Hard Coating Composition Anti-Fouling UV Curing
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Solution Overview
Problem
Existing hard coating compositions lack sustained anti-fouling properties, scratch resistance, and abrasion resistance, and are difficult to form using high-cost equipment or require high temperatures, while existing water-repellent treatments provide temporary hydrophobicity that is easily removed by rain or washing water.
Innovation Solution
A composition comprising polysilazane, a reactive solvent with a hydroxyl group, titanium dioxide, and zirconia, which forms a hard coating layer through a process that includes UV curing, providing long-lasting anti-fouling, scratch resistance, and abrasion resistance by converting into dense silica glass and utilizing photocatalytic decomposition for self-cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PECVD, CVD or sputtering is used to form a silica film, then scratch resistance and abrasion resistance are improved, but the apparatus cost is high and control for forming a good-quality film is difficult
Solution Approach 1:
The patent replaces complex physical vapor deposition apparatus (PECVD, CVD, sputtering) with a simple dip-coating or spray-coating process. The silica film is formed by coating a sol-gel composition containing tetraethyl orthosilicate (TEOS) and catalyzing it with acid or base, eliminating the need for expensive vacuum equipment and complex process control systems while achieving comparable scratch resistance
Solution Approach 2:
The patent changes the process parameters from high-vacuum plasma conditions to ambient temperature and pressure conditions. By using sol-gel chemistry with controlled pH (acid or base catalysis) and simple thermal treatment at 400-600°C, the patent achieves film formation without requiring the extreme parameters of PECVD or sputtering equipment
2Ease of manufacture
If sol-gel process is used to form a silica film, then the process is simple and accessible, but a high burning temperature of 500° C. or more is required
Solution Approach 1:
The patent modifies the sol-gel process parameters by using catalysts (acid or base) to accelerate the hydrolysis and condensation reactions of TEOS. This allows the gelation and subsequent drying to proceed at lower temperatures, reducing the burning temperature requirement from 500°C or higher to 400-600°C, while maintaining process simplicity and accessibility
3Reliability
If water-repellent wax is applied to form a hydrophobic coating, then hydrophobicity is achieved, but the hydrophobic effect is temporary and easily removed by rainwater or washing water
Solution Approach 1:
The patent creates a composite material system combining organic polymers (acrylic resin, polyurethane resin, or epoxy resin) with inorganic hydrophobic particles (silica, alumina, or titania). This composite coating provides both mechanical durability from the polymer matrix and sustained hydrophobicity from the inorganic particles, resulting in long-lasting anti-fouling properties that resist removal by water
Solution Approach 2:
The patent utilizes the porous structure of the inorganic particle network within the polymer matrix to trap and retain hydrophobic substances. The porous morphology provides high surface area and capillary action that maintains hydrophobic effect over extended periods, preventing easy removal by rainwater or washing water
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 composition achieves excellent self-cleaning, antibacterial properties, and sustained superhydrophilicity, maintaining performance even after light exposure ends, with improved adhesion and mechanical properties, suitable for automotive and building surfaces.
Implementation Method 1
which forms a hard coating layer through a process that includes UV curing
Implementation Method 2
utilizing photocatalytic decomposition for self-cleaning
Implementation Method 3
The composition achieves excellent self-cleaning, antibacterial properties, and sustained superhydrophilicity
Data Source
AI summary
Provided is a composition for forming a hard coating layer including about 0.1 wt % to about 15 wt % of a polysilazane, about 55 wt % to about 94.6 wt % of a reactive solvent containing hydroxyl group, about 5 wt % to about 20 wt % of a titanium dioxide (TiO2), and about 0.3 wt % to about 10 wt % of a zirconia (ZrO2). The composition provides a hard coating film which has excellent anti-fouling and superhydrophilicity, scratch resistance, abrasion resistance, antimicrobial property, weatherability, and a method for manufacturing the same which allow non-vacuum wet coating, thereby shortening fabrication time and providing excellent processability.