Perforated Cross-Linked Covering Layer for Bubble-Free Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying covering layers to substrates using liquid coating preparations or partly cross-linked lacquer layers face issues such as health and environmental hazards from organic solvents, long application times, air and moisture entrapment, and aesthetic and durability problems due to air enclosure and moisture retention.
Innovation Solution
A method involving the application of a non-cross-linked adhesive layer to a substrate followed by a cross-linked covering layer with openings, which can be created using laser perforations or mechanical/chemical means, preventing air and moisture entrapment and allowing for quicker application and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid coating preparations with organic solvents are used, then the covering layer can be applied to the substrate, but health and environmental hazards arise from solvent emissions
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating system by using a powder-based cross-linked covering layer instead of liquid preparations with organic solvents. This parameter change eliminates solvent emissions while maintaining coating applicability through the use of an adhesive layer and controlled application process.
Solution Approach 2:
The patent creates an inert application environment by applying the cross-linked covering layer in a controlled manner where no volatile organic compounds are released during application. The cross-linked structure prevents solvent evaporation, effectively creating an inert atmospheric condition during the coating process.
2Manufacturing precision
If liquid coating preparations are applied carefully, then a uniform covering layer is achieved, but the process takes a relatively long time
Solution Approach 1:
The covering layer is pre-formed with cross-linking before application to the substrate. This preliminary action allows the covering layer to be prepared in advance with controlled properties, then quickly applied as a pre-formed layer, significantly reducing application time while maintaining uniformity.
Solution Approach 2:
The coating system is segmented into two independent components: an adhesive layer applied to the substrate and a separate cross-linked covering layer. This segmentation allows each component to be optimized independently - the adhesive ensures proper bonding while the pre-formed covering layer provides uniform appearance and rapid application.
3Ease of manufacture
If a partly cross-linked lacquer layer is used, then the covering layer can be applied, but air and moisture become trapped causing aesthetic defects and reduced lifespan
Solution Approach 1:
The covering layer incorporates a porous structure with openings that allow air and moisture to escape during application. This porous design prevents entrapment of gases and moisture, eliminating aesthetic defects and improving the reliability and lifespan of the coating while maintaining ease of application.
Solution Approach 2:
The patent extracts the harmful trapped air and moisture from the coating system by providing escape pathways through the porous structure of the covering layer. This extraction prevents the formation of voids and bubbles that would otherwise cause aesthetic defects and reduce coating durability.
4Ease of operation
If the covering layer is applied outside, then on-site application is achieved, but contaminants such as dust, sand, and moisture enter the coating
Solution Approach 1:
The covering layer is pre-formed and cross-linked before application, allowing it to be prepared in a controlled environment. This preliminary action enables the covering layer to be manufactured with high purity, then quickly applied on-site as a pre-formed unit, minimizing exposure to environmental contaminants.
Solution Approach 2:
The covering layer is applied as a flexible, pre-formed layer that can be handled and positioned like a thin film or sheet. This form factor allows for easy on-site application while protecting the coating material from contamination during handling and installation.
5Ease of operation
If the coating layer does not dry quickly, then application is possible, but people brush against it causing stains and damage
Solution Approach 1:
The covering layer undergoes cross-linking before application, which initiates the curing process in advance. This preliminary action creates a layer that is already partially cured and resistant to damage, allowing immediate handling and protection against staining while maintaining application flexibility.
Solution Approach 2:
Instead of applying a liquid coating that requires drying time, the patent inverts the process by applying a pre-formed, cross-linked covering layer. This inversion eliminates the vulnerable wet-drying period, as the covering layer arrives in its final cross-linked state and is resistant to damage immediately upon application.
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 results in an aesthetically pleasing, durable product with reduced environmental impact, as it prevents air and moisture entrapment, reduces contamination risks, and enhances the lifespan of both the substrate and the covering layer, while allowing for quicker and more controlled application.
Implementation Method 1
The adhesive layer further preferably consists of adhesive agent which is applied to the substrate. This adhesive agent for instance makes it possible to bind the covering layer to the substrate
Implementation Method 2
The openings in the covering layer are filled with the material of the non-cross-linked adhesive layer
Data Source
AI summary
Provided are methods for applying a covering layer to a substrate, including applying an adhesive layer in non-cross-linked state to the substrate and applying thereto a cross-linked covering layer, characterized in that the covering layer is provided with openings, and methods for manufacturing a coating package, and using the coating package.