UV Curable Coating Composition for Universal Substrate Adhesion
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Solution Overview
Problem
Current UV curable hard coating compositions face challenges in achieving adequate adhesion and scratch resistance on various plastic lens substrates, particularly CR-39 and urethane-based substrates, while also encountering issues with haze and nonuniformity on polycarbonate substrates.
Innovation Solution
A UV curable coating composition comprising a polyfunctional epoxy oligomer, non-hydrolyzed epoxy silane, polyfunctional acrylic compound, and a combination of cationic and free radical photoinitiators, along with a surfactant, which provides improved adhesion and scratch resistance across different substrates by optimizing viscosity and using specific chemical structures and reaction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polysiloxane-based thermosetting composition is used for hard coating, then adhesion to CR-39 and urethane substrates is excellent, but adhesion to polycarbonate and acrylic substrates is significantly deteriorated
Solution Approach 1:
The patent uses a composite coating composition combining polysiloxane with both hydrolyzed silane and non-hydrolyzed silane modifiers, creating a multi-functional material that achieves universal adhesion across different substrate types while maintaining the base benefits of polysiloxane systems
2Loss of time
If a UV curable hard coating composition is used, then curing time is reduced, but adhesion and scratch resistance suitable for all plastic lens substrates is difficult to achieve
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific ratios of hydrolyzed silane (5-20 parts) and non-hydrolyzed silane (80-95 parts) relative to polysiloxane, along with controlled amounts of acrylic compounds and photoinitiators, to achieve both rapid UV curing and reliable performance across all substrate types
Solution Approach 2:
The coating composition uses a composite system combining polysiloxane base resin with multiple functional additives including hydrolyzed silane for adhesion, non-hydrolyzed silane for scratch resistance, and photoinitiators for UV curing, achieving multi-functional performance
3Strength
If colloidal silica is applied to improve scratch resistance, then scratch resistance is improved, but haze problem and adhesion problem in polycarbonate-based substrate are not overcome
Solution Approach 1:
The patent replaces colloidal silica with non-hydrolyzed silane compounds and controls the particle size and distribution of silane modifiers to achieve scratch resistance without causing haze or adhesion problems on polycarbonate substrates
Solution Approach 2:
The patent uses small molecular weight silane compounds that can be uniformly distributed and cured in the coating matrix, replacing larger colloidal silica particles that cause scattering and adhesion issues
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 composition ensures excellent adhesion and scratch resistance on urethane, polycarbonate, and acrylic substrates, while minimizing haze and nonuniformity, with the cationic and free radical photoinitiators ensuring uniformity and maintaining high viscosity for effective coating.
Implementation Method 1
at least two photoinitiators
Data Source
AI summary
Provided is a UV curable coating composition, and more particularly, to a UV curable coating composition including: at least one polyfunctional epoxy oligomer; at least one epoxy compound; at least one non-hydrolyzed epoxy silane; at least one polyfunctional acrylic compound; at least two photoinitiators; and at least one surfactant. The UV curable coating composition according to the present invention can be coated on various substrates and provide excellent adhesion and scratch resistance to the coating layer regardless of a substrate type unlike conventional coating compositions.