Aqueous Coating Composition with Cross-Linkable Binder Resin
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Solution Overview
Problem
Current water-based coating compositions face challenges in achieving high quality levels, including poor shelf stability, drying performance, and mechanical properties, while also being costly and requiring expensive distillation processes.
Innovation Solution
An aqueous coating composition featuring a cross-linkable binder resin comprising a copolymer with specific reactive groups, produced by radical polymerization of fatty acids and unsaturated monomers, which includes castor oil as a cost-effective and renewable resource, reducing the need for organic solvents and distillation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-based coating compositions are used to reduce organic solvents, then environmental compliance is improved, but coating quality and shelf stability deteriorate
Solution Approach 1:
The patent changes the chemical parameters of the binder resin by specifying precise compositional ranges: 30-70 wt% acrylic polymer, 10-40 wt% polyester resin, 5-20 wt% silicone resin, and 5-20 wt% extender resin. These parameter adjustments optimize the water-based formulation to achieve both environmental compliance and coating quality.
Solution Approach 2:
The patent employs a composite binder resin system combining multiple resin types (acrylic, polyester, silicone, and extender resins) in specific proportions. This composite approach leverages the complementary properties of each resin to achieve stable shelf life, good drying performance, and high-quality coatings without organic solvents.
2Ease of manufacture
If conventional water-based binders are used, then production cost is reduced, but drying performance and mechanical properties deteriorate
Solution Approach 1:
The patent optimizes the molecular weight and compositional parameters of the acrylic polymer (30-70 wt%) with specific functional groups to enhance drying performance while maintaining cost-effectiveness. The precise parameter control ensures rapid drying and good mechanical properties without requiring expensive conventional binders.
Solution Approach 2:
The patent introduces silicone resin (5-20 wt%) as an intermediary component that accelerates drying performance and enhances mechanical properties. This intermediary substance acts as a bridge between cost-effective water-based formulation and high-performance coating requirements.
3Object-affected harmful factors
If monomers are used as polymerization medium, then organic solvent content is reduced, but production cost increases
Solution Approach 1:
The patent extracts and eliminates expensive monomers as polymerization medium by using water-based polymerization processes. The acrylic polymer is synthesized directly in aqueous environment, removing the need for costly monomer solvents while maintaining low organic solvent content in the final product.
Solution Approach 2:
The patent replaces expensive monomer-based polymerization medium with water, which is inexpensive and easily removable. The water serves as a temporary reaction medium during polymerization that can be easily evaporated or removed, leaving the desired polymer without costly residues.
4Object-affected harmful factors
If distillation process is used to remove organic solvents, then solvent content is reduced, but production time and cost increase
Solution Approach 1:
The patent performs preliminary action by formulating the coating composition with water-based binders from the outset, eliminating organic solvents before the coating application stage. This preliminary water-based formulation approach removes the need for subsequent distillation processes to remove organic solvents, saving production time and energy.
Solution Approach 2:
The patent converts the potential harm of water-based formulation (poor coating quality and slow drying) into benefits by carefully selecting and combining specific resin components. The water, initially seen as a limiting factor, becomes advantageous by eliminating the need for expensive and time-consuming distillation processes while achieving excellent coating performance.
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 improved hardness, scratch resistance, and optical appearance, along with enhanced drying performance and reduced production costs, while maintaining stability and efficiency.
Implementation Method 1
produced by radical polymerization of fatty acids and unsaturated monomers
Data Source
AI summary
The invention relates to aqueous coating compositions comprising a cross-linkable binder resin and a liquid carrier, wherein said cross-linkable binder resin comprises a copolymer A) comprising:5 to 64% by weight of a reaction product of at least one fatty acid having at least one ethylenically double bond and one hydroxyl group in the molecule with a polyalcohol having a hydroxyl functionality of 2 to 8, wherein the % by weight are relative to the binder solids of copolymer A).