Process for the production of a multilayer coated surface and a product containing a multilayer coated surface
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Solution Overview
Problem
Existing methods for producing multilayer coated surfaces on furniture and other carriers fail to achieve a significant difference in gloss between layers, limiting the visual and haptic effects that can be achieved, and often require the use of matting agents or excimer treatments, which can be costly and restrictive.
Innovation Solution
A method involving the application of at least two electron curable varnish layers, where one layer is refined with an excimer lamp and the other with electron beam or UV light, allowing for varying gloss levels and adhesion enhancement without the need for matting agents in all layers, enabling the creation of three-dimensional decorative surfaces with distinct gloss and texture effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If excimer treatment is applied to all varnish layers, then a matte effect is achieved, but production costs increase and process complexity increases
Solution Approach 1:
The patent applies different treatments to different layers: the first varnish layer is treated with excimer radiation to create a matte effect, while the second varnish layer is cured with electron beam or UV radiation to maintain gloss. This local differentiation of treatment methods allows selective matte effect application, reducing overall excimer usage and costs while achieving the desired visual contrast between layers.
2Shape
If excimer treatment is applied to all varnish layers, then a matte effect is achieved, but the number of treatment steps increases
Solution Approach 1:
The patent implements local quality by applying excimer treatment only to the first varnish layer while using electron beam or UV radiation for the second layer. This selective approach reduces the number of excimer treatment steps from two to one, simplifying the overall process while maintaining the matte effect where needed and preserving gloss where desired.
Solution Approach 2:
The patent segments the curing process into two distinct parts: excimer radiation for the first layer and electron beam/UV radiation for the second layer. This segmentation allows optimization of each layer's surface properties independently, reducing overall process complexity by avoiding redundant excimer treatment steps.
3Device complexity
If the same treatment is applied to all layers, then process simplicity is maintained, but visual effect and gloss difference between layers is insufficient
Solution Approach 1:
The patent applies local quality by using excimer radiation specifically on the first varnish layer to create a matte surface, while applying electron beam or UV radiation to the second layer to maintain gloss. This localized treatment differentiation creates significant gloss contrast between layers, enhancing the visual effect while maintaining reasonable process simplicity.
Solution Approach 2:
Instead of applying the more complex excimer treatment to all layers, the patent inverts the approach by using it only where needed (first layer) and employing simpler electron beam or UV radiation for the second layer. This inversion achieves superior gloss differentiation while simplifying the overall process.
4Shape
If matting agents are added to all layers, then matte effect is achieved, but material cost and formulation complexity increase
Solution Approach 1:
The patent replaces the chemical approach (adding matting agents to all layers) with a physical approach (applying excimer radiation to the first layer). This substitution eliminates the need for matting agents in the second layer, reducing material costs and formulation complexity while achieving the desired matte effect through controlled physical treatment.
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 method allows for the production of surfaces with greater gloss differences between layers, achieving a matte or glossy effect depending on layer treatment, providing enhanced visual and haptic experiences while reducing costs by minimizing excimer treatment usage.
Implementation Method 1
the layer which is applied first, counting from the side of the carrier, containing an interlayer adhesion increasing additive, is irradiated with an excimer lamp
Implementation Method 2
pre-polymerized by electron radiation or UV light
Implementation Method 3
pre-polymerized by electron radiation or UV light
Implementation Method 4
the combined layers are cured by electron radiation or UV light
Implementation Method 5
the combined layers are cured by electron radiation or UV light
Data Source
AI summary
The method according to the invention consists in that the carrier is covered with at least two varnished layers, the two layers being made of electron curable varnishes, which may contain an additive increasing adhesion between the layers, and if the layer which is applied first, counting from the side of the carrier, containing an interlayer adhesion increasing additive, is irradiated with an excimer lamp and then pre-polymerized by electron radiation or UV light, then after applying the second layer also containing an interlayer adhesion increasing additive, the combined layers are cured by electron radiation or UV light. On the other hand, if the layer applied first, counting from the carrier side, is only pre-polymerized by electron radiation or UV light, then after applying the second layer, which then contains an additive increasing adhesion between the layers, it is subjected to irradiation by an excimer lamp and then the combined layers are cured by electron radiation or UV light. As a result, it is possible to obtain a product whose layer refined with excimer lamp and the layer only cured with electron radiation or UV light, are bound together regardless of the order of their occurrence.