Core-Shell Matting Particles for Resin Stability

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Solution Overview

Problem

Conventional silica particles used as matting agents face issues with settling during storage due to high density and poor compatibility with organic resin binders, affecting the stability and effectiveness of matting compositions.

Innovation Solution

Development of core-shell particles with a vinyl polymer core and a hydrophobic silane shell, synthesized through soapless emulsion polymerization and sol-gel reactions, which are compatible with organic resin binders and provide improved matting performance by increasing surface roughness and reducing gloss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silica particles are used as matting agent, then matting effect is achieved, but storage stability deteriorates due to particle settling

Engineering Contradiction:

Improvematting effectVSAvoidstorage stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The invention creates a core-shell composite particle where a vinyl polymer core is coated with a hydrophobic silane shell. This composite structure combines the matting capability of inorganic particles with the low density and high compatibility of organic polymers, preventing settling while maintaining matting effect.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the density parameter of the matting particle by replacing dense silica (2.2 g/cm³) with low-density vinyl polymer core-shell particles. This parameter change prevents gravitational settling during storage while maintaining the surface roughness needed for matting effect.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If silica particles are used as matting agent, then matting effect is achieved, but compatibility with organic resin binder deteriorates

Engineering Contradiction:

Improvematting effectVSAvoidcompatibility with organic resin binder

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The core-shell composite structure allows the vinyl polymer core to provide excellent compatibility with organic resin binders through chemical similarity and van der Waals interactions, while the outer shell maintains the matting functionality.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The vinyl polymer material in the core is chemically homogeneous with organic resin binders, both being organic polymers. This material homogeneity ensures excellent compatibility, proper dispersion, and stable interaction between the matting particles and the binder.

Inventive Principle:

Principle #33Homogeneity

3Ease of manufacture

If conventional emulsion polymerization with soap is used, then particle formation is achieved, but environmental friendliness and process simplicity deteriorate

Engineering Contradiction:

Improveparticle formationVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes the harmful component (soap/surfactant) from the conventional emulsion polymerization process. By conducting soapless emulsion polymerization, the process eliminates environmental pollution while still achieving proper particle formation and dispersion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the potentially harmful soap-free condition into a benefit by achieving cleaner production, easier continuous processing, and no interference with subsequent emulsion polymerization steps, while still maintaining effective particle formation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 core-shell particles enhance storage stability and matting effect by rising to the surface of the film, reducing gloss and improving compatibility with resin binders, resulting in a superior matting composition with enhanced antireflective properties.

Implementation Method 1

carrying out a soapless emulsion polymerization to form the core

Methodology Applied

Scientific EffectEmulsion polymerization:

Implementation Method 2

carrying out a sol-gel reaction to form the shell

Methodology Applied

Scientific EffectSol-gel reaction:

Implementation Method 3

The core-shell particles have high hydrophobicity and low density, so they will rise up to the surface of the film

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS10287386B2Core-shell particle, method of manufacturing the same and applications thereof

Publication Date: 2019.05.14 ETERNAL MATERIALS CO LTD

AI summary

The present invention is related to a core-shell particle and preparation and use thereof. The core of the core-shell particle includes a vinyl polymer. The shell of the core-shell particle includes a hydrophobic silane bonded to a surface of the core via a silane coupling agent. The core-shell particles are applied in a matting material as a matting agent.