Coating Composition with Liquid Binder and Powder Catalyst
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Solution Overview
Problem
Existing coating systems face challenges with premature curing inhibition by oxygen and limited durability due to the use of peroxides, which are harmful and only suitable for specific binder types, leading to tacky layers with low curing efficiency.
Innovation Solution
A coating composition featuring cross-linkable polymer binders in a liquid phase combined with a dry, sprinkleable powder phase containing a catalyst or its precursor, which undergoes polar reactions for controlled cross-linking, allowing for a long pot life and fast curing without radical polymerization inhibition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If peroxides are used to cure the paint layer, then curing can be achieved, but oxygen in the air causes premature inhibition of radical polymerisation resulting in a tacky layer with low degree of curing
Solution Approach 1:
The patent extracts the harmful peroxide curing mechanism from the system and replaces it with a carbodiimide-based crosslinking mechanism that is not susceptible to oxygen inhibition, thereby eliminating the tacky layer problem while maintaining curing functionality
Solution Approach 2:
The patent changes the chemical reaction mechanism from radical polymerisation (peroxide-based) to carbodiimide crosslinking, fundamentally altering the curing parameters to eliminate oxygen sensitivity and improve curing efficiency
2Ease of manufacture
If peroxides are used for curing, then specific binder types can be cured, but peroxides are detrimental to health and the environment and cannot be sprinkled with bare hands
Solution Approach 1:
The patent removes peroxides from the coating system entirely and substitutes them with carbodiimide crosslinking agents, eliminating the health and environmental hazards associated with peroxide handling while maintaining effective crosslinking functionality
Solution Approach 2:
The patent employs a water-based coating composition that is environmentally benign and safe for handling, replacing the hazardous peroxide system with a safer alternative that does not require special protective measures during application
3Duration of action of stationary object
If radical polymerisation is used for cross-linking, then curing can occur, but the reaction can be inhibited by oxygen leading to tacky layers
Solution Approach 1:
The patent fundamentally changes the crosslinking mechanism from radical polymerisation to carbodiimide chemistry, altering the reaction parameters to eliminate oxygen inhibition while maintaining appropriate curing speed and producing a durable, non-tacky coating layer
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 easy and safe application with a durable coating layer, providing a long pot life and preventing premature curing, while ensuring the coating is not affected by oxygen, resulting in a robust and effective curing process.
Implementation Method 1
cross-linkable by polar reaction and at least one catalyst... Polar reactions are non-radical reactions. No radical formation takes place. Polar reactions take place between nucleophiles and electrophiles and involve electron pair exchange.
Implementation Method 2
one or more polymer binder components having functional groups capable of cross-linking... compounds capable of activating cross-linking of the binder components
Data Source
AI summary
Coating composition comprising a liquid first phase comprising one or more polymer binder components having functional groups capable of cross-linking by electron pair exchange, and a second phase which is a powder material, such as sand, comprising one or more compounds capable of activating crosslinking of the binder components in the liquid phase after the second phase is exposed to the first phase. The activating compound in the second phase may include a Lewis acid or Lewis base. Alternatively, the liquid phase comprises a compound which is reactive with the activating compound in the powder phase to form a Lewis base or Lewis acid. Method of applying a coating composition curable by cross-linking chemistry based on electron pair exchange, wherein after application of a layer of the coating composition on a substrate, a powder material comprising one or more cross-linking activating compounds is sprinkled over the wet layer. The thickness of the freshly applied coating layer is less than the particle size of at least a part of the powder material. After sprinkling the powder material over the coating layer, a second coating layer is applied.