Scratch-Resistant Film Cross-Linked Copolymer Coating
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Solution Overview
Problem
Conventional direct coating methods for automobile exterior parts and household appliances are labor-intensive, hazardous, and limit design variability, while decorative films lack sufficient scratch, weather, and corrosion resistance.
Innovation Solution
A film obtained by cross-linking a vinyl compound copolymer with polyisocyanate, comprising specific monomer units, which provides excellent scratch resistance, resilience, and resistance to friction-induced scratches, and is laminated on a thermoplastic resin film for enhanced durability and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If direct coating with hardening resin paint is used, then scratch resistance and durability are improved, but manufacturing complexity and labor requirements increase
Solution Approach 1:
The patent applies the copying principle by transferring the protective coating from a separate applied layer back onto the film itself during manufacturing. The film is coated with the hardening resin paint, cured to form a protective layer, and then this coated film is applied to the article surface. This eliminates the need for separate masking, coating, and finishing operations at the application site, as the protective coating is already integrated into the film before installation.
Solution Approach 2:
The patent implements preliminary action by pre-coating the film with hardening resin paint and pre-curing it during the film manufacturing process. This prepares the protective coating in advance, so that when the film is applied to the article, the coating is already in place and ready to provide scratch resistance and durability, eliminating the need for on-site coating operations.
2Ease of operation
If decorative film is used instead of direct coating, then ease of application and design flexibility are improved, but scratch resistance and weather resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining the decorative film substrate with a cross-linked polymer coating layer. The film provides design flexibility and ease of application, while the cross-linked coating layer (formed from polydimethylsiloxane copolymer and polyisocyanate) provides enhanced scratch resistance, weather resistance, and durability. This composite structure integrates the advantages of both the decorative film and the protective coating.
Solution Approach 2:
The patent uses parameter changes by modifying the chemical structure and cross-linking density of the coating polymer to achieve optimal balance between flexibility and hardness. The cross-linked structure with specific molecular weight and composition provides sufficient hardness for scratch resistance while maintaining enough flexibility to prevent cracking during film application and use, thus resolving the contradiction between ease of application and scratch resistance.
3Strength
If polydimethylsiloxane copolymer is used for paint film, then scratch resistance is improved, but weather resistance and impact resistance remain insufficient
Solution Approach 1:
The patent applies composite materials by combining the polydimethylsiloxane copolymer with polyisocyanate to form a cross-linked polymer structure. This cross-linked composite provides not only improved scratch resistance from the polydimethylsiloxane component but also enhanced weather resistance, impact resistance, and overall durability from the cross-linked network structure, resolving the insufficiencies of the uncross-linked copolymer.
Solution Approach 2:
The patent uses parameter changes by modifying the molecular structure through cross-linking. The cross-linking increases the molecular weight and creates a three-dimensional network structure, which fundamentally changes the physical and chemical properties of the polymer, providing superior weather resistance, impact resistance, and durability while maintaining the scratch resistance benefits of the polydimethylsiloxane copolymer.
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 resulting film exhibits superior resilience from scratch, stain resistance, weather resistance, chemical resistance, and bending durability, making it a suitable alternative to direct coating for protecting and decorating surfaces of articles.
Implementation Method 1
a film obtained by cross-linking a vinyl compound copolymer with polyisocyanate
Implementation Method 2
the film immediately deforms elastically and does not easily crack; when the pressure is removed, the deformed film goes back to its original form without leaving plastic deformation
Data Source
AI summary
The present invention provides a paint film which is superior in scratch resistance, weather resistance, stain resistance, chemical resistance, bending durability and impact resistance and is useful as a scratch resistant film or a decorative film.The film is obtained by cross-linking a vinyl compound copolymer with polyisocyanate, wherein the vinyl compound copolymer comprises the following monomer units: (A) a mole % of a vinyl compound which has no siloxane structure, nor hydroxyl group; (B) b mole % of a vinyl compound which has a polydimethylsiloxane structure and no hydroxyl group; (C) c mole % of a vinyl compound which has a linear or branched alkyl group having a hydroxyl group, the alkyl group having 1 to 6 carbon atoms; and (D) d mole % of a vinyl compound represented by the formula:CH2═C(R)—COO—Ywherein R is H or CH3, and Y is a saturated hydrocarbon group with a hydroxyl group at an end and, optionally, one or more lactone, carbonate, ester, ether, or urethane groups.