Dual-Cure UV-Coated Insulation for Corrosion-Resistant Heat Retention
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Solution Overview
Problem
Current thermal insulation materials for high-temperature applications, such as in petroleum and power plants, face challenges with low strength, vulnerability to physical impacts and moisture, and reduced thermal insulation properties due to the inclusion of organic fibers, while lacking effective dual-curing UV film coatings that ensure uniform coverage and corrosion resistance.
Innovation Solution
A thermosetting resin composition with a water-soluble acrylic adhesive, E-Glass long fibers, and a dual-curable coating system that combines UV curing with thermal curing, using a UV-curable film to enhance scratch resistance, chemical resistance, and formability, while maintaining high thermal efficiency and water repellency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic fibers are included in thermal insulation material to improve flexibility and workability, then ease of manufacture is improved, but thermal insulation properties deteriorate due to reduced thermal resistance
Solution Approach 1:
The patent removes organic fibers from the thermal insulation material composition entirely, using only inorganic fibers (glass fiber, rock wool, ceramic fiber) to maintain thermal insulation properties while achieving flexibility and workability through alternative means such as fiber arrangement and bonding methods.
2Loss of energy
If inorganic fiber materials are used to improve thermal insulation and fire resistance, then thermal insulation properties are improved, but strength and resistance to physical impacts deteriorate
Solution Approach 1:
The patent creates a composite structure by combining inorganic thermal insulation fibers with a UV-curable resin coating layer, forming a multi-layer composite material that integrates thermal insulation functionality with protective surface properties including enhanced strength and impact resistance.
3Reliability
If conventional thermal curing is used to coat the surface of thermal insulation material, then corrosion resistance is improved, but manufacturing time and energy consumption increase due to high temperature and long cycle requirements
Solution Approach 1:
The patent replaces conventional thermal curing (heat-based chemical reaction) with UV curing (light-based photopolymerization), where a UV-reactive resin coating is cured by ultraviolet light irradiation, dramatically reducing curing time and energy consumption while maintaining or improving corrosion resistance.
4Temperature
If glass fiber mat is used to improve electrical insulation and weather resistance, then fire resistance is improved, but strength and resistance to external physical impacts deteriorate
Solution Approach 1:
The patent applies a flexible UV-cured resin film coating over the glass fiber mat, creating a protective shell that enhances impact resistance and mechanical strength while preserving the underlying glass fiber's fire resistance and electrical insulation properties.
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 dual-curable coating system provides a strong, flexible, and uniformly coated thermal insulation material with improved scratch resistance, corrosion prevention, and enhanced thermal efficiency, capable of adhering to complex surfaces and maintaining performance under high temperatures and moisture exposure.
Implementation Method 1
a UV-curable film to enhance scratch resistance, chemical resistance, and formability
Implementation Method 2
Thermal insulation is the reduction of heat loss or inflow of heat to the outside by covering the outside of the part to be kept at a constant temperature
Data Source
AI summary
The present invention relates to a heat conservation-insulating material which is coated with a UV film and has maximized heat efficiency, wherein: the material uses a thermosetting water-soluble acrylic adhesive to ensure the minimum uniform coating film thickness required for corrosion prevention of a pipe and strength reinforcement during curing and allow easy installation with flexibility and sufficient working time before the installation; and a surface of the insulating material is UV-coated and thermosetting-coated by dual-cure curing method so that even a part where light or ultraviolet rays cannot penetrate can be cured, a heat conservation-insulating material having vivid colors can be obtained even when dye and pigment are added to realize various colors, and the cutting processability is excellent to enable a uniform coating on various surfaces, such as metal, plastic, glass, ceramics, stone, wood, and various building materials, or even on sharply bent shapes.