Matte Multilayer Surface Coating with Excimer and Electron Beam Pre-Polymerization
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Solution Overview
Problem
Current methods for achieving a matte finish on furniture surfaces with a thickness exceeding 20 μm often result in defects such as pinhead highlights due to the instability of the coating, as excimer lamps primarily affect the outer layer, leading to partial exposure of the bottom layer.
Innovation Solution
Pre-stabilizing the electron curable varnish layer by exposing it to UV radiation with wavelengths of 254 nm or 395 nm, followed by electron beam pre-polymerization, before matting with excimer rays, ensures stability and constant thickness of the multilayer structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers of electron curable varnish are applied with total thickness exceeding 20 μm and then matted with excimer lamps, then a matte finish is achieved, but defects such as pinhead highlights appear due to instability of the coating structure
Solution Approach 1:
The patent applies preliminary action by pre-polymerizing the electron curable varnish layers with an electron beam before applying the excimer lamp treatment. This preliminary electron beam treatment stabilizes the coating structure and prevents the formation of pinhead highlights and other defects that would otherwise occur during the matting process, while still achieving the desired matte finish.
2Manufacturing precision
If excimer lamps are used to matte the outer layer of varnish, then a matte effect is obtained, but the remaining coating becomes unstable causing partial exposure of the bottom layer
Solution Approach 1:
The patent applies preliminary action by pre-polymerizing the electron curable varnish layers with an electron beam before applying the excimer lamp treatment. This preliminary electron beam treatment stabilizes the coating structure and prevents the formation of pinhead highlights and other defects that would otherwise occur during the matting process, while still achieving the desired matte finish.
Solution Approach 2:
The patent changes the physical and chemical state of the varnish layers by applying electron beam radiation before excimer lamp treatment. This parameter change (electron beam irradiation) transforms the varnish from an unstable, partially cured state to a stabilized, pre-polymerized state, preventing subsequent defects during the matting process.
3Manufacturing precision
If matting agents are added to coatings to achieve matte finish, then gloss level is reduced, but rheological properties are negatively impacted and coating process becomes complicated
Solution Approach 1:
The patent replaces the mechanical addition of matting agents with a radiation-based process. Instead of physically adding particles that complicate the coating formulation and application, the patent uses electron beam and excimer lamp radiation to create the matte effect through photochemical and physical changes in the coating itself, eliminating the need for matting agents and simplifying the coating process.
Solution Approach 2:
The patent changes the physical and chemical state of the varnish layers by applying electron beam radiation before excimer lamp treatment. This parameter change (electron beam irradiation) transforms the varnish from an unstable, partially cured state to a stabilized, pre-polymerized state, preventing subsequent defects during the matting process.
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
This approach allows for the creation of stable multilayer matte surfaces with a thickness of 20-30 μm, maintaining a matte finish and preventing defects, while ensuring a clear haptic effect and aesthetic quality.
Implementation Method 1
exposing it to UV radiation with wavelengths of 254 nm or 395 nm, with each previously applied layer being pre-polymerized with an electron beam
Implementation Method 2
pre-polymerized with an electron beam with a generator power of 2-7 kGy, which causes varnish pre-polymerization
Implementation Method 3
UV excimer lamps operating at a wavelength of 172 nm cause the gelation effect of the top layer of varnish, which results in the creation of a microstructure giving a deep matte optical effect
Implementation Method 4
all electron curable varnish layers are finally cured, with full cross-linking achieved by treating the surfaces with UV radiation of a longer wavelength or with an electron beam with a defined dose
Data Source
AI summary
The invention relates to a method for the production of a matte multilayer coated surface with an increased haptic effect and a substrate with decorations in the form of wooden, stone or fancy motifs, characterized in that the topcoat electron curable varnish layer (4) is exposed to an excimer lamp and electron beam radiation and the structural electron curable varnish layer (5) is successively applied, exposed to an LED lamp emitting UV radiation with a wavelength of 395 nm or a PAC lamp with a wavelength of 254 nm and to an excimer lamp. The combined layers are cured by an electron beam with a minimum dose of 40 kGy. The invention also relates to a surface obtained by this method. The surface, according to the invention, is used as an outer layer of furniture boards.