Multi-layered Coating Film Adhesion and Scratch Resistance
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Solution Overview
Problem
Existing methods for forming multi-layered coating films on plastic substrates fail to achieve excellent adhesion, weather resistance, and scratch resistance simultaneously, with previous compositions either lacking sufficient weather resistance or having insufficient adhesion to the substrate.
Innovation Solution
A method involving the use of an active energy ray-curable top coating composition containing a silsesquioxane compound with organic groups having urethane bonds and (meth)acryloyloxy groups, along with a photoinitiator, applied in a multi-layered coating film process that includes an undercoating film, to enhance adhesion and resistance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating composition containing inorganic material or inorganic-organic hybrid material is used to improve scratch resistance and weather resistance, then scratch resistance and weather resistance are improved, but adhesion to plastic substrate is insufficient
Solution Approach 1:
The invention divides the coating system into two separate layers: an undercoating layer that provides adhesion to the substrate, and a top coating layer that provides scratch and weather resistance. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The invention uses composite materials in both layers: the undercoating composition contains polyester resin combined with silane-modified polyester resin for enhanced adhesion, while the top coating composition contains poly(meth)acrylate combined with urethane(meth)acrylate and polyisocyanurate for superior durability. This composite approach allows simultaneous achievement of adhesion and resistance properties.
2Strength
If an organic-based top coating composition is used to ensure adhesion, then adhesion is maintained, but weather resistance and scratch resistance are insufficient
Solution Approach 1:
The invention separates the functional requirements into two distinct coating layers, allowing the undercoating to focus on adhesion using organic-based materials while the top coating focuses on weather and scratch resistance using a specialized composition with poly(meth)acrylate, urethane(meth)acrylate, and polyisocyanurate.
Solution Approach 2:
The top coating composition uses a composite of poly(meth)acrylate, urethane(meth)acrylate, and polyisocyanurate that provides superior weather and scratch resistance while maintaining compatibility with the undercoating layer for good adhesion performance.
3Device complexity
If a single-layer coating composition is used to simplify the process, then manufacturing complexity is reduced, but it cannot simultaneously achieve excellent adhesion, weather resistance, and scratch resistance
Solution Approach 1:
The invention divides the coating system into two layers with distinct compositions and functions. The undercoating composition contains polyester resin and silane-modified polyester resin for adhesion, while the top coating composition contains poly(meth)acrylate, urethane(meth)acrylate, and polyisocyanurate for durability. This segmentation enables simultaneous achievement of multiple performance requirements that cannot be met by a single-layer system.
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 method achieves a multi-layered coating film with superior scratch resistance, weather resistance, and adhesion to plastic substrates, addressing the limitations of previous technologies by ensuring both performance metrics are met simultaneously.
Implementation Method 1
an active energy ray-curable top coating composition (II) comprising a silsesquioxane compound (a) and a photoinitiator (b)
Data Source
AI summary
The present invention provides a method of forming a multi-layered coating film including the steps of (1) forming an undercoating film using an undercoating composition (I), and (2) forming a top coating film on the undercoating film after the formation of the undercoating film, the top coating film being formed using an active energy ray-curable top coating composition (II) containing a silsesquioxane compound (a) and a photoinitiator (b), the silsesquioxane compound (a) containing one or more organic groups each directly bonded to a silicone atom, and at least one of the organic groups having one or more urethane bonds and one (meth)acryloyloxy group.