Crosslinkable Coating Composition Reducing Odor
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Solution Overview
Problem
Conventional polyurethane coatings derived from isocyanates pose environmental and health concerns, and existing isocyanate-free alternatives often have issues with odor, which cannot be effectively addressed by adding odor masking agents.
Innovation Solution
A crosslinkable composition comprising a polyol, a polycarbamate, a polyaldehyde, an acid catalyst with a pKa of less than 6.0, and a hindered phenol with a molecular weight of 300 or more, which reduces odor while maintaining comparable drying speed and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If isocyanate-free polyurethane coatings are used, then environmental and health safety is improved, but odor increases
Solution Approach 1:
The patent changes the molecular weight parameter of the hindered phenol antioxidant from conventional low molecular weight to high molecular weight (300 or more), which fundamentally alters the odor profile while maintaining the antioxidant function. This parameter change allows the coating to remain isocyanate-free for safety while reducing odor through the selection of higher molecular weight compounds that have lower volatility and odor.
2Object-generated harmful factors
If high molecular weight hindered phenol is added, then odor is reduced, but drying speed and hardness may be affected
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: the molecular weight of hindered phenol (300 or more), the pKa of acid catalyst (less than 6.0), and the functionality of polyol/polycarbamate (2 or more functional groups). These coordinated parameter changes ensure that odor is reduced through high molecular weight antioxidant while drying speed and hardness are maintained through appropriate catalyst strength and polymer functionality.
Solution Approach 2:
The patent creates a composite coating system combining multiple components with specific properties: polyol or polycarbamate with 2+ functional groups, polyaldehyde, acid catalyst with pKa < 6.0, and hindered phenol with molecular weight ≥ 300. This composite formulation achieves the balance between odor reduction and performance maintenance through synergistic interactions among components.
3Object-generated harmful factors
If high molecular weight hindered phenol is added, then odor is reduced, but coating hardness may be compromised
Solution Approach 1:
The patent specifies that the polyol or polycarbamate must have an average of 2 or more functional groups, which ensures sufficient crosslinking density and network formation for adequate hardness. Simultaneously, the acid catalyst with pKa less than 6.0 provides optimal catalytic activity to achieve proper curing. These parameter specifications ensure that hardness is maintained despite the use of high molecular weight hindered phenol for odor reduction.
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 composition provides a coating with reduced odor and comparable drying speed and hardness to conventional compositions, making it a more environmentally friendly and odor-effective alternative.
Implementation Method 1
a hindered phenol having a molecular weight of 300 or more
Implementation Method 2
an acid catalyst having a pKa of less than 6.0
Implementation Method 3
a polyol, a polycarbamate, or mixtures thereof; having an average of 2 or more functional groups; (b) a polyaldehyde, an acetal or hemiacetal of the polyaldehyde
Data Source
AI summary
A crosslinkable composition, a coating made therefrom, a process for producing a coating with reduced odor, and a method of reducing the odor of a coating.