High-Solid Alkyd Dispersion with Low Acid Value
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Solution Overview
Problem
Current water-based alkyd dispersions require functionalization of resins to achieve coating properties comparable to solvent-grade alkyds, and they often have high volatile organic compounds (VOC) levels, which is a challenge for meeting stringent VOC regulations.
Innovation Solution
An aqueous, high-solid, solvent-free alkyd dispersion is developed, comprising 40-70% alkyds with an acid value less than 20 and molecular weight greater than 1000 Dalton, along with less than 10% stabilizing agents and 30-55% water, produced through a continuous process involving emulsification and neutralization, resulting in a dispersion with particle sizes between 0.05-5 μm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If current water-based alkyd dispersions use low molecular weight resins with high acid values or high levels of emulsifying agents to improve water dispersibility, then water dispersibility is improved, but the coating performance and solid content are compromised
Solution Approach 1:
The patent changes the molecular weight parameter to greater than 1000 Dalton and acid value parameter to less than 20, which fundamentally alters the resin properties to enable high solid content (40-70% alkyd) while maintaining water dispersibility through controlled neutralization with amines rather than relying on high acid values or excessive emulsifying agents
Solution Approach 2:
The patent creates a water-based dispersion that copies the performance characteristics of solvent-grade alkyds by using high molecular weight resins with controlled neutralization, achieving comparable coating properties without the need for functionalization or high VOC solvents
2Reliability
If solvent-borne coatings are used to achieve coating performance, then coating performance is improved, but volatile organic compounds (VOC) levels increase
Solution Approach 1:
The patent replaces the solvent-based mechanical system with a water-based dispersion system, using water as the continuous phase instead of organic solvents, thereby eliminating VOC emissions while maintaining coating performance through high solid content (40-70% alkyd) and controlled neutralization chemistry
Solution Approach 2:
The patent changes the base medium parameter from organic solvent to water, and adjusts the resin parameters (molecular weight >1000 Dalton, acid value <20) to enable high solid content in water, achieving low VOC levels while maintaining coating performance comparable to solvent-grade alkyds
3Reliability
If resin functionalization is used to achieve coating properties, then coating performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs neutralization of the alkyd resin with amines during the dispersion formulation process rather than requiring pre-functionalization of the resin, simplifying manufacturing by using standard alkyd resins (acid value <20, molecular weight >1000 Dalton) that are neutralized in situ to achieve water dispersibility and coating properties
Solution Approach 2:
The patent avoids expensive and complex resin functionalization processes by using readily available high molecular weight alkyd resins with controlled neutralization, reducing manufacturing complexity while achieving comparable coating performance through simple amine neutralization during formulation
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 solution provides coatings with scrub resistance, improved tannin stain resistance, and heat age stability while maintaining low VOC levels, addressing the need for performance comparable to solvent-grade alkyds without resin functionalization and high VOC content.
Implementation Method 1
continuously emulsifying said one or more molten or liquid alkyds in the water in the presence of said one or more stabilizing agents
Implementation Method 2
from 40 to 70 percent by weight of one or more alkyds based on the total weight of the dispersion, wherein each one or more alkyds has an acid value of less than 20
Data Source
AI summary
The instant invention provides a high-solid, solvent-free alkyd dispersion, and a continuous process for producing the same. The aqueous alkyd dispersion, according to the present invention comprises (a) from 40 to 70 percent by weight of one or more alkyds based on the total weight of the dispersion, wherein each one or more alkyds has an acid value of less than 20 and a molecular weight (Mn) in the range of greater than 1000 Dalton; (b) from less than 10 percent by weight of one or more surfactants, based on the total weight of the dispersion; and (c) from 30 to 55 percent by weight of water, based on the total weight of the dispersion; and the dispersion has an average particle size diameter in the range of 0.05 to 5 μm.