UV-Cured Structuring Agent With Adhesion Promoter for Laminate Embossing
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Solution Overview
Problem
Existing methods for producing structuring agents for resin-containing laminate surfaces are costly, require high energy consumption, and suffer from inadequate adhesion of lacquers to carrier materials, leading to surface defects and detachment issues during pressing.
Innovation Solution
A method involving the application of an adhesion promoter layer comprising acrylated oligomer, reactive diluent, and photoinitiator before applying a UV-curable lacquer layer, which is then cured with high-energy radiation, ensuring strong adhesion and high mechanical and thermal resistance of the structuring agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a UV-curable lacquer layer is applied directly to the carrier material without adhesion promoter, then the production process is simpler and faster, but the adhesion between lacquer and carrier material is insufficient causing detachment during pressing
Solution Approach 1:
An adhesion promoter layer composed of acrylated oligomer, reactive diluent, and photoinitiator is applied between the UV-curable lacquer layer and the carrier material. This intermediary layer chemically bonds to both the carrier material and the lacquer, creating strong adhesion and preventing detachment during the pressing process while maintaining production efficiency
2Reliability
If electron beam radiation is used to cure the lacquer layer, then complete curing is achieved, but the investment costs and energy consumption are very high
Solution Approach 1:
The curing method is changed from electron beam radiation to UV radiation by modifying the photoinitiator system in the lacquer formulation. The lacquer contains photoinitiators that are specifically activated by UV wavelengths, enabling effective curing with lower energy consumption and reduced investment costs while achieving complete curing through optimized UV irradiation parameters
3Strength
If the lacquer layer is made harder to increase mechanical resistance, then the structuring agent withstands pressing better, but the adhesion to the carrier material decreases causing detachment
Solution Approach 1:
The system is designed as a composite structure with three distinct layers: the carrier material, the adhesion promoter layer with intermediate hardness optimized for bonding, and the hard lacquer layer for mechanical resistance. This composite approach allows the lacquer to be hard for pressing durability while the adhesion promoter maintains strong bonding to the carrier material
4Manufacturing precision
If high pressure and high temperature are used during pressing to achieve good texturing, then the laminate surface is properly textured, but the structuring agent suffers considerable wear and requires frequent replacement
Solution Approach 1:
The adhesion promoter layer is applied in advance to the carrier material before the lacquer layer, creating a pre-bonded interface that is optimized for both adhesion and pressure distribution. This preliminary preparation ensures that during high-pressure pressing, the structuring agent maintains integrity and withstands wear, extending its service life while achieving good texturing quality
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 method enables cost-effective production of structuring agents with high adhesion and durability, allowing for precise texturing of laminate surfaces without visible detachment, and supports efficient UV curing for rapid production.
Implementation Method 1
a UV-curable lacquer layer of acrylated oligomer is applied to the carrier material, forming a three-dimensional embossed structure into the lacquer layer applied to the carrier material, and curing the lacquer layer by irradiation with high-energy radiation, preferably UV light
Implementation Method 2
at least one adhesion promoter layer comprising acrylated oligomer, a reactive diluent and a photoinitiator which reacts to high-energy radiation, preferably UV radiation, is applied to the carrier material
Data Source
AI summary
A method for producing a structuring agent for texturing an embossable material surface, in particular a resin-containing laminate surface, including the steps of providing a web-shaped carrier material made of paper and/or plastic, applying a UV-curable lacquer layer made of acrylated oligomer to the carrier material, forming a three-dimensional embossed structure into the lacquer layer applied to the carrier material and curing the lacquer layer by irradiation with high-energy radiation, preferably UV light, during the molding of the embossed structure. The invention provides that before the UV-curable lacquer layer is applied at least one adhesion promoter layer including acrylated oligomer, a reactive diluent and a photoinitiator which reacts to high-energy radiation, preferably UV radiation, is applied onto the carrier material, and that the lacquer layer having the embossed structure is cured by irradiation with high-energy radiation, preferably UV light, to such an extent that, in the finished state, the structuring agent has an average Martens hardness according to DIN EN ISO 14577 in the range from 10 to 80 N/mm2, preferably in the range from 30 to 80 N/mm2, the indenter used as a test body for measuring the Martens hardness being pressed into the surface of the lacquer layer having the embossed structure. A structuring agent is also disclosed.