Radiation Curable Protective Coating for Soft Substrates
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Solution Overview
Problem
Soft coatings such as solar control and insulating low-E coatings have limited mechanical, chemical, and corrosion resistance, making them prone to damage during production, processing, transport, and storage, and existing protective methods are either ineffective or environmentally unfriendly.
Innovation Solution
A coated substrate with a soft coating and a protective coating obtained by curing a radiation curable composition containing cyclic ether compounds, which provides mechanical, chemical, and corrosion resistance, and can be removed by heat treatment without damaging the soft coating's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective coating is applied to protect the soft coating, then mechanical, chemical and corrosion resistance is improved, but the complexity of the coating structure increases
Solution Approach 1:
The patent applies a multi-layer composite coating structure consisting of a soft coating layer and a protective coating layer. The soft coating provides optical properties (low emissivity, IR reflection) while the protective coating provides mechanical, chemical and corrosion resistance. This composite structure resolves the contradiction by combining materials with complementary functions, where each layer protects the underlying layer without compromising the overall performance.
Solution Approach 2:
The coating system is segmented into distinct functional layers: the soft coating layer (containing metal-based infrared reflecting layers) and the protective coating layer (applied over the soft coating). This segmentation allows each layer to be optimized for its specific function while working together as an integrated system, thereby improving reliability without excessive complexity.
2Ease of manufacture
If polymer water based or solvent based systems are used for protective coating, then ease of application is improved, but energy consumption increases due to heat and time required for evaporation
Solution Approach 1:
The patent replaces the thermal evaporation process (mechanical/thermal system) with a radiation curing process. Instead of using heat and time to evaporate water or solvents, the protective coating is cured through radiation (UV or other radiation sources), which significantly reduces energy consumption and eliminates the need for exhaust systems and burners while maintaining ease of application.
Solution Approach 2:
The protective coating utilizes radiation-induced phase transition from liquid to solid state through curing, rather than relying on thermal evaporation of solvents. This phase transition mechanism eliminates the energy-intensive drying process while preserving the benefits of liquid-based application methods.
3Ease of manufacture
If water or solvent based protective coatings are used, then ease of application is improved, but degradation of the soft coating occurs due to water or solvent ingress
Solution Approach 1:
The protective coating is applied as a preliminary layer before the soft coating is exposed to environmental conditions. This protective barrier is established in advance to prevent water or solvent ingress that could degrade the soft coating, while still allowing the use of water or solvent based application methods.
Solution Approach 2:
The protective coating acts as an intermediary barrier between the environment (water, solvents, chemicals) and the soft coating. It mediates the interaction by providing a protective interface that prevents harmful substances from reaching the soft coating, thereby maintaining the soft coating's integrity while allowing ease of application.
4Ease of operation
If the protective coating is removed by aqueous washing, then ease of removal is improved, but corrosion protection during storage is lost
Solution Approach 1:
The protective coating utilizes radiation curing to transition from a removable state to a permanently bonded protective state. After application, the coating can be easily removed if needed, but once cured through radiation exposure, it becomes a durable protective layer that maintains corrosion protection during storage and handling without requiring aqueous washing for removal.
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 effectively protects the soft coating from mechanical, chemical, and corrosion damage during various stages, is environmentally friendly by reducing solvent and water use, and allows for heat treatment without compromising the soft coating's optical, energy, or thermal properties.
Implementation Method 1
a protective coating obtained by the application and curing of a radiation curable composition comprising one or more compound bearing one or more cyclic ether CEC
Implementation Method 2
soft coatings such as solar control or insulating low-E coatings present a low emissivity and are used in glazing for their IR reflecting ability
Data Source
AI summary
The present invention relates to a coated substrate comprising a soft coating deposited by physical vapor deposition provided on at least a part of at least one main face of the substrate and a protective coating provided on at least a part of said face above the soft coating. The present invention also relates to a process for making a coated substrate comprising a soft coating and a protective coating and to the use of a protective coating to protect a coated substrate provided with a soft coating.