Thin layer UV curing coating on non-woven facers
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Solution Overview
Problem
There is a need for non-woven facers in construction boards with improved properties such as abrasion resistance and reduced porosity, which existing UV-curable coatings have not effectively addressed.
Innovation Solution
A UV-cured coated facer is created using a non-woven fiber mat with an intermediate coating comprising a binder and filler, followed by a filler-free UV-curable coating composition that is cured with a light source, providing excellent scratch resistance and high air resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional aqueous coating composition is used on non-woven facers, then the coating can be applied and heat cured, but the abrasion resistance and porosity reduction are insufficient
Solution Approach 1:
The patent changes the curing method parameter from thermal curing to UV curing, and modifies the coating composition by replacing aqueous binders with UV-curable oligomers and monomers. This parameter change enables simultaneous achievement of high abrasion resistance and effective porosity reduction through photopolymerization crosslinking
Solution Approach 2:
The patent creates a composite coating system combining UV-curable oligomers, monomers, and photoinitiators on the non-woven facer. This composite material formulation provides enhanced abrasion resistance while the low-viscosity monomers penetrate and seal pores, achieving both contradictory requirements
2Reliability
If existing UV-curable coatings with fillers are applied, then some protective properties are achieved, but abrasion resistance and porosity reduction remain inadequate
Solution Approach 1:
The patent extracts and eliminates filler materials from the UV-curable coating composition. By removing fillers that interfere with UV penetration and crosslinking density, the coating achieves superior abrasion and scratch resistance while maintaining effective pore sealing through the oligomer and monomer components
Solution Approach 2:
The patent changes the coating composition parameters by using a filler-free formulation with specific oligomer to monomer ratios. This parameter optimization allows deep UV penetration for complete curing, achieving both high air resistance through pore sealing and excellent scratch resistance through dense crosslinked network formation
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 results in a facer with significantly improved abrasion resistance and air resistance, as demonstrated by high Gurley air permeation values and reduced weight loss during abrasion testing, outperforming conventional coated facers.
Implementation Method 1
a UV-curable coating composition disposed on the intermediate coating, wherein said UV-curable coating composition is essentially free of a filler
Data Source
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AI summary
A UV-cured coated facer includes a non-woven mat having a first side and a second side and an intermediate coating disposed on the first side of the non-woven mat. The intermediate coating includes a coating binder and a filler. The UV-cured coated facer also includes a UV- curable coating composition disposed on the intermediate coating, wherein the UV-curable coating composition is essentially free of a filler.