Refractory Multilayer Sheet Adhesion and Coating Uniformity
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Solution Overview
Problem
The existing fire-resistant multilayer sheets face issues with delamination and coating unevenness due to the lack of an anchor effect between the substrate and the thermally expandable material, which can lead to adhesion problems and color inconsistencies.
Innovation Solution
Incorporating an intervening layer of thermoplastic resin between the thermally expandable material and the substrate to enhance adhesion and prevent delamination, while maintaining a flat substrate to reduce coating unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the substrate is embossed to give unevenness to achieve an anchor effect, then adhesion between substrate and thermally expandable material is improved, but coating uniformity deteriorates due to uneven surface
Solution Approach 1:
The substrate surface is divided into two functional zones: an embossed back surface for adhesion and a flat front surface for coating. This segmentation allows each surface to fulfill its specific function without compromising the other.
Solution Approach 2:
Different surface qualities are applied to different locations of the substrate: the back surface has embossed unevenness for anchor effect, while the front surface remains flat for uniform coating application.
2Manufacturing precision
If a flat substrate is used to reduce coating unevenness, then coating uniformity is improved, but adhesion between substrate and thermally expandable material deteriorates due to lack of anchor effect
Solution Approach 1:
The substrate is segmented into two distinct surfaces with different properties: a flat front surface for coating and an embossed back surface for adhesion.
Solution Approach 2:
Local quality varies across the substrate: the front surface maintains flatness for uniform coating, while the back surface has embossed features for mechanical interlocking.
3Strength
If the substrate is embossed, then adhesion is improved, but color uniformity deteriorates due to liquid components reaching the coating surface through voids
Solution Approach 1:
The substrate surface is segmented into adhesion zone (embossed back) and coating zone (flat front), preventing liquid migration from reaching the coating surface.
Solution Approach 2:
The flat front surface quality ensures uniform coating appearance and color, while the embossed back surface provides adhesion without affecting the visible surface.
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 improved aesthetic appearance and excellent adhesion between layers, ensuring both fire resistance and a uniform appearance in final products.
Implementation Method 1
thermally expandable material comprising a thermally expandable resin composition containing a binder resin and a thermally expandable graphite
Implementation Method 2
an intervening layer 5 containing a thermoplastic resin disposed between the thermally expandable material 2 and the substrates 3
Data Source
Figure 1~4
AI summary
The present invention provides a fire-resistant multilayer sheet with reduced coating unevenness, and with excellent adhesion between a thermally expandable material and a substrate. The fire-resistant multilayer sheet 1 comprises a thermally expandable material 2 comprising a thermally expandable resin composition containing a binder resin and a thermally expandable graphite; a substrate 3 laminated with the thermally expandable material 2; a coating layer 4 laminated on the substrate 3, and an intervening layer 5 containing a thermoplastic resin disposed between the thermally expandable material 2 and the substrate 3.