Dual-Layer Active Energy Ray-Curable Coating for Adhesion and Scratch Resistance
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Solution Overview
Problem
Existing active energy ray-curable compositions face challenges in maintaining adhesiveness and scratch resistance, especially when exposed to severe conditions such as hot water and alkaline solutions, leading to potential peeling off from the base.
Innovation Solution
An image forming method involving two active energy ray-curable compositions: Composition A with a polymerizable monomer having a phosphoric ester group and a polyester resin for adhesiveness, and Composition B with a multifunctional polymerizable compound for scratch resistance, applied and cured in a specific sequence to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single active energy ray-curable composition is used, then the curing process is simple, but the scratch resistance and adhesiveness under severe conditions are insufficient
Solution Approach 1:
The invention divides the coating system into two separate compositions: Composition A (applied first, containing adhesion promoters) and Composition B (applied second, containing scratch resistance agents). This segmentation allows each composition to specialize in providing specific properties, with Composition A ensuring strong base adhesiveness and Composition B providing scratch resistance, thereby resolving the technical contradiction between reliability and process complexity.
Solution Approach 2:
The invention creates a composite coating structure by laminating two different active energy ray-curable compositions. Composition A forms the base layer with excellent adhesiveness to the substrate, while Composition B forms the top layer with high scratch resistance. This composite material approach allows the final cured object to simultaneously achieve both strong adhesion and scratch resistance under severe conditions.
2Reliability
If Composition A with phosphoric ester group is used, then adhesiveness to base is improved, but scratch resistance may be compromised
Solution Approach 1:
The invention separates the functions of adhesion and scratch resistance into two distinct compositions. Composition A contains phosphoric ester groups that provide excellent adhesiveness to the base, while Composition B contains components that provide scratch resistance. By applying Composition B over the cured Composition A, both properties are achieved without compromise.
Solution Approach 2:
The invention creates a composite coating where Composition A (with phosphoric ester groups for adhesion) forms the bottom layer bonded to the base, and Composition B (with scratch resistance properties) forms the top layer. This composite structure allows the phosphoric ester groups in Composition A to maximize adhesiveness while Composition B provides the necessary scratch resistance, resolving the contradiction between these two properties.
3Strength
If Composition B with multifunctional polymerizable compound is used, then scratch resistance is improved, but adhesiveness to base may be reduced
Solution Approach 1:
The invention divides the functional requirements into two compositions: Composition A (applied first) contains components optimized for base adhesiveness, and Composition B (applied second) contains components optimized for scratch resistance. This segmentation ensures that Composition B's scratch resistance components do not interfere with base adhesion, as Composition A already establishes the adhesive bond to the base.
Solution Approach 2:
The invention creates a composite coating structure where Composition A forms the adhesive base layer bonded to the substrate, and Composition B forms the protective top layer providing scratch resistance. The multifunctional polymerizable compounds in Composition B provide excellent scratch resistance in the top layer without compromising the adhesiveness established by Composition A at the base interface.
4Reliability
If dual composition application is used, then scratch resistance and adhesiveness are both improved, but the number of steps increases
Solution Approach 1:
The invention segments the coating into two compositions that can be applied in sequence. While this adds a step, each composition is optimized for specific properties, and both can be cured by active energy rays. The segmentation allows for specialized formulation of each layer to achieve maximum durability under severe conditions.
Solution Approach 2:
The invention uses a composite material approach with two active energy ray-curable compositions. Composition A is applied and cured first, then Composition B is applied and cured. This composite structure provides superior durability under severe conditions including hot water and alkaline solutions, with the dual-layer system ensuring both adhesiveness and scratch resistance are maintained.
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 achieves excellent scratch resistance and adhesiveness even after exposure to extreme conditions, preventing peeling and maintaining integrity on the base.
Implementation Method 1
an active energy ray-curable composition is cured by irradiation with an active energy ray
Data Source
Figure 1~2
AI summary
An image forming method is provided that includes: applying, on a base, an active energy ray-curable composition A containing a polymerizable monomer having a phosphoric ester group and a polyester resin; curing the active energy ray-curable composition A; applying, on a cured object of the active energy ray-curable composition A, an active energy ray-curable composition B containing a multifunctional polymerizable compound having two or more polymerizable functional groups in its molecule; and curing the active energy ray-curable composition B.