Matte Coating Agent Resin Particle Segmentation

Solution Overview

Problem

The existing methods for molding skin materials using matte coating agents face issues with film whitening or breakage due to stretching and friction with molds, which affect moldability and the matte effect.

Innovation Solution

A matte coating agent containing a combination of resin particles with different volume average particle diameters (1 to 5 µm, 5 to 10 µm, and 10 to 20 µm) and silica particles, applied to a polyurethane resin, which helps prevent film breakage and enhances moldability by creating surface irregularities and improving heat and scratch resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a matte coating agent is applied to a thermoplastic resin base material for molding, then a matte effect is obtained, but the film is whitened or broken due to stretching and friction with molds during molding

Engineering Contradiction:

Improvematte effectVSAvoidfilm integrity during molding

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The coating agent is divided into multiple resin particle components with different hardness and particle diameters (softer particles: 5-20 μm, harder particles: 1-5 μm). This segmentation allows the softer particles to absorb stretching stress and prevent film breakage, while the harder particles maintain the matte effect by creating surface irregularities that scatter light.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating film have different particle distributions - softer resin particles are distributed throughout to provide stress absorption and flexibility, while harder resin particles are positioned at the surface to provide light scattering for the matte effect. This local differentiation of particle properties resolves the contradiction between matte appearance and film integrity.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If the coating film is made flexible to prevent breakage during molding, then moldability is improved, but the matte effect may be compromised

Engineering Contradiction:

ImprovemoldabilityVSAvoidmatte effect

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The coating agent is divided into multiple resin particle components with different hardness and particle diameters (softer particles: 5-20 μm, harder particles: 1-5 μm). This segmentation allows the softer particles to absorb stretching stress and prevent film breakage, while the harder particles maintain the matte effect by creating surface irregularities that scatter light.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating film have different particle distributions - softer resin particles are distributed throughout to provide stress absorption and flexibility, while harder resin particles are positioned at the surface to provide light scattering for the matte effect. This local differentiation of particle properties resolves the contradiction between matte appearance and film integrity.

Inventive Principle:

Principle #3Local quality

3Device complexity

If a single type of resin particle is used in the coating agent, then the formulation is simple, but the film is prone to whitening and breakage during molding

Engineering Contradiction:

Improvecoating formulation complexityVSAvoidfilm integrity during molding

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The coating agent is divided into multiple resin particle components with different hardness and particle diameters (softer particles: 5-20 μm, harder particles: 1-5 μm). This segmentation allows the softer particles to absorb stretching stress and prevent film breakage, while the harder particles maintain the matte effect by creating surface irregularities that scatter light.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coating agent uses a composite formulation combining softer resin particles (5-20 μm diameter, lower hardness) with harder resin particles (1-5 μm diameter, higher hardness). This composite structure provides both flexibility for molding and structural integrity to prevent whitening and breakage, resolving the contradiction between formulation simplicity and film reliability.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP3680299B1Lusterless paint and skin material

Publication Date: 2022.01.19 DAINICHISEIKA COLOR & CHEMICALS MFG CO LTD

AI summary

The present invention relates to a matte coating agent containing 1 to 150 parts by mass of resin particles A having a volume average particle diameter of 1 to 5 µm, 1 to 150 parts by mass of resin particles B having a volume average particle diameter of 5 to 10 µm, and 1 to 150 parts by mass of resin particles C having a volume average particle diameter of 10 to 20 µm based on 100 parts by mass of a polyurethane resin, the total content of the resin particles A, the resin particles B, and the resin particles C being 3 to 250 parts by mass based on 100 parts by mass of the polyurethane resin, and the volume average particle diameter becoming larger sequentially from the resin particles A to the resin particles B to the resin particles C.