PVDF Polymer Coated Sheet with Hot Embossed Pattern

Solution Overview

Problem

Existing polymer coated steel sheets with PVC layers have inferior sustainability, low fire resistance, and weaknesses in UV and hot climates, and are not cost-effective.

Innovation Solution

A polymer coated sheet with a metallic substrate, featuring an inner polymer layer of polyester, polyurethane, or acrylic, an intermediate layer of polyester, polyurethane, or PVDF resin, and an outer PVDF layer with an embossed pattern, providing improved corrosion resistance, UV resistance, and sustainability while reducing material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PVC polymer coating is used with thickness of around 200 microns, then the emboss can be formed, but the sustainability is inferior and fire resistance is low

Engineering Contradiction:

Improvefire resistanceVSAvoidpolymer coating thickness

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent changes the polymer chemistry from PVC to PVDF, which fundamentally alters the material properties. PVDF provides superior fire resistance and UV stability while allowing for reduced thickness applications, directly resolving the contradiction between fire resistance and coating thickness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a multi-layer composite structure consisting of an inner polymer layer (PVDF or polyester), intermediate layer (PVDF or polyester), and outer embossed layer (PVDF). This composite approach allows each layer to be optimized for specific functions, achieving high fire resistance and sustainability with reduced total material usage compared to single-layer PVC systems

Inventive Principle:

Principle #40Composite materials

2Reliability

If PVC polymer coating is used, then the emboss can be formed, but the UV and hot climate resistance is weak

Engineering Contradiction:

ImproveUV resistanceVSAvoidpolymer coating thickness

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent changes the polymer chemistry from PVC to PVDF, which fundamentally alters the material properties. PVDF provides superior fire resistance and UV stability while allowing for reduced thickness applications, directly resolving the contradiction between fire resistance and coating thickness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a multi-layer composite structure consisting of an inner polymer layer (PVDF or polyester), intermediate layer (PVDF or polyester), and outer embossed layer (PVDF). This composite approach allows each layer to be optimized for specific functions, achieving high fire resistance and sustainability with reduced total material usage compared to single-layer PVC systems

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If 200 microns of polymer coating is used, then the emboss can be formed, but the manufacturing cost is higher and sustainability is reduced

Engineering Contradiction:

Improveemboss depth and clarityVSAvoidpolymer coating thickness

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent changes the polymer chemistry from PVC to PVDF, which fundamentally alters the material properties. PVDF provides superior fire resistance and UV stability while allowing for reduced thickness applications, directly resolving the contradiction between fire resistance and coating thickness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a multi-layer composite structure consisting of an inner polymer layer (PVDF or polyester), intermediate layer (PVDF or polyester), and outer embossed layer (PVDF). This composite approach allows each layer to be optimized for specific functions, achieving high fire resistance and sustainability with reduced total material usage compared to single-layer PVC systems

Inventive Principle:

Principle #40Composite materials

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 achieves excellent corrosion and UV resistance, improved fire resistance, and cost-effectiveness by using less material than traditional PVC-based products, while maintaining the required emboss depth and clarity.

Implementation Method 1

an emboss pattern is hot embossed in the outer polymer layer which is of PVDF

Methodology Applied

Scientific EffectHot embossing:

Implementation Method 2

the polymer coating provides the required barrier properties regarding corrosion

Methodology Applied

Scientific EffectCorrosion resistance:

Implementation Method 3

it has perceived weaknesses in strong UV and hot climates

Methodology Applied

Scientific EffectUV resistance:

Implementation Method 4

improved fire resistance properties

Methodology Applied

Scientific EffectThermal resistance:

Implementation Method 5

The intermediate layer may provide the required colour with excellent colour stability and also is receptive to the outer layer and embossing

Methodology Applied

Scientific EffectColour stability:

Implementation Method 6

Such an inner layer provides both excellent corrosion resistance and the required long term adhesion between the pretreatment and subsequent polymer layers

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4144446A1Polymer coated sheet product and method of manufacturing it

Publication Date: 2023.03.08 TATA STEEL UK

Figure 1~2D
Figure 3a~4

AI summary

Polymer coated sheet product comprising a metallic substrate provided with a polymer coating, the polymer coating comprising an inner polymer layer contacting the metallic substrate and an outer polymer layer wherein an emboss pattern is hot embossed in the outer polymer layer.