Branched Polysiloxane Anti-Misting Coating Additive
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Solution Overview
Problem
High-speed coating processes in the paper industry face significant misting and aerosoling issues, which pose manufacturing challenges and industrial hygiene risks, and existing mist suppressant compositions do not adequately address these problems while providing cost savings and ease of production.
Innovation Solution
A composition comprising a silicone-based coating component and an anti-misting amount of branched polysiloxane, resulting from the copolymerization of organosilicon compounds with unsaturated hydrocarbon functional groups and silylhydride-containing compounds under hydrosilylation conditions, is used to reduce misting during high-speed coating operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed coating processes are used to increase productivity, then coating speed increases, but misting and aerosoling problems worsen
Solution Approach 1:
A silicone-based mist suppressant composition is introduced as an intermediary substance added to the coating formulation. This suppressant acts as a mediator that modifies the coating's surface properties and flow characteristics, reducing mist formation during high-speed application without compromising coating performance
Solution Approach 2:
The invention changes the chemical composition parameters of the coating by incorporating specific silicone-based mist suppressants at controlled concentrations (typically 0.1-10% by weight). This parameter modification alters the coating's rheological properties and surface tension, enabling high-speed application with reduced misting
2Object-generated harmful factors
If specialized mist suppressant compositions are used to reduce misting, then mist formation decreases, but manufacturing cost increases
Solution Approach 1:
The invention employs cost-effective silicone-based mist suppressants that can be readily incorporated into standard coating formulations. These suppressants are used at relatively low concentrations (0.1-10% by weight), making them economically viable alternatives to expensive specialized mist suppressant compositions while maintaining effective mist reduction
Solution Approach 2:
The silicone-based mist suppressant composition serves multiple functions: it reduces misting during application, maintains coating release properties, and ensures proper adhesion. This multi-functionality eliminates the need for separate specialized mist suppressant products, reducing overall manufacturing costs
3Object-generated harmful factors
If existing mist suppressant compositions are used, then some mist reduction is achieved, but ease of use and production simplicity are compromised
Solution Approach 1:
The invention combines the mist suppressant functionality directly into the coating formulation itself, creating an integrated composition that requires no separate application steps or specialized equipment. The silicone-based suppressant is mixed with the coating materials to form a unified composition that is easier to handle and apply than separate mist suppressant systems
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 composition significantly reduces misting during high-speed coating operations while offering economic benefits and ease of use, providing effective paper release and adhesive properties.
Implementation Method 1
copolymerizing under hydrosilylation conditions a component mixture comprising: (a) one or more organosilicon compounds containing at least two unsaturated hydrocarbon functional groups per molecule, said unsaturated hydrocarbon functional groups capable of undergoing a hydrosilylation reaction with a silylhydride-containing compound under hydrosilylation conditions; and (b) one or more silylhydride-containing compounds containing at least two silylhydride functional groups per molecule
Data Source
AI summary
The invention relates to coating formulations comprising (i) a silicone-based coating component susceptible to misting under mist-producing conditions; and (ii) an anti-misting amount of a branched polysiloxane component resulting from copolymerizing under hydrosilylation conditions a component mixture comprising (a) one or more organosilicon compounds containing at least two unsaturated hydrocarbon functional groups per molecule, and (b) one or more silylhydride-containing compounds containing at least two silylhydride functional groups per molecule, with the provision that (i) at least one component (a) or (b) contains at least three functional groups per molecule; (ii) a component (a) or (b) having a higher number of functional groups per molecule is present in a molar amount equal to or lower than a molar amount of the other component (a) or (b) having a lower number of functional groups per molecule; and (iii) unsaturated hydrocarbon compounds are excluded from the component mixture. The invention also relates to a process for coating a substrate with the above coating formulation, as well as hardened silicone-based coatings or films obtained by subjecting the coated substrate to one or more curing steps.