UV-Cured In-Mold Coating for Abrasion-Resistant Plastic Glazing

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Solution Overview

Problem

Conventional methods for applying coatings to plastic glazing assemblies are time-consuming, energy-inefficient, and costly, with high manufacturing costs due to thermal curing processes and incompatibility with abrasion-resistant layers, leading to increased waste and environmental concerns.

Innovation Solution

An in-mold coating process where a plastic resin is injected into a mold with a pre-applied weatherable coating, cured within the mold, and then an abrasion-resistant layer is deposited using vacuum techniques like plasma-enhanced chemical vapor deposition, allowing for uniform thickness and reduced processing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal curing methods are used to cure the coating, then the coating achieves acceptable weatherability and adhesion, but the manufacturing time and energy consumption increase substantially

Engineering Contradiction:

Improvecoating weatherability and adhesionVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the conventional thermal curing process with a UV irradiation curing process. The UV-curable coating composition contains photoinitiators that trigger polymerization upon exposure to UV light, transforming the coating from a liquid state to a cured solid state in minutes rather than hours. This substitution of curing mechanism dramatically reduces manufacturing time and energy consumption while maintaining coating performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional thermal curing methods are used to cure the coating, then the coating achieves acceptable weatherability and adhesion, but the energy input required increases substantially

Engineering Contradiction:

Improvecoating weatherability and adhesionVSAvoidcuring energy input

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional coating methods are used, then the coating can be applied to the plastic glazing, but the transfer efficiency is low and environmental sustainability is reduced due to solvent waste

Engineering Contradiction:

Improvecoating applicationVSAvoidcoating waste and solvent emissions

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent changes the fundamental parameters of the coating composition by using a UV-curable formulation instead of a conventional solvent-based coating. The UV-curable coating contains photoinitiators and reactive monomers/oligomers that polymerize upon UV exposure, eliminating the need for solvents that would otherwise evaporate as waste. This parameter change achieves high transfer efficiency and environmental sustainability.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If inexpensive organic polymers are used in the coating matrix, then the manufacturing cost is reduced, but the coating is not compatible with the deposition of an abrasion resistant layer

Engineering Contradiction:

Improvecoating costVSAvoidabrasion resistance compatibility

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite coating composition that combines UV-curable organic polymers with inorganic fillers such as silica, alumina, or titania. This composite structure provides the cost benefits of organic polymers while the inorganic components create a surface that is compatible with subsequent abrasion-resistant layer deposition. The composite material achieves both economic and performance requirements.

Inventive Principle:

Principle #40Composite materials

5Reliability

If a silicon hard-coat is used in the coating, then the coating is compatible with the deposition of an abrasion resistant layer, but the manufacturing cost increases many times compared to conventional organic coatings

Engineering Contradiction:

Improveabrasion resistance compatibilityVSAvoidcoating cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

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 significantly reduces manufacturing costs and time, ensures compatibility with abrasion-resistant layers, and enhances the durability and weatherability of plastic glazing assemblies, achieving high transfer efficiency and environmental sustainability.

Implementation Method 1

The UV-curable coating composition contains photoinitiators that trigger polymerization upon exposure to UV light, transforming the coating from a liquid state to a cured solid state

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

an abrasion-resistant layer is deposited using vacuum techniques like plasma-enhanced chemical vapor deposition

Methodology Applied

Scientific EffectPlasma-enhanced chemical vapor deposition: Plasma Enhanced Chemical Vapour Deposition

Data Source

PatentUS8236383B2Abrasion resistant plastic glazing with in-mold coating

Publication Date: 2012.08.07 EXATEC LLC

AI summary

This invention relates to plastic glazing assemblies for vehicle tops, windows, headlamps, and taillights, as well as residential and commercial glazing, aircraft glazing, and sunglasses. More specifically, a method of manufacturing a plastic glazing assembly exhibiting a high level of weatherability and abrasion resistance is disclosed which integrates the in-mold application of a coating and the subsequent deposition of an abrasion resistant layer to a molded plastic part.