Polymeric Superstrate Dye Diffusion for Selective Colored Finishes
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Solution Overview
Problem
Existing methods do not allow for the application of a protective polyurethane or acrylic coating to an article and subsequent coloring, nor do they enable coloring of restricted areas or creating color gradients on substrates like metal, wood, glass, ceramic, and polymeric materials.
Innovation Solution
A process involving the application of a polymeric superstrate to a substrate, followed by contact with a material system containing water, a carrier, a dye, and a diol, under conditions that facilitate the diffusion of dye into the superstrate, allowing for the creation of colored articles with desired color intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective polyurethane or acrylic coating is applied to an article, then the article gains protective coverage, but the ability to subsequently color the coating or create color gradients is lost
Solution Approach 1:
The patent applies a preliminary plasma treatment to the polyurethane or acrylic coating surface before dyeing. This plasma activation creates surface groups that enhance dye adhesion and penetration, enabling subsequent coloring while preserving the protective coating's integrity. The plasma treatment is performed as a preliminary step that prepares the surface for dye absorption without compromising the coating's protective properties.
2Ease of manufacture
If dye is applied to a polymeric coating, then coloration is achieved, but the ability to create restricted area coloring or color gradients is limited
Solution Approach 1:
The patent employs localized plasma treatment to specific areas of the coating surface before dye application. By controlling the plasma treatment zone, the invention enables selective dye penetration in restricted areas, allowing for precise color patterns, gradients, and multi-color effects. Different areas of the coating can receive different plasma treatment intensities or durations, creating local variations in dye absorption and achieving sophisticated color designs.
3Productivity
If conventional dyeing methods are used on molded articles, then coloring is achieved, but the process requires complex baths with multiple additives and extended processing time
Solution Approach 1:
The patent replaces the complex chemical dye bath system with a plasma-based coloring method. Instead of using extensive dye baths containing water, dyes, carriers, surfactants, and other additives, the invention uses plasma treatment that can be applied directly to the coating surface. This substitution dramatically simplifies the process equipment and eliminates the need for complex bath compositions while achieving effective and durable coloring.
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
Enables the effective coloring of various materials, including metal, wood, glass, and polymeric materials, with controlled color intensity and distribution, achieving attractive and durable colored finishes.
Implementation Method 1
under conditions calculated to bring about diffusion of said dye into 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.