Self-Cleaning Substrates via Segmented Roll Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Applying titanium dioxide (TiO2) coatings to substrates for architectural products while maintaining aesthetic features is difficult and costly.
Innovation Solution
A method involving roll coating to produce colored, self-cleaning substrates by applying a colored coating, followed by a barrier coating, and then a self-cleaning coating, which retains the intended color and gloss, using titanium dioxide-containing coatings that facilitate photocatalysis for self-cleaning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium dioxide coatings are applied to substrates for self-cleaning properties, then self-cleaning capability is improved, but aesthetic features (color and gloss) are deteriorated
Solution Approach 1:
The coating system is divided into three separate layers: a base coat providing color and gloss, a barrier coat preventing TiO2 migration, and a self-cleaning coat containing TiO2 particles. This segmentation allows each layer to perform its specific function without compromising the others, resolving the contradiction between self-cleaning capability and aesthetic features.
Solution Approach 2:
A barrier coat consisting of inorganic particles (such as silica) is introduced as an intermediary layer between the base coat and the self-cleaning coat. This intermediary prevents the migration of TiO2 particles into the base coat, thereby maintaining the aesthetic features while preserving self-cleaning functionality.
2Reliability
If titanium dioxide coatings are applied to substrates, then self-cleaning properties are achieved, but production cost increases
Solution Approach 1:
The patent combines multiple functional requirements (aesthetic coating, barrier function, and self-cleaning capability) into a single integrated multi-layer coating system that can be applied in one continuous manufacturing process. This merging reduces the need for separate production steps and minimizes overall manufacturing costs despite the added functionality.
Solution Approach 2:
The multi-layer coating system provides multiple functions simultaneously: the base coat provides aesthetics, the barrier coat prevents particle migration, and the self-cleaning coat provides photocatalytic cleaning. This multi-functionality eliminates the need for separate treatments or coatings, thereby reducing overall production costs while achieving self-cleaning properties.
3Manufacturing precision
If colored coating is applied to achieve predetermined color, then color accuracy is improved, but self-cleaning functionality is compromised
Solution Approach 1:
The coating is segmented into distinct functional layers: the base coat dedicated to color accuracy and the self-cleaning coat dedicated to photocatalytic functionality. This segmentation ensures that the colored coating maintains its color accuracy without compromising self-cleaning functionality, as the TiO2-containing layer is separate from the pigment-containing layer.
Solution Approach 2:
The barrier coat acts as an intermediary that allows the colored base coat to maintain its color accuracy while enabling the self-cleaning functionality to operate from the outer layer. The barrier prevents interference between the colored coating and the self-cleaning coating, ensuring both color accuracy and self-cleaning functionality are preserved.
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 method results in substrates that are self-cleaning, retain their intended color and gloss, and are cost-effective, suitable for architectural applications without detrimental effects on aesthetics.
Implementation Method 1
titanium dioxide-containing coatings that facilitate photocatalysis for self-cleaning properties
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A methods, apparatus and compositions for producing colored, self-cleaning substrates by roll coating are provided. The roll coated, colored, self-cleaning substrates retain the predetermined color and a predetermined gloss of the colored coating, thereby facilitating their use in architectural applications. The roll coated, colored, self-cleaning substrates may be iridescent-free.