Thermoplastic Surface Modification via Carrier Polymer Adhesion
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Solution Overview
Problem
Existing polymer parts, such as PVC substrates, lack stable and cost-effective methods for imparting improved surface characteristics like cleanability, thermal conductivity, and mold protection during manufacturing, often requiring costly coatings that alter part dimensions.
Innovation Solution
A melt processible thermoplastic composition comprising a base polymer and a combination of a carrier polymer and a surface modifying additive, where the carrier polymer has a lower solubility parameter and viscosity, allowing for improved surface properties without altering the part's dimensions, achieved through a masterbatch process or physical blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating is applied to the part surface to improve surface properties, then surface characteristics such as cleanability and thermal conductivity are improved, but the dimensions of the part are altered and manufacturing cost increases
Solution Approach 1:
The patent combines the surface modifying additive with the carrier polymer to form an integrated composition that is incorporated into the base polymer during the same manufacturing process. This merging eliminates the need for separate coating steps while achieving improved surface properties, thereby maintaining part dimensions and reducing manufacturing complexity.
Solution Approach 2:
The surface modifying additive is pre-combined with the carrier polymer before incorporation into the base polymer matrix during extrusion or injection molding. This preliminary action ensures that the surface modifying components are already in position and properly distributed before the part is formed, eliminating the need for post-manufacturing coating operations.
2Reliability
If a coating is applied to the part surface to improve surface properties, then surface characteristics are improved, but manufacturing cost increases
Solution Approach 1:
By merging the surface modifying additive with the carrier polymer and incorporating both into the base polymer during the primary manufacturing process, the patent eliminates the need for separate coating operations. This integration reduces manufacturing steps, labor costs, and material handling requirements, thereby reducing overall manufacturing cost while maintaining improved surface properties.
Solution Approach 2:
The carrier polymer serves multiple functions: it acts as a processable polymer component, a vehicle for delivering surface modifying additives, and a binder that integrates the surface modifying additives into the final part structure. This multi-functionality reduces the need for additional specialized materials and processes, lowering manufacturing cost.
3Manufacturing precision
If surface modifying additives are incorporated into the base polymer during manufacturing, then surface properties are improved without altering part dimensions, but the viscosity relationship between carrier polymer and base polymer must be carefully controlled
Solution Approach 1:
The patent specifies particular viscosity relationships between the carrier polymer and base polymer (carrier polymer viscosity being 10-100 times lower than base polymer viscosity) to ensure proper flow and distribution during manufacturing. By controlling these parameters, the invention achieves uniform distribution of surface modifying additives without requiring complex processing equipment or multiple manufacturing steps.
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 provides parts with enhanced surface characteristics, including improved cleanability and durability, while maintaining cost-effectiveness and stability over time, as demonstrated by increased dirt pick-up resistance and environmental cleanability after weathering.
Implementation Method 1
the carrier polymer being adhered to the surface modifying additive
Implementation Method 2
the carrier polymer and the surface modifying additive are intimately mixed or dispersed with each other
Implementation Method 3
melt processible thermoplastic composition
Implementation Method 4
processing a major proportion of a base polymer... to form a part
Implementation Method 5
processing a major proportion of a base polymer... to form a part
Data Source
AI summary
The disclosure provides a melt processible theromoplastic composition, comprising a major proportion of a base polymer comprising a first melt processible thermoplastic polymer having a first Fedor's solubility parameter and a first viscosity; and a combination of a carrier polymer and a surface modifying additive, the carrier polymer comprising a second melt processible thermoplastic polymer which has a second Fedor's solubility parameter that is at least about 2.5 (J/cm3)1/2 lower than the first Fedor's solubility parameter, and a second viscosity, the carrier polymer being adhered to the surface modifying additive, and wherein the first viscosity is at least about 10 times the second viscosity.