Layered Building Board with Polyurethane-Acrylate Adhesive Coating
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Solution Overview
Problem
Existing facade panels made of fiber cement and laminated materials suffer from inadequate UV resistance, leading to color changes over time, and have glossy, difficult-to-clean surfaces with insufficient scratch resistance.
Innovation Solution
A multilayer building board is developed with a core impregnated with thermosetting resin, featuring an adhesive layer composed of isocyanates and (meth)acrylates, and a decorative layer applied directly to the adhesive layer, which is cured to form a polyurethane-acrylate bond, enhancing adhesion and surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a PMMA film with UV filters is applied to the decorative paper, then UV resistance is improved, but the surface becomes glossy and difficult to clean
Solution Approach 1:
The invention changes the surface parameters by applying a crosslinked polymer coating with specific surface energy characteristics that provides UV resistance while maintaining a non-glossy, easily cleanable surface. The coating composition and curing parameters are optimized to achieve the desired surface properties.
Solution Approach 2:
The invention uses a composite structure combining the decorative paper with a crosslinked polymer coating system. This composite provides both UV protection and improved surface properties for ease of cleaning, while avoiding the glossiness problem of PMMA films.
2Object-affected harmful factors
If a PMMA film is applied to the decorative paper, then UV resistance is improved, but scratch resistance remains insufficient
Solution Approach 1:
The invention changes the mechanical properties of the surface coating by using a crosslinked polymer system that achieves both UV resistance and enhanced scratch resistance. The crosslinking density and polymer composition are controlled to provide the required hardness and durability.
3Strength
If decorative paper impregnated with melamine resin is used, then adhesion of subsequent layers is poor, but the paper exhibits excellent mechanical properties
Solution Approach 1:
The invention introduces a surface treatment or primer layer as an intermediary between the melamine resin-coated paper and the subsequent polymer coating. This intermediary layer provides both good adhesion to the melamine surface and proper bonding properties for the final coating, solving the adhesion problem while preserving the mechanical properties of the paper.
4Object-affected harmful factors
If a thick protective layer of plastic material is applied in a single coating step, then UV protection is achieved, but complete conversion requires high energy irradiation
Solution Approach 1:
The invention divides the protective coating into multiple thinner layers that are applied and cured sequentially. This segmentation allows each layer to be fully cured with moderate energy input, avoiding the need for high energy irradiation that would be required for a single thick layer, while still providing adequate UV protection.
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 solution provides improved scratch resistance, ease of cleaning, and adherence to decorative layers, meeting EN438 outdoor application requirements and EN16094 micro-scratch resistance levels.
Implementation Method 1
a further (meth)acrylate layer is applied to this adhesive layer, which preferably has a thickness of more than 20 μm, more preferably more than 30 μm, and most preferably more than 40 μm. These two layers are then cured together
Implementation Method 2
The polymerization is triggered by irradiation, so that complete conversion occurs due to the thickness of the applied layer
Data Source
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AI summary
The present invention concerns a layered building board for inside and outside, comprising a core layer (20) and a melamine-impregnated paper (21) arranged thereon. In order to improve the adhesion of further layers, an adhesion layer (30) comprising polyurethane and acrylate is provided on the paper.