Pre-cured Coating Layer with Integrated Support Fabric
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Solution Overview
Problem
Conventional liquid paints and lacquers pose health and environmental hazards, require laborious application, and have unpredictable drying processes leading to quality issues and inefficiencies in the wood-processing industry, often necessitating uncoated wood products.
Innovation Solution
A coating layer based on cured polyester and polyacrylate with integrated support fabric, which can be applied directly to substrates without further drying or treatment, offering enhanced porosity, adhesion, and durability through electron beam curing, and optionally including a removable protective layer and adhesive for improved handling and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid paints and lacquers are used for coating application, then the coating can be applied to substrates, but organic solvents are harmful to health and environment, and the drying process takes about 3 days
Solution Approach 1:
The coating layer is pre-cured before application to the substrate. The polyester and polyacrylate are fully polymerized and cured in advance, so that when the coating is applied, it does not require additional drying time. This preliminary curing action eliminates the 3-day drying period while maintaining coating application capability.
Solution Approach 2:
The coating formulation changes from a liquid state requiring solvent evaporation to a pre-cured state. By altering the chemical state of the coating materials before application, the drying process is eliminated, and the coating can be applied directly in a ready-to-use condition.
2Ease of manufacture
If liquid raw materials are used for coating, then coating layers can be applied to surfaces, but the application process is laborious and difficult to control thickness
Solution Approach 1:
The coating is provided as a flexible, pre-cured film or layer that can be directly applied to the substrate. This thin film approach simplifies the application process compared to liquid raw materials, as the pre-cured coating maintains its structural integrity and thickness during application, making it easier to control and apply uniformly.
3Productivity
If coating layer is applied freshly to substrate, then coating can be applied directly, but the coating absorbs contaminants from ambient air during drying
Solution Approach 1:
The coating layer is pre-cured before application, so that when it is applied to the substrate, it is already in a stable, non-porous state. This preliminary curing action prevents the coating from absorbing contaminants from ambient air during the application process, ensuring consistent quality without requiring protective measures during drying.
4Ease of manufacture
If conventional liquid paints are used, then coating layers can be applied, but blisters form in porous wood surfaces undermining protective action
Solution Approach 1:
The coating formulation is changed to a pre-cured state with controlled porosity. The pre-curing process creates a stable coating structure that does not allow blister formation on porous wood surfaces, while still maintaining the protective function. The chemical state change prevents the coating from reacting with the substrate in a way that causes blisters.
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 solution provides a stable, high-gloss, durable coating that reduces handling and storage risks, eliminates the need for solvent use and drying time, and enhances substrate durability, allowing for efficient and consistent application in both manual and mechanical processes.
Implementation Method 1
The cured polyacrylate and cured polyester is understood to mean a material which is completely reacted, i.e. material which is fully polymerized
Implementation Method 2
the cured polyester and polyacrylate has, as the coating layer, a sufficient porosity to provide a passage for air and moisture which may be enclosed between the substrate and the coating layer
Data Source
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AI summary
Coating system for directly applying a coating layer to a substrate, the system comprising a coating layer based on a material of a cured polyester and/or a cured polyacrylate, and wherein a support fabric is integrated into the material of the coating layer on a first side of the coating layer. Use of the coating system according to the invention, comprising the steps of: - applying the coating layer directly to a substrate. Method for manufacturing such a coating system.