Water-Based Primer for Elastic Substrates
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Solution Overview
Problem
Conventional water-based and solvent-based paints face challenges in adhesion to elastic and plasticized substrates, emit volatile organic compounds (VOCs), and have limited resistance to aggressive chemicals and dirt, making them unsuitable for flexible surfaces like artificial leather.
Innovation Solution
A composite structure comprising a carrier layer, a water-based primer layer with high water content and minimal organic solvents, and an excimer lacquer layer that provides improved adhesion, chemical resistance, and embossability, while eliminating VOCs and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional water-based coatings are used on elastic substrates, then the coating can be applied to flexible surfaces, but the coating has limited resistance to aggressive chemicals and poor adhesion
Solution Approach 1:
The coating system is divided into multiple layers: a primer layer containing dispersed curable solid and a topcoat layer. This segmentation allows each layer to perform its specific function - the primer provides adhesion and surface roughness, while the topcoat provides chemical resistance.
Solution Approach 2:
The primer layer acts as an intermediary between the elastic substrate and the topcoat. It contains a dispersed curable solid that creates a rough surface profile, serving as a mechanical anchor for the topcoat while also providing chemical resistance properties.
2Reliability
If UV coatings are used to improve chemical resistance, then the coating achieves high resistance to aggressive chemicals, but the coating becomes too hard for elastic substrates and is difficult to apply
Solution Approach 1:
Different regions of the coating system have different properties: the primer layer is formulated to be compatible with elastic substrates and provide flexibility, while the topcoat layer provides the hard, chemically resistant surface. This local differentiation resolves the contradiction between hardness and flexibility.
3Shape
If conventional matting agents are used to create matte surfaces, then the surface appearance is adjusted, but the coating offers only temporary resistance to dirt and colored media
Solution Approach 1:
The coating uses a composite formulation with dispersed curable solid particles that provide both matting effect and durable soiling resistance. The combination of these materials creates a surface that is both matte in appearance and highly resistant to dirt and colored media penetration.
4Reliability
If primers with organic solvents are used to improve adhesion, then the adhesion of excimer coating to substrate is enhanced, but VOCs are emitted and mechanical integrity is negatively influenced
Solution Approach 1:
The primer formulation is changed from organic solvent-based to water-based with dispersed curable solid. This parameter change eliminates VOC emissions while maintaining adhesion properties through the rough surface profile created by the dispersed solid particles upon curing.
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 composite structure achieves durable, VOC-free, and embossable coatings with enhanced resistance to chemicals and dirt, offering a visually and olfactorily neutral finish on flexible substrates with reduced energy usage.
Implementation Method 1
a water-based primer layer which has been cured by UV irradiation
Implementation Method 2
an excimer lacquer layer which has been cured by UV irradiation
Data Source
AI summary
A composite structure comprising a substrate, a water-based primer layer, and an excimer lacquer layer is described, as is a method for producing such a composite structure, comprising the steps of providing a substrate, applying a water-based primer to a surface of the substrate, curing the water-based primer to form a cured primer layer, applying an excimer lacquer to the cured primer layer, and curing the excimer lacquer. A composite structure obtainable by this method is also described, as well as the use of such composite structures as covering material.