Coated Granular Material Catalyst Curing Speed

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Solution Overview

Problem

Existing coating systems for granular substances using polyurethane coatings face challenges such as high inflammability and toxicity of catalysts, increased costs due to explosion-proof requirements and after-treatment needs, slow curing times, and issues with catalyst solubility and distribution, leading to inefficient production processes.

Innovation Solution

A coated granular substance with a resin comprising the reaction product of a polyol and isocyanate components, cured by a hydroxy group-containing amine compound, which is added in liquid form to accelerate curing and reduce catalyst usage, allowing for faster production and improved coating quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If low-boiling amine catalysts are used in gaseous form, then curing speed is improved, but safety hazards and environmental toxicity worsen

Engineering Contradiction:

Improvecuring speedVSAvoidtoxicity and inflammability

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state parameter of the catalyst from gaseous to liquid form, and modifies the chemical structure by incorporating hydroxy groups into the amine catalyst. This parameter change maintains high curing activity while eliminating the safety and environmental problems associated with low-boiling gaseous amine catalysts.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive explosion-proof equipment and complex after-treatment systems with a simple liquid catalyst that requires no special safety measures. The liquid catalyst formulation eliminates the need for costly safety infrastructure while achieving the same curing function.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If explosion-proof systems and after-treatment facilities are installed, then safety is improved, but production costs worsen

Engineering Contradiction:

ImprovesafetyVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the need for explosion-proof systems and after-treatment facilities by replacing gaseous catalysts with liquid catalysts. This removal of harmful gaseous components directly eliminates the requirement for costly safety infrastructure and environmental control equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If multiple coating layers are applied, then coating quality is improved, but production time worsens due to rinsing requirements

Engineering Contradiction:

Improvecoating qualityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent enables continuous multi-layer coating operations without interruption for rinsing. The liquid catalyst formulation allows successive coating layers to be applied continuously, maintaining the curing process without breaks, thereby eliminating time loss while achieving high coating quality through multiple layers.

Inventive Principle:

Principle #20Continuity of useful action

4Ease of operation

If catalyst is added to polyol component, then mixing is simplified, but curing uniformity worsens due to premature reaction

Engineering Contradiction:

Improvemixing simplicityVSAvoidcuring uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent incorporates the catalyst into the polyol component in advance, before coating application. The liquid catalyst formulation ensures that mixing occurs first, followed by uniform distribution and then controlled curing, preventing premature reaction while maintaining operational simplicity.

Inventive Principle:

Principle #10Preliminary action

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 enables rapid curing of the coating, reduces catalyst consumption, and eliminates the need for expensive explosion-proof systems and after-treatment, resulting in cost-effective and efficient production of coated granular substances with enhanced release properties.

Implementation Method 1

cured by the addition of a catalyst... said catalyst comprising a hydroxy group-containing amine compound

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10947410B2Coated granular material

Publication Date: 2021.03.16 ASK CHEM GMBH

AI summary

The present invention relates to a coated granular substance, wherein the coating comprises a resin comprising the reaction product of a polyol component and an isocyanate component and cured by the addition of a catalyst, said catalyst comprising a hydroxy group-containing amine compound.Further, the present invention relates to a process for coating a granular substance, comprising the steps of (a) providing a granular substance; (b) providing a polyol component and an isocyanate component; (c) optionally mixing the polyol component with the isocyanate component; (d) adding the mixture of step (c) or the polyol component and the isocyanate component as individual substances to the provided granular substance and producing a coating on the granular substance; (e) adding a catalyst to cure the coating; (f) optionally repeating steps (d) and (e), wherein the catalyst comprises a hydroxy group-containing amine compound.