Multilayer Coating Film Depth via Photoluminescent Pigment
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Solution Overview
Problem
Conventional multilayer coating films with a feeling of depth require complex application steps and high costs due to the separation of photoluminescent and colored pigments into distinct layers, leading to increased operations and expenses.
Innovation Solution
A method involving an intermediate coating composition with a photoluminescent pigment of specific particle size and shape, applied directly on an electrodeposition coating film, followed by a base and clear coating composition, simplifying the process while maintaining high hiding properties and reducing light transmittance to prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photoluminescent pigment and colored pigment are separated into distinct coating layers, then the feeling of depth is improved, but the number of coating steps increases and manufacturing cost rises
Solution Approach 1:
The patent combines photoluminescent pigment and colored pigment into a single intermediate coating layer, eliminating the need for separate photoluminescent and colored coating layers. This merging maintains the feeling of depth effect while reducing the total number of coating steps and associated manufacturing costs.
Solution Approach 2:
The intermediate coating layer serves multiple functions simultaneously: it provides both the photoluminescent effect and the colored pigment effect. This multi-functional layer replaces what would traditionally require separate specialized layers, simplifying the overall coating structure.
2Reliability
If photoluminescent pigment with large particle size is used, then the feeling of depth is enhanced, but peeling occurs at the interface between coating film and base material
Solution Approach 1:
The patent specifies a particle size range of 5-20 μm for the photoluminescent pigment, optimizing the balance between achieving the desired feeling of depth effect and preventing peeling. This parameter optimization ensures that particles are large enough to provide the depth effect but small enough to maintain proper adhesion to the base material.
3Ease of manufacture
If number of coating layers is reduced, then manufacturing cost and operation complexity decrease, but hiding property and light transmittance control become difficult
Solution Approach 1:
The intermediate coating layer uses a composite formulation containing both photoluminescent pigment and colored pigment together with resin components. This composite material approach allows the single layer to achieve the hiding property and light transmittance characteristics that would traditionally require multiple separate layers, maintaining manufacturing precision while reducing process complexity.
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 reduces the number of coating layers, simplifies operations, and lowers costs while achieving a multilayer coating film with enhanced feeling of depth and improved durability by avoiding peeling issues.
Implementation Method 1
an intermediate coating composition containing a photoluminescent pigment
Data Source
AI summary
A method of forming a multilayer film including an intermediate forming an uncured intermediate coating film by applying an intermediate coat containing a photoluminescent pigment directly on top of an electrodeposited coating film formed on an object to be coated, forming an uncured base coating film by applying a base coating composition containing a colored pigment on the uncured intermediate coating film, forming an uncured clear coating film by applying a clear coating composition on the uncured base coating film, and simultaneously baking and curing the uncured intermediate coating film, uncured base coating film, and uncured clear coating film. The photoluminescent pigment in the intermediate coat is a thin-film shape having a volume-average particle diameter (D50) of 5-20 μm and an average thickness of 0.01-0.3 μm.