Coating Composition Eliminates Bubbling Without Methylcellulose
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Solution Overview
Problem
Existing covering compositions containing methylcellulose often experience bubbling issues during spray coating, leading to compromised coating film performance and corrosion resistance due to increased voids in the coating film.
Innovation Solution
A covering composition is developed that is substantially free from methylcellulose, incorporating a heat-resistant resin, a non-melt-processible fluorine-containing polymer, and a melt-processible fluorine-containing polymer dispersed in a water medium, with a nonionic surfactant added to adjust viscosity and improve wettability, thereby suppressing bubbling and enhancing coating film properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If methylcellulose is added to the covering composition, then the coating film properties are improved, but bubbling occurs during spray coating leading to increased voids and reduced corrosion resistance
Solution Approach 1:
The patent removes methylcellulose from the covering composition to eliminate the bubbling problem. The composition is made substantially free from methylcellulose (less than 0.050 mass%), which prevents bubble formation during spray coating and improves corrosion resistance by reducing voids in the coating film.
Solution Approach 2:
The patent changes the viscosity parameters by adjusting the particle size distribution of the resin particles (average 0.1 to 10 μm) and the proportions of different fluorine-containing polymers. This parameter optimization allows the composition to achieve suitable coating properties without methylcellulose, preventing bubbling while maintaining film quality.
2Ease of manufacture
If methylcellulose is used as a thickener, then the viscosity is increased to improve coating properties, but the coating material bubbles during spray coating
Solution Approach 1:
The patent extracts methylcellulose from the formulation to eliminate bubble generation during spray coating. The composition achieves adequate viscosity and coating properties through the synergistic combination of heat-resistant resin particles and fluorine-containing polymers with controlled particle sizes, without requiring methylcellulose as a thickener.
Solution Approach 2:
The patent uses a composite system comprising heat-resistant resin particles and multiple fluorine-containing polymers (non melt-processible and melt-processible types) with specific particle size distributions. This composite material approach provides the necessary rheological properties for coating application while avoiding the bubbling issue associated with methylcellulose.
3Productivity
If the coating composition contains voids due to bubbling, then the application process is simpler, but the corrosion resistance and mechanical stability are reduced
Solution Approach 1:
The patent removes the source of void formation (methylcellulose) from the composition to prevent bubbling during spray coating. This elimination ensures that the coating film forms without voids, maintaining both high corrosion resistance and mechanical stability while preserving spray coating applicability.
Solution Approach 2:
The patent optimizes particle size parameters (average 0.1 to 10 μm) and composition ratios to achieve a homogeneous dispersion that prevents bubble formation. The controlled particle size distribution ensures proper flow characteristics during application while preventing void formation in the final coating film, thereby maintaining corrosion resistance.
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 effectively reduces bubbling and improves the mechanical stability and corrosion resistance of the coating film, ensuring better coating film properties and reduced voids, making it suitable for applications requiring high corrosion resistance.
Implementation Method 1
a nonionic surfactant added to adjust viscosity and improve wettability
Data Source
AI summary
A covering composition in which a heat-resistant resin (A), a non melt-processible fluorine-containing polymer (B) and a melt-processible fluorine-containing polymer (C) are dispersed in a water medium. The particulate resins (A) to (C) have an average particle size of 0.1 to 10 μm, and the covering composition is substantially free from methylcellulose. Also disclosed is a covered article including a substrate; a primer layer formed by directly applying the covering composition to the substrate; and a topcoat layer containing a fluorine-containing polymer.