Cross-linked Modified Wax Coating for Controlled Release Fertilizers
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Solution Overview
Problem
Existing controlled release fertilizers are expensive to manufacture and lack the ability to customize release rate profiles effectively, often requiring significant amounts of coating materials and not being abrasion-resistant.
Innovation Solution
A controlled release fertilizer composition using a plant nutrient coated with a reaction product of an isocyanate and a polyol, where the coating includes a modified wax that is cross-linked with sulfur, oxygen, or a peroxide moiety, such as a cross-linked alpha olefin wax or a combination with a polyhydroxyl compound, to achieve a more controlled release rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating materials are used in controlled release fertilizers, then the release rate can be controlled, but the manufacturing cost increases and abrasion resistance is insufficient
Solution Approach 1:
The patent applies composite materials by combining polyol, isocyanate, and wax to form a multi-component coating system. This composite coating provides both controlled release functionality and enhanced abrasion resistance while maintaining cost-effectiveness through optimized material composition and cross-linking mechanisms.
Solution Approach 2:
The patent utilizes parameter changes by controlling the cross-linking degree of the coating through isocyanate-to-polyol ratio and curing conditions. By adjusting these parameters, the coating achieves optimal balance between abrasion resistance, controlled release properties, and manufacturing cost without requiring excessive material application.
2Reliability
If significant amounts of coating materials are applied, then abrasion resistance improves, but the cost of manufacturing increases
Solution Approach 1:
The patent optimizes the amount of coating materials by controlling the cross-linking reaction parameters. By adjusting isocyanate-to-polyol ratio, temperature, and curing time, the coating achieves maximum abrasion resistance with minimized material usage, avoiding excessive coating application while maintaining protective properties.
Solution Approach 2:
The composite coating system combines multiple materials (polyol, isocyanate, wax) that work synergistically. This composite approach provides enhanced abrasion resistance at lower total coating loading compared to single-material coatings, reducing the quantity of coating materials required while maintaining reliability.
3Adaptability or versatility
If conventional coatings are used, then the fertilizer can be manufactured, but the release rate profile cannot be customized effectively
Solution Approach 1:
The patent enables customization of release rate profiles by adjusting coating formulation parameters such as isocyanate-to-polyol ratio, wax content, and cross-linking degree. These parameter adjustments allow tailoring of release characteristics without requiring complex multi-layer coatings or sophisticated processing equipment, maintaining formulation simplicity while achieving versatility.
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 use of cross-linked modified waxes in the coating reduces the amount of coating materials needed while enhancing the fertilizer's abrasion resistance and allowing for customizable release profiles, resulting in a more efficient and cost-effective controlled release of nutrients.
Implementation Method 1
the modified wax is an unsaturated wax component that is cross-linked with sulfur, oxygen and/or a peroxide cross-linking moiety
Implementation Method 2
enhancing the fertilizer's abrasion resistance
Implementation Method 3
a reaction product of a mixture including an isocyanate and a polyol
Data Source
AI summary
A controlled release fertilizer material comprising a particulate plant nutrient surrounded by a coating of a mixture including an isocyanate and a polyol, and further comprising a modified wax that may include a polyhydroxyl compound in which the wax and/or the polyhydroxyl compound are cross-linked with a sulfur or oxygen or a peroxide cross-linking moiety. In certain embodiments, the wax and polyhydroxyl compound are cross-linked at unsaturated sites in the wax or polyhydroxyl compound using heat, UV or ionizing radiation.