Aqueous Hybrid Binders for High-Gloss Paints
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Solution Overview
Problem
Existing water-based alkyd-acrylate hybrid binders for high-gloss paints and varnishes fail to achieve desired gloss and surface smoothness while maintaining low residual monomer content and high opacity.
Innovation Solution
A process involving radical emulsion polymerization of α,β-ethylenically unsaturated monomers, followed by the addition of a water-soluble alkyd resin or alkyd emulsion after polymerization, with specific temperature and stirring conditions to enhance gloss and reduce residual monomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If aqueous polymer dispersions are used for high-gloss paints, then the coatings can be produced with water-based formulation, but the gloss and surface smoothness are insufficient
Solution Approach 1:
The patent uses hybrid binders combining acrylic polymer dispersion with alkyd resin (water-soluble or emulsion form) to create a composite binding system. This composite approach allows the acrylic component to provide water-based formulation benefits while the alkyd component enhances gloss and surface smoothness, resolving the contradiction between water-based safety and high-gloss performance
Solution Approach 2:
The patent optimizes multiple parameters including the ratio of acrylic to alkyd components, molecular weight of polymers, particle size distribution of the dispersion, and curing conditions. By systematically adjusting these parameters, the formulation achieves both adequate water-based safety and high gloss/surface quality requirements
2Illumination intensity
If additives are used to improve gloss, then the reflectometer value increases, but the proportion of volatile organic compounds (VOC) increases
Solution Approach 1:
The patent changes the fundamental parameter of the binding agent from traditional solvent-based resins to water-based polymer dispersions hybridized with alkyd. This parameter change allows achieving high gloss through the alkyd component's film-forming properties and light-reflecting surface characteristics without relying on VOC-containing additives, thus resolving the contradiction between gloss enhancement and VOC reduction
3Illumination intensity
If alkyd resin is added to polymer dispersion, then gloss and surface smoothness improve, but residual monomer content increases
Solution Approach 1:
The patent performs preliminary polymerization of the acrylic component to completion before adding the alkyd resin. This preliminary action ensures that the acrylic polymer is fully formed with minimal residual monomers, and the subsequent alkyd addition does not introduce new monomers but rather complements the existing polymer matrix to enhance gloss and surface properties
Solution Approach 2:
The hybrid binder system combines fully polymerized acrylic dispersion with alkyd resin in a composite structure. The acrylic component provides the water-based matrix with low residual monomers, while the alkyd component provides the gloss-enhancing film-forming properties, achieving both low residual monomer content and high gloss through material composition rather than incomplete polymerization
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 process increases the gloss of coating materials while minimizing residual acrylate monomers, achieving high gloss and opacity in paints, particularly in high-gloss varnishes.
Implementation Method 1
producing an aqueous polymer dispersion (PD) by radical emulsion polymerization of at least one α,β-ethylenically unsaturated monomer (M)
Implementation Method 2
optionally subsequent chemical deodorization
Data Source
AI summary
The present invention relates to the use of aqueous hybrid binding agents for producing coating agents, in particular in high-gloss coating materials (high-gloss paints), and to a method for the production thereof having low residual monomer content.