Cellulose Composite Coating Resolving Sagging and Popping
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Solution Overview
Problem
Aqueous coating materials face challenges with dispersion stability, particularly during spray coating and baking, where sagging or popping occurs, and in wet-on-wet coating methods, leading to poor interface control and chipping resistance.
Innovation Solution
A composition comprising a cellulose composite with a hydrophilic polymer and crystalline cellulose, along with a synthetic resin and hardening agent, achieving high viscosity and stability to prevent sagging and popping, and maintaining interface control during wet-on-wet coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thickener is used to achieve high viscosity in aqueous coating material, then storage stability is improved, but coatability and smoothness deteriorate due to extremely precise viscosity control requirements
Solution Approach 1:
The patent uses crystalline cellulose composite particles with specific size parameters (0.1-10 μm average particle size) to modify the rheological properties of the coating material. This particle size parameter enables the material to achieve high viscosity for storage stability while maintaining coatability, resolving the contradiction between stability and ease of operation.
Solution Approach 2:
The patent employs a composite system consisting of crystalline cellulose composite particles combined with thickeners in an aqueous coating material. This composite approach allows the crystalline cellulose to provide structural support and viscosity enhancement while the thickeners contribute to flow control, achieving both storage stability and coatability simultaneously.
2Stability of the object's composition
If viscosity is increased to prevent sagging or popping in baking coating, then storage stability is improved, but workability deteriorates
Solution Approach 1:
The patent utilizes crystalline cellulose composite particles with controlled size parameters (0.1-10 μm) to modify the viscosity profile of the coating material. These particles provide shear-thinning behavior that maintains high viscosity at rest for sagging prevention while reducing viscosity during application for good workability, resolving the contradiction between stability and ease of operation.
Solution Approach 2:
The patent employs a dynamic viscosity system where the coating material exhibits different viscosity characteristics under different flow conditions. The crystalline cellulose composite creates a non-Newtonian fluid behavior that is highly viscous when stationary (preventing sagging) but becomes less viscous under shear stress during spray coating (maintaining workability).
3Stability of the object's composition
If crystalline cellulose composite with average particle size of approximately 10 μm is used, then dispersion stability is improved, but smoothness deteriorates and clogging risk increases
Solution Approach 1:
The patent segments the crystalline cellulose into composite particles with a specific size distribution (0.1-10 μm average particle size). This segmentation into fine particles improves smoothness and reduces clogging risk while the composite structure maintains dispersion stability, resolving the contradiction between stability and manufacturing precision.
Solution Approach 2:
The patent applies different particle size characteristics to different functional requirements: the crystalline cellulose composite particles provide dispersion stability through their specific size and structure, while the fine particle size (0.1-10 μm) ensures smoothness and prevents clogging. This local optimization of particle properties resolves the contradiction between stability and manufacturing precision.
Data Source
AI summary
Disclosed is a composition containing 100 parts by mass of a pigment, 0.01-50 parts by mass of a cellulose composite and waster. The composition has a solid content of more than 25% by mass, and a viscosity of not less than 30 mPa·S. The cellulose composite contains 0.5-50% by mass of a hydrophilic polymer having an acid value of not less than 2.0 and a weight average molecular weight of from 1 × 103 to 1 × 107 and 54-99.5°/a by mass of a crystalline cellulose. The cellulose composite has an average particle diameter of not more than 10 µm.