Multilayered Laminate Gloss Control via Segmented Coating Layers
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Solution Overview
Problem
Conventional methods for achieving high gloss and stone-like effects on architectural materials and wood-based substrates are challenging due to the complexity of controlling coating parameters, leading to inconsistent results and difficulties in achieving a high-gloss coating surface.
Innovation Solution
A multilayered laminate comprising a support substrate with a transparent overcoat, a stone-like topcoat system, and an adhesive primer coat, where the overcoat is formed from an aqueous polymer dispersion with specific particle size ranges and the topcoat system includes a multicolored spot layer and background color layer, providing a high gloss and stone-like effect when released from the support substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional wet coating methods are used to achieve high gloss, then gloss level can be improved, but manufacturing precision and consistency deteriorate due to difficulty in controlling coating parameters
Solution Approach 1:
The coating system is segmented into multiple functional layers: a release layer that imparts gloss, a stone-like effect layer, and an adhesive primer layer. This segmentation allows each layer to perform its specific function independently, with the release layer controlling gloss without being affected by parameters in other layers, thereby improving manufacturing precision and consistency
Solution Approach 2:
The gloss properties are preliminarily established in the release layer before application to the substrate. The release layer is pre-formed with specific polymer dispersions and curing conditions that lock in the desired gloss level, eliminating the need to control multiple parameters during final coating application, thus improving consistency
2Adaptability or versatility
If multiple coating layers are applied to achieve both stone-like effect and high gloss, then functional requirements are met, but device complexity and process difficulty increase
Solution Approach 1:
The release layer and stone-like effect layer are combined into a single laminate structure where the release layer serves dual purposes: providing gloss to the final coating and acting as a release agent during application. This merging reduces the number of separate coating steps needed while achieving both stone-like effect and high gloss
Solution Approach 2:
The release layer is designed with multi-functionality: it provides the gloss finish, acts as a release agent for easy removal from the support substrate, and serves as a protective layer during handling. This universal design reduces overall system complexity while meeting multiple requirements
Data Source
Figure 1
AI summary
This disclosure is directed to a multilayered laminate, comprising (a) a support substrate having at least one releasable major surface; (b) a transparent overcoat formed of a first coating composition on the releasable major surface of the support substrate, wherein the first coating composition comprises an aqueous polymer dispersion having a particle size in the range of 30 to 400 nm; (c) a stone-like topcoat system on the transparent overcoat, wherein the stone-like topcoat system comprises a multicolored spot layer and a background color layer; (d) an adhesive primer coat formed of a second coating composition on the stone-like topcoat system, wherein the second coating composition comprises an aqueous polymer dispersion selected from aqueous acrylic dispersions, aqueous organic silicone dispersions and aqueous vinyl acetate dispersions, wherein the transparent overcoat in the multilayered laminate, when released from the support substrate, a gloss of at least 60% at 60°.