Partial Matting UV Varnish via Excimer Irradiation
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Solution Overview
Problem
Existing methods for achieving partial matting of UV coating layers result in inconsistent scratch resistance across the surface, requiring multiple steps and thickness differences between matted and glossy areas.
Innovation Solution
A process involving the application of a UV lacquer layer on a carrier substrate, followed by excimer irradiation using a stencil with UV-permeable and opaque areas to create a micro-rough surface for matting, while maintaining high scratch resistance and even thickness across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple coating steps are used to achieve partial matting, then matting effect is improved, but device complexity and production time increase
Solution Approach 1:
The patent segments the UV-curable coating into two functional layers: a base layer providing scratch resistance and a top layer providing matting effect. This segmentation allows each layer to be optimized independently and applied in a single coating step, resolving the contradiction between achieving matting effect and simplifying the coating process.
Solution Approach 2:
The patent introduces a specific intermediary layer (the matting top layer with 3-30 μm thickness containing matting agents) between the substrate and the environment. This intermediary layer serves as the mediating element that provides the matting effect without requiring multiple coating steps, as it is applied as part of a single coating process.
2Manufacturing precision
If multiple coating steps are used to achieve partial matting, then matting effect is improved, but productivity decreases
Solution Approach 1:
The patent merges the application of the base layer and the matting top layer into a single coating step. The coating composition is formulated to create both layers simultaneously, and the UV irradiation cures both layers in one operation. This merging eliminates the time required for multiple separate coating steps, thereby improving productivity while maintaining the matting effect.
Solution Approach 2:
The patent ensures continuity of the coating process by applying both the base layer and the matting top layer in an uninterrupted single step. The UV irradiation continuously cures the coating as it is applied, eliminating idle time between coating steps and maintaining continuous production flow, thus improving productivity.
3Manufacturing precision
If UV irradiation is applied to create micro-folding for matting, then matting effect is improved, but scratch resistance may be compromised
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different layers: the base layer maintains a smooth, highly crosslinked structure for scratch resistance, while the top layer develops micro-folding for matting effect. The UV irradiation parameters are optimized to induce micro-folding specifically in the top layer without compromising the integrity and scratch resistance of the base layer.
Solution Approach 2:
The patent uses a composite coating structure with two distinct layers having different properties. The base layer is formulated for high scratch resistance with complete UV crosslinking, while the top layer contains matting agents and is designed to develop micro-folding under UV irradiation. This composite structure allows both scratch resistance and matting effect to coexist without compromise.
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
Enables single-operation partial matting of UV coating layers with consistent scratch resistance and high contrast between matted and glossy areas, facilitating efficient and cost-effective large-volume production of decorative and functional parts.
Implementation Method 1
irradiation of monochromatic short-wave UV light, which is able to generate polymer radicals in the wet layer consisting of monomers or oligomers
Implementation Method 2
a Polymerization and crosslinking is triggered, which leads to micro-folding via shrinkage
Implementation Method 3
excimer irradiation using a stencil with UV-permeable and opaque areas
Data Source
AI summary
The method involves applying an UV lacquer coating (4) on a carrier substrate (1), and treating the coating in the substrate using an excimer radiator (7), where the radiator is formed with a serigraphic template (6) provided with areas (6a) permeable for excimer radiations and areas (6b) impermeable for the excimer radiations. The coating is illuminated by the template, where the template has a cylindrical net- or web-like frame that is sealed by an excimer radiation impermeable layer i.e. plastic layer. A cylinder made of quartz or magnesium fluoride is provided in the template.