Protected Graphics Assembly High-Gloss Polymer Layer
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Solution Overview
Problem
Conventional methods for applying and maintaining graphical images on surfaces face challenges such as fading due to UV radiation, mechanical or chemical degradation, and inadequate adherence, which affects the quality and permanence of the images, particularly in the transportation industry where additional weight from protective layers compromises aerodynamic performance.
Innovation Solution
A protected graphics assembly comprising a polymer layer essentially free of low surface energy materials, a graphics layer, and an optional adhesive layer, with a thickness of 50 microns or less, providing a high gloss value and improved interlayer adhesion without the need for additional protective layers, allowing for easy removal and application on curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer films (polyesters or fluoropolymers) are used to protect graphics, then the graphics are protected from degradation, but the visual quality is compromised due to insufficient gloss and distortion of underlying graphics
Solution Approach 1:
The patent changes the key parameter of the polymer film from conventional materials (polyesters, fluoropolymers) to a high-gloss polymer material with gloss value greater than 90. This parameter change resolves the contradiction by providing both protection and high visual quality without distortion.
Solution Approach 2:
The patent creates a composite structure consisting of a polymer film layer combined with a graphics layer. The polymer film is specifically engineered to be essentially free of low surface energy materials while maintaining high gloss, creating a composite material that simultaneously provides protection and optical clarity.
2Reliability
If low surface energy additives (silicones) are added to ink to improve mar resistance, then the ink's durability is improved, but the adherence of ink to substrate decreases
Solution Approach 1:
The patent extracts and removes low surface energy additives (such as silicones) from the ink formulation. By taking out these problematic additives, the ink maintains good adherence to the substrate while still achieving mar resistance through the protective polymer film layer rather than through additive modification of the ink itself.
Solution Approach 2:
The patent introduces a polymer film layer as an intermediary between the ink and the environment. This intermediary layer provides the mar resistance and protection that would otherwise require low surface energy additives in the ink, thereby allowing the ink to adhere properly to the substrate without compromising durability.
3Reliability
If additional protective layers are applied to graphics, then the permanence of graphics is improved, but the weight increases compromising aerodynamic performance
Solution Approach 1:
The patent employs a thin polymer film as a flexible protective shell over the graphics. This thin film provides the necessary protection for graphic permanence while minimizing weight addition, thereby preserving aerodynamic performance in transportation applications.
Solution Approach 2:
The patent changes the thickness parameter of the protective layer to be extremely thin (50 microns or less), and changes the material composition to be essentially free of low surface energy materials. This parameter optimization provides adequate protection while minimizing weight impact on aerodynamic performance.
4Reliability
If conventional polymer films are used with low surface energy materials, then the graphics are protected, but the ease of removal decreases due to interlayer delamination and strong adhesion
Solution Approach 1:
The patent changes the surface energy parameter of the polymer film by making it essentially free of low surface energy materials. This parameter change allows the protective film to provide adequate protection while enabling easier removal when desired, preventing interlayer delamination issues and allowing clean graphic replacement.
Data Source
AI summary
An improved protected graphics assembly according to the invention comprises the following sequential layers: optionally, at least one adhesive layer; at least one graphics layer; and at least one outwardly exposed polymer layer that is essentially free of low surface energy materials and has a gloss value of greater than 90 when tested according to ASTM D2457-03 at a 60-degree angle. The assembly is beneficially applied to a variety of articles and used in a variety of related methods. In an exemplary embodiment, a race car comprises a protected graphics assembly that comprises: optionally, at least one adhesive layer; at least one outwardly exposed polymer layer that is essentially free of low surface energy materials; and at least one graphics layer substantially protected from exterior exposure by the polymer layer.