Composition and process for applying hydrophobic coating to fibrous substrates
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Solution Overview
Problem
Current methods for applying hydrophobic coatings to fibrous substrates face challenges such as textile shrinkage, inconsistent application, energy-intensive water removal processes, chemical waste, and incompatibility with certain materials due to water-based chemistry, leading to limitations in coating compatibility and environmental concerns.
Innovation Solution
A curable coating composition comprising free-radical-curable monomers with hydrocarbyl groups and crosslinking monomers, applied with limited organic compounds and water content, is used in conjunction with heat and/or superatmospheric pressure to facilitate free-radical polymerization and curing, ensuring effective penetration and adhesion on fibrous substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water-based chemical bath is used for coating, then coating application is achieved, but textile shrinkage and inconsistent application occur
Solution Approach 1:
The invention changes the fundamental parameter of the coating medium from water-based to oil-based chemistry. This parameter change eliminates the shrinkage and inconsistency problems associated with water-based baths while enabling the use of monomeric ingredients that are incompatible with water.
Solution Approach 2:
The invention introduces an oil-based carrier system as an intermediary medium to deliver monomeric coating ingredients to the textile substrate. This intermediary approach allows for better penetration and distribution of active ingredients without causing substrate damage.
2Loss of energy
If water-based coating process is used, then coating is applied, but large amounts of energy are required to remove water
Solution Approach 1:
The invention changes the solvent parameter from water to oil-based carriers, fundamentally altering the drying/curing requirements. This eliminates the need for high-energy water removal processes while maintaining effective coating delivery to the substrate.
3Loss of substance
If water-based chemistry is used, then coating application is achieved, but chemical waste water is generated
Solution Approach 1:
The invention changes the chemical basis from water-based to oil-based chemistry, eliminating the generation of chemical wastewater. This parameter change maintains all necessary coating functions while removing the environmental burden of water treatment and disposal.
4Adaptability or versatility
If water-based coating is used, then coating is applied, but materials incompatible with water cannot be coated
Solution Approach 1:
The invention changes the chemical compatibility parameter from water-based to oil-based chemistry, enabling the use of monomeric ingredients and materials that are incompatible with water. This expands the range of usable coating materials while maintaining effective application.
5Productivity
If conventional pad and cure method is used, then coating is applied, but the process is time-consuming and complex
Solution Approach 1:
The invention changes the chemistry from water-based to oil-based monomeric systems, which simplifies the overall process by eliminating multiple steps such as extensive drying, curing, and wastewater treatment. This parameter change reduces both time and complexity while maintaining coating effectiveness.
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
This method provides a durable, water-repellent finish with reduced environmental impact, improved adhesion, and compatibility with a wider range of materials, while minimizing energy consumption and chemical waste, achieving effective hydrophobic and oleophobic properties at low coating weights.
Implementation Method 1
curing the curable coating composition by free-radical polymerization to form a coated substrate
Implementation Method 2
at least one crosslinking monomer having at least two free-radical-curable polymerizable groups
Implementation Method 3
heating the moistened and coated fibrous substrate to volatilize the water and produce steam at superatmospheric pressure
Implementation Method 4
volatilize the water and produce steam
Data Source
AI summary
Fabrics are treated with a hydrophobic treatment that includes at least one hydrophobic monomer and a crosslinker. The treatment is low in volatile organic compounds and water. It is a liquid at 22° C. or a suspension having a phase that is liquid at 22° C. The monomer and crosslinker are cured in a free radical polymerization to form a hydrophobic coating on a fibrous substrate.