Double-Coated Radiation Curing PVC Pre-Coating Material
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Solution Overview
Problem
Existing multi-coated radiation curing pre-coating technologies for PVC transparent films are complex and require multiple layers, leading to inefficiencies in material usage, process complexity, and potential issues like whitening and cracking during the host pressing process.
Innovation Solution
A double-coated radiation curing PVC pre-coating material comprising a PVC transparent film with a radiation curing coating consisting of an elastic attached base coat and a top coat, where the elastic attached base coat contains bifunctional urethane acrylate and reactive diluent, and the top coat includes hexa-functional urethane acrylate, hard filler, and initiator, simplifying the coating process and improving adhesion and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-coated radiation curing pre-coating (4 layers) is used, then adhesion and coating performance are improved, but process complexity and material usage increase
Solution Approach 1:
The patent combines the functions of multiple coating layers (attached base coat, elastic base coat, and top coat) into a simplified double-coated structure. The radiation curing coating is divided into only two essential layers: an elastic attached base coat for adhesion and flexibility, and a top coat for surface performance, eliminating redundant layers while maintaining comprehensive coating functionality.
Solution Approach 2:
The elastic attached base coat serves multiple functions simultaneously: it provides adhesion to the PVC transparent film, ensures flexibility and elongation (50%+), and creates a suitable substrate for the top coat. This multi-functional design reduces the need for separate specialized layers.
2Reliability
If multi-coated radiation curing pre-coating (4 layers) is used, then coating performance is improved, but production efficiency decreases
Solution Approach 1:
The patent merges multiple coating steps into a simplified double-coated process. By reducing from four radiation curing coating layers to two, the number of application and curing cycles is halved, directly improving production efficiency while maintaining comprehensive coating performance through carefully designed material compositions.
Solution Approach 2:
The elastic attached base coat is designed with pre-calibrated properties (50%+ elongation, specific Tg) that are prepared in advance through controlled synthesis of bifunctional urethane acrylate and reactive diluent. This preliminary preparation ensures optimal performance without requiring additional processing steps during production.
3Strength
If conventional base coat materials are used, then adhesion is achieved, but flexibility and elongation are insufficient
Solution Approach 1:
The patent fundamentally changes the chemical and physical parameters of the base coat by using bifunctional urethane acrylate with controlled molecular weight and reactive diluent with specific glass transition temperature. This results in an elastic attached base coat with 50%+ elongation and appropriate Tg, simultaneously achieving strong adhesion and high flexibility that conventional materials cannot provide.
Solution Approach 2:
The elastic attached base coat is formulated as a composite system combining bifunctional urethane acrylate (20-50%) for adhesion and flexibility with reactive diluent (20-40%) for permeability and film flexibility. This composite material approach allows optimization of multiple properties simultaneously.
4Ease of operation
If standard reactive diluent is used, then coating application is facilitated, but adhesion to PVC layer and film flexibility are insufficient
Solution Approach 1:
The patent selects reactive diluent with specifically controlled glass transition temperature and molecular structure (using epoxy diluents with long chain segments). This parameter optimization ensures the reactive diluent provides both ease of application and excellent adhesion to the PVC transparent film, while contributing to overall film flexibility.
Solution Approach 2:
The reactive diluent acts as an intermediary substance that bridges the PVC transparent film and the cross-linked coating network. Its specific molecular structure and Tg properties enable it to penetrate and adhere to the PVC layer while maintaining compatibility with the acrylate monomers, ensuring strong interfacial adhesion.
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 simplifies the coating process, reduces material and equipment requirements, enhances adhesion and flexibility, and prevents whitening and cracking, while maintaining high tenacity and elongation, thus improving the overall performance of PVC pre-coating for applications like SPC (Stone Plastic Composites).
Implementation Method 1
applying the elastic attached base coat onto the PVC transparent film, curing it using LED lamp, applying the functional layer and the top coat successively and curing it using excimer lamp
Data Source
AI summary
This invention provides a double-coated radiation curing PVC pre-coating material, which includes the PVC transparent film and the radiation curing coating from bottom to top, and the radiation curing coating includes the elastic attached base coat and the top coat from bottom to top.