.09.26 ASHLAND LICENSING & INTELLECTUAL PROPERTY LLC

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AI summary

A prepreg which is capable of being cured-in-place into a solid surface by irradiation, heating or a combination of the two is prepared. The cured-in-place solid surfaces can be used as veneer cladding for rigid substrates such as floor and wall tiles, kitchen and bath counter tops, sinks, cabinet door veneers, bath surrounds, architectural surfaces such as columns and roofs and the like.