UV-Cured Polymeric Coating for Corrosion-Resistant Metal Wires

Solution Overview

Problem

Current methods for coating metal wires and cables to prevent corrosion and deterioration are inefficient, leading to environmental and health hazards due to VOC emissions, bulky equipment requirements, and industrial waste, particularly in processes involving thermal curing and heavy metals.

Innovation Solution

A method involving the application of a liquid or solid compound containing monomers, oligomers, and photoinitiators followed by ultraviolet radiation to trigger cross-linking polymerization, forming a flexible, adhesive, and protective polymeric coating that also acts as a lubricant, reducing equipment bulk and energy costs while minimizing VOC emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal curing process is used to form protective coatings on wires and cables, then coating protection and durability are improved, but equipment complexity and energy consumption increase significantly

Engineering Contradiction:

Improvecoating protectionVSAvoidequipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the thermal curing system with a UV irradiation system. Instead of using bulky thermal curing equipment that requires high energy input, the invention uses UV lamps to initiate photopolymerisation of the coating composition, forming a protective coating without the need for complex thermal processing equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing mechanism from thermal to photonic. By modifying the chemical composition of the coating to include photopolymerisable groups and photoinitiators, the curing process can be activated by UV radiation at ambient or lower temperatures, eliminating the need for high-temperature thermal curing equipment.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If thermal curing process is used to form protective coatings on wires and cables, then coating protection and durability are improved, but energy consumption increases

Engineering Contradiction:

Improvecoating protectionVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the thermal curing system with a UV irradiation system. Instead of using bulky thermal curing equipment that requires high energy input, the invention uses UV lamps to initiate photopolymerisation of the coating composition, forming a protective coating without the need for complex thermal processing equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing mechanism from thermal to photonic. By modifying the chemical composition of the coating to include photopolymerisable groups and photoinitiators, the curing process can be activated by UV radiation at ambient or lower temperatures, eliminating the need for high-temperature thermal curing equipment.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If solvent-based protective paintings are used for coating wires and cables, then coating application is simplified, but atmospheric emissions of VOCs increase causing environmental impact and health risks

Engineering Contradiction:

Improvecoating applicationVSAvoidVOC emissions

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition of the coating from solvent-based to water-based or solvent-free formulation. The coating composition uses water or no volatile solvent as the carrier, eliminating VOC emissions while maintaining the ease of application through spray, dip, or brush methods.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent eliminates the harmful VOC component from the coating formulation while retaining the beneficial properties of liquid coating application. By using water-based or solid powder formulations that cure via UV irradiation, the system converts a harmful process into an environmentally friendly one without sacrificing application ease.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If heavy metal coatings are used to protect wires and cables from corrosion, then corrosion protection is improved, but environmental problems and health hazards increase due to processing residues

Engineering Contradiction:

Improvecorrosion protectionVSAvoidprocessing residues

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent uses a composite organic coating formulation containing polymers, photoinitiators, and functional additives that provide corrosion protection without heavy metals. The coating composition creates a protective barrier against corrosion while being environmentally friendly and free from hazardous processing residues.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent replaces permanent heavy metal coatings with an organic polymer coating that can be applied as a thin, disposable protective layer. This coating provides adequate corrosion protection for the service life of the wire or cable without creating persistent environmental contamination from heavy metal residues.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 method effectively limits corrosion and deterioration, reduces equipment size and energy costs, and minimizes environmental impact by using UV curing to form a protective and lubricant coating on metal wires and cables, enhancing their lifespan and processing efficiency.

Implementation Method 1

application of an amount of ultraviolet radiation, sufficient to trigger the cross-linking polymerisation which causes the solidification of the compound and the consequent formation of a coating

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentEP3553794B1Method to limit corrosion and deterioration of wires and cables of ferrous metal and their alloys

Publication Date: 2023.11.22 LUBRIMETAL

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AI summary

Disclosed herein is a method using ultraviolet radiation to form a solid polymeric coating on a surface of wires of ferrous and non-ferrous metal and their alloys with homogeneous section of any shape and size and cables formed by stranded wires, characterised in that it comprises the steps of: - application: coating the surface of wires and cables with a compound in liquid state or in the form of powders and solid particles of various size and shape, which is constituted by monomers and/or oligomers and/or polymers, as well as additives and photoinitiators; - curing: exposing the previously applied compound to an amount of ultraviolet radiation, with one or more wavelengths, sufficient to react the photoinitiators and to trigger the cross-linking polymerisation which causes the curing of the compound and therefore forms the polymeric coating and having flexibility, elongation, curing and adherence features such as to ensure high protective capacities. The method applies to protective, decorative or lubricating coatings.