Photocurable Coating for Bent Deco Films
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Solution Overview
Problem
Deco films attached to bent products experience high defective rates due to peeling off from plastic substrates, especially under high temperature and high humidity conditions, leading to poor adhesion and deformation.
Innovation Solution
A photocurable composition comprising urethane acrylamide oligomers derived from urethane prepolymers with isocyanate end groups and polar group-containing acrylamides, urethane acrylate oligomers from urethane prepolymers with isocyanate end groups and polar group-containing (meth)acrylates, and amide group-containing acrylic polymers, which form a durable coating layer upon curing, enhancing adhesion and maintaining shape on curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a transparent film is used on a plastic substrate for deco films on bent products, then the product can be made eco-friendly and aesthetic patterns can be formed, but the transparent film peels off from the substrate in a short period of time
Solution Approach 1:
The patent uses a composite coating system consisting of multiple layers: a bottom coat layer containing reactive diluents and photoinitiators, and a top transparent film layer. The layers are chemically bonded through UV-curable composition that forms strong adhesion to both the plastic substrate and the transparent film, preventing peeling while maintaining aesthetic patterns.
Solution Approach 2:
The patent modifies the chemical composition parameters of the coating layers by incorporating specific reactive diluents (polyol compounds with hydroxyl groups) and photoinitiators that undergo chemical transformation upon UV exposure. This parameter change enables the coating to form strong chemical bonds with the substrate and transparent film, dramatically improving adhesion durability.
2Adaptability or versatility
If a deco film is attached to a bent product, then the product design is enhanced, but the transparent film falls off under high temperature or high humidity conditions
Solution Approach 1:
The patent employs a multi-layer composite structure where the bottom coat layer acts as a strong adhesive interface between the plastic substrate and the transparent film. The composition includes polyol-based reactive diluents that form robust chemical bonds, ensuring the transparent film remains attached under high temperature and high humidity conditions while allowing diverse product designs.
Solution Approach 2:
The patent applies different functional properties to different layers: the bottom coat layer is designed with high adhesion properties containing reactive diluents and photoinitiators for strong bonding, while the top layer maintains transparency and aesthetic qualities. This local differentiation of material properties ensures both design flexibility and reliability under severe conditions.
3Ease of manufacture
If conventional coating materials are used on bent surfaces, then the application process is simple, but deformation occurs under high temperature and high humidity conditions
Solution Approach 1:
The patent changes the chemical composition parameters by using UV-curable materials that undergo rapid polymerization upon UV exposure. This parameter change allows the coating to be applied simply in liquid form and then transformed into a stable, deformation-resistant solid structure that maintains shape integrity under high temperature and high humidity conditions.
Solution Approach 2:
The patent replaces traditional thermal curing mechanisms with UV photopolymerization. The UV-curable composition undergoes rapid chemical bonding when exposed to UV light, creating a stable cross-linked network structure that provides excellent shape stability under severe conditions without requiring complex thermal processing equipment.
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 coating layer provides excellent adhesion and durability on bent articles, maintaining its form and integrity even under high temperature and high humidity conditions, reducing peeling and deformation issues.
Implementation Method 1
photocurable composition including: a urethane acrylamide oligomer derived from a first urethane prepolymer having an isocyanate end group and a polar group-containing acrylamide; a urethane acrylate oligomer derived from a second urethane prepolymer having an isocyanate end group and a polar group-containing (meth)acrylate
Data Source
AI summary
A photocurable composition is provided. The photocurable composition includes: a urethane acrylamide oligomer derived from a first urethane prepolymer having an isocyanate end group and a polar group-containing acrylamide; a urethane acrylate oligomer derived from a second urethane prepolymer having an isocyanate end group and a polar group-containing (meth)acrylate; and an amide group-containing acrylic polymer derived from acrylamide and a polar group-containing (meth)acrylate.