Gradient-Cured Multilayer Coating for Deformable Metal Bases
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Solution Overview
Problem
Conventional cured layers on metal bases, such as aluminum tubes, are not adherent enough, particularly when the metal base is deformed by folding or squashing, leading to potential separation and reduced chemical resistance.
Innovation Solution
A multilayer body structure is developed with specific curing ratios for the cured layers on both sides of the metal base, utilizing a curable composition cured by ultraviolet LED irradiation, ensuring high adhesion and chemical resistance, and optionally incorporating a coloring pigment-free layer for improved flexibility and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cured layer is formed on the metal base using conventional methods, then the metal base is protected against light, air, and water, but the cured layer is not adherent enough to the metal base, particularly when the metal base is deformed
Solution Approach 1:
The invention applies different curing ratios at different locations within the cured layer. The inner side (adjacent to metal base) has a curing ratio of 70-90% to ensure strong adhesion, while the outer side has a curing ratio of 50-70% to maintain flexibility. This spatial variation in curing degree resolves the contradiction between adhesion strength and overall protective function.
Solution Approach 2:
The invention changes the physical parameter of curing ratio from uniform to gradient distribution. By controlling the polymerization initiator concentration and UV irradiation conditions, the curing ratio varies continuously from the inner side to the outer side of the cured layer, optimizing both adhesion and flexibility simultaneously.
2Object-affected harmful factors
If the cured layer is highly crosslinked to improve chemical resistance, then chemical resistance improves, but the cured layer becomes brittle and loses adhesion when the metal base is folded or squashed
Solution Approach 1:
The invention creates local quality differences in the cured layer by varying the curing ratio spatially. The inner portion (70-90% cured) provides chemical resistance and adhesion, while the outer portion (50-70% cured) maintains flexibility. This local differentiation resolves the contradiction between chemical resistance and flexibility.
Solution Approach 2:
The cured layer functions as a composite material system with two distinct phases: a highly crosslinked inner phase for chemical resistance and a less crosslinked outer phase for flexibility. This composite structure allows both contradictory properties to coexist in different regions of the same material layer.
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 multilayer body achieves high adhesion to the metal base even under deformation, maintains chemical resistance, and allows for clear indication of printed layers, reducing production costs and environmental impact.
Implementation Method 1
the polymerization initiator contains a compound that can initiate polymerization upon irradiation of ultraviolet radiation from an ultraviolet LED
Data Source
AI summary
An embodiment of the present invention relates to a multilayer body and a method for producing the multilayer body, and the multilayer body includes a metal base, and a cured layer 1, the cured layer 1 having a curing ratio of 70 to 90% on the metal base side, and the cured layer 1 having a curing ratio of 50 to 70% on the side opposite to the metal base side.