UV-Curable Coating Composition for Repairable Appliance Finishes
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Solution Overview
Problem
Existing active energy ray-curable coating compositions struggle with forming coating films that have both excellent appearance and repairability, particularly on large substrates like home electric appliances and automobile parts, due to issues with foreign matter adherence and insufficient repairability.
Innovation Solution
An active energy ray-curable coating composition comprising a polymerizable unsaturated group-containing acrylic resin, a urethane (meth)acrylate, a polymerizable unsaturated compound, and a photopolymerization initiator, with specific molecular weight ranges and proportions to achieve a cured coating film with improved repairability and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating composition containing (meth)acryloyl group-containing polypentaerythritol, urethane poly(meth)acrylate compound, (meth)acryloyl group-containing (iso)cyanurate, ultraviolet absorber, and photopolymerization initiator is used to form a crosslinked cured film with excellent abrasion resistance, surface smoothness, thermal resistance, chemical resistance, durability, and weather resistance, then the coating film appearance and basic properties are improved, but the repairability becomes insufficient
Solution Approach 1:
The patent changes the molecular weight parameters of the polymer components. Specifically, it uses (meth)acryloyl group-containing acrylic resin with weight average molecular weight of 5,000 to 30,000 and urethane (meth)acrylate with weight average molecular weight of 1,000 to 5,000. This parameter adjustment creates a coating film with molecular weight between crosslinks of 300 to 900 g/mol, which provides both durability and repairability by optimizing the balance between crosslink density and chain mobility.
Solution Approach 2:
The patent creates a composite coating system by combining multiple components with specific functions: (A) acrylic resin for film formation and durability, (B) urethane (meth)acrylate for flexibility and repairability, (C) low molecular weight polymerizable unsaturated compound for crosslinking, and (D) photopolymerization initiator for curing. This composite approach allows the coating film to exhibit both excellent durability and improved repairability simultaneously.
2Productivity
If active energy ray-curable coating composition is applied to substrates with relatively large area to be coated, then productivity and energy saving are improved, but foreign matter adherence to the wet coating film surface increases, resulting in coating film defects
Solution Approach 1:
The patent adjusts the molecular weight parameters of the resin components to create a coating film with specific molecular weight between crosslinks (300 to 900 g/mol). This parameter optimization enables the coating to maintain excellent appearance quality even when applied to large substrate areas, reducing the impact of foreign matter adherence while preserving high productivity benefits.
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 forms a coating film with enhanced repairability and appearance, allowing for effective removal of foreign matter while maintaining excellent properties, such as abrasion resistance and surface smoothness.
Implementation Method 1
active energy ray-curable coating composition comprising: (A) a polymerizable unsaturated group(s)-containing acrylic resin, (B) a urethane (meth)acrylate, (C) a polymerizable unsaturated compound, and (D) a photopolymerization initiator
Data Source
AI summary
This invention provides the following active energy ray-curable coating composition: an active energy ray-curable coating composition comprising (A) a polymerizable unsaturated group(s)-containing acrylic resin having a weight average molecular weight in the range of 5,000 to 30,000, (B) a urethane (meth)acrylate having a weight average molecular weight in the range of 1,000 or more but less than 5,000 and containing an average of two to four polymerizable unsaturated groups per molecule, (C) a polymerizable unsaturated compound having a weight average molecular weight in the range of 200 or more but less than 1,000 and containing an average of two to nine polymerizable unsaturated groups per molecule, and (D) a photopolymerization initiator, the molecular weight between crosslinks of a cured coating film obtained by applying the active energy ray-curable coating composition being in the range of 300 to 900 g/mol.