Coated articles and their method of manufacturing and use
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shuttering boards for concrete shuttering require coatings that are environmentally friendly, reduce toxic phenol and formaldehyde levels, and maintain smooth, water-resistant surfaces while being reusable, without increasing brittleness or cracking.
Innovation Solution
A coated article comprising a carrier material, preferably paper, with a resin composition of melamine-urea-phenol-formaldehyde-co-condensate or a mixture of melamine-formaldehyde, urea-formaldehyde, and phenol-formaldehyde resins, with specific molar ratios and a B-stage crosslinking degree, to achieve low formaldehyde emission, improved surface properties, and reduced water permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phenol-formaldehyde resins are used to achieve smooth surface properties, then surface quality is improved, but toxicity and environmental safety deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by introducing melamine and urea components into the resin system, replacing pure phenol-formaldehyde resin. This parameter change maintains the smooth surface quality while reducing phenol content and formaldehyde release, thereby resolving the contradiction between surface quality and toxicity
Solution Approach 2:
The patent creates a composite resin system combining melamine-formaldehyde, urea-formaldehyde, and phenol-formaldehyde resins in specific ratios. This composite material approach leverages the advantages of each component: melamine and urea reduce toxicity while phenol-formaldehyde contributes to surface smoothness, thus resolving the contradiction
2Quantity of substance
If formaldehyde to phenol molar ratio is increased to reduce free phenol levels, then phenol content is reduced, but formaldehyde release increases
Solution Approach 1:
The patent changes the molar ratio parameters to phenol:formaldehyde = 1:5 to 1:10, which is lower than conventional ratios. This parameter change, combined with the introduction of melamine and urea, reduces both phenol content and formaldehyde release by providing alternative reaction pathways and reducing free formaldehyde groups
Solution Approach 2:
The patent introduces melamine and urea as intermediary substances that react with formaldehyde to form methylol compounds, reducing free formaldehyde groups. These intermediaries facilitate the reduction of phenol content without proportionally increasing formaldehyde release
3Duration of action of stationary object
If phenol-formaldehyde resin is used for shuttering boards, then reusability is improved, but brittleness increases
Solution Approach 1:
The patent creates a composite resin system where melamine and urea components modify the phenol-formaldehyde resin matrix. This composite structure reduces brittleness through the flexible molecular structure of melamine and urea while maintaining the durability and reusability provided by the phenol-formaldehyde component
4Quantity of substance
If complex process steps are added to reduce phenol levels, then phenol content is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates phenol-reducing components (melamine and urea) directly into the resin formulation during manufacturing, rather than requiring post-production processing steps. This preliminary action reduces phenol content inherently, eliminating the need for complex vacuum heating or azeotropic distillation processes
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 shuttering boards with enhanced environmental safety, low formaldehyde emission, improved surface quality, and reduced water permeability, while maintaining reusability and avoiding cracking, comparable to phenolic resin compositions.
Implementation Method 1
a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate
Implementation Method 2
the polymer chains in the composition are only partially crosslinked, namely the degree of crosslinking is below 100%
Implementation Method 3
it would be advantageous if the shuttering board coating had good water resisting properties
Data Source
AI summary
The present invention relates to a coated article, comprising a carrier material and a resin composition, preferably a B-stage resin composition. The invention further relates to the method of preparing said coated article and in particular to the use of said coated articles for the manufacture of shuttering boards.