Polymeric Superstrate Dye Diffusion for Selective Surface Coloring
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Solution Overview
Problem
Existing methods cannot apply protective coatings to articles and color them subsequently, nor can they create color gradients or restrict coloring to specific areas on substrates like metal, wood, glass, ceramic, and polymeric materials effectively.
Innovation Solution
A process involving fixing a polyurethane or acrylic superstrate to a substrate, followed by applying a dye-containing material system that includes water, a carrier, and a diol, under conditions that allow dye diffusion into the superstrate, which can be polysiloxane or polystyrene-based, to achieve desired coloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dyes are mixed in polyurethane or acrylic coatings and applied to substrate, then protective coating is applied, but coloring cannot be done subsequent to application and restricted areas cannot be colored
Solution Approach 1:
The patent segments the coloring process from the coating application process. The coating is applied first as a separate step, then the dyeing process is applied subsequently to specific areas. This allows the coating to be applied uniformly while coloring can be selectively applied to restricted areas or create color gradients, resolving the contradiction between ease of manufacture and adaptability of coloring application.
Solution Approach 2:
The patent applies preliminary action by first applying the protective coating to the substrate before applying the dye. The coating serves as a prepared base that can subsequently accept dye application. This preliminary coating step enables subsequent coloring operations to be performed on specific areas or with gradient effects, as the coating is already in place to receive the dye.
2Quantity of substance
If dyes are mixed in coatings during application, then color is applied, but color gradients cannot be created
Solution Approach 1:
The patent applies local quality by allowing different concentrations of dye to be applied to different areas of the coating after the coating is already in place. This enables the creation of color gradients where the color intensity varies spatially across the surface, rather than being uniformly distributed. The coating serves as a uniform base that can receive varying amounts of dye in different locations.
Solution Approach 2:
The preliminary application of the coating before dyeing allows for precise control of color distribution. The coating provides a uniform starting layer that can subsequently receive controlled amounts of dye in specific patterns or gradients, enabling manufacturing precision in color distribution that cannot be achieved when dye is pre-mixed into the coating.
3Ease of manufacture
If existing dyeing methods are used on molded articles, then coloring is achieved, but control over color intensity and gradients is limited
Solution Approach 1:
The patent segments the process into distinct steps: first applying the protective coating, then separately applying the dye to the coating. This segmentation provides control over color intensity and gradients because the dye application can be independently controlled after the coating is already in place, allowing for precise manipulation of color distribution without affecting the coating application process.
Solution Approach 2:
The patent enables parameter changes in the dyeing process by allowing control over dye concentration, application method, and exposure time after the coating is applied. This provides manufacturing precision in color control, as parameters such as dye concentration and application duration can be adjusted to achieve desired color intensities and gradients while maintaining ease of manufacture through the simplified two-step process.
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
This process enables the creation of colored articles with controlled color intensity and gradients on various materials, including metals, woods, and polymers, providing an attractive metallic effect and uniform tinting.
Implementation Method 1
applying a dye-containing material system to at least a portion of said superstrate under conditions calculated to diffuse dye to said portion of said superstrate
Data Source
AI summary
A process for making a colored article of manufacture is disclosed. Accordingly an article of manufacture is first prepared of a material selected from the group consisting of metal, wood, glass, ceramic, masonry and polymeric materials. A polymeric coating (superstrate) is then applied to at least a portion of the surface of the article. At least a portion of the superstrate is brought into contact with a material system that contains (i) water, (ii) a carrier, (iii) a dye and (iv) a diol, under conditions calculated to bring about diffusion of said dye into said superstrate.