Printed Deformable Films: Segmented Coating for Forming
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Solution Overview
Problem
Current methods for producing deformed printed films fail to meet requirements for simple application using standard printing processes, thermal drying, and final hardening via actinic radiation, resulting in coatings with inadequate chemical and mechanical resistance.
Innovation Solution
A method involving printing a thermoplastic film with a first coating agent, followed by thermal deformation and subsequent hardening with a second actinic radiation-curable coating agent, where the components are selected to achieve a glass transition temperature of at least 35°C, allowing for thermoplastic deformability and final cross-linking into a duromer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating is applied using conventional painting methods and dried to achieve good surface properties, then high cross-linking density is achieved, but the coating becomes too rigid and cracks during forming
Solution Approach 1:
The patent divides the coating process into two distinct stages: a first coating applied before forming that remains thermoplastic and deformable, and a second coating applied after forming that provides the final cross-linked protective layer. This segmentation allows each coating to fulfill its specific function without compromising the other - the first coating enables deformation while the second provides durability.
Solution Approach 2:
The first coating is applied and dried in advance before the forming process, creating a preparatory layer that facilitates subsequent deformation. This preliminary action ensures the substrate is properly prepared for forming while maintaining the flexibility needed for the shaping process.
2Reliability
If coating is applied using conventional painting methods, then good surface coverage is achieved, but the process is complex and uneconomical for small areas and multi-colored decorations
Solution Approach 1:
The patent replaces conventional mechanical painting methods (doctor blades, spraying, dipping) with printing processes for applying the first coating. This substitution enables precise application to small areas, multi-colored decorations, and complex patterns while reducing material waste and improving economic efficiency.
3Reliability
If polymeric components with glass transition temperature above 40°C are added to improve blocking resistance, then handling is improved, but the coating becomes less deformable
Solution Approach 1:
The patent segments the coating functionality between two separate coatings: the first coating uses lower glass transition temperature components that remain deformable during forming, while the second coating applied after forming provides the blocking resistance and final protective properties. This segmentation resolves the contradiction by assigning different functional requirements to different stages of the process.
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 produces films with enhanced blocking resistance, chemical, and mechanical properties, comparable to conventionally painted objects, while enabling precise deformation and multi-colored decorations.
Implementation Method 1
Thermal drying and, if necessary, curing via a polyaddition mechanism, which leads to a block-resistant thermoplastic printed film that can be deformed with appropriate tools
Implementation Method 2
Final hardening of the coating applied via printing processes on the deformed film by actinic radiation, achieving resistance properties of the coating that can also be achieved by conventional painting of already formed objects
Implementation Method 3
the coated film is deformed by thermal deformation such as deep drawing, vacuum deep drawing, pressing, blow molding and / or high-pressure forming
Data Source
AI summary
The present invention relates to printed films, to a process for printing these films, to the curing of layers applied by printing, and to shaped articles obtained from the layers.