Crushed foam coating
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Solution Overview
Problem
Existing crushed foam coatings lack the desired thickness, add-on, and softness after standard coating and crushing processes, failing to provide significant improvements over conventional coatings.
Innovation Solution
A process involving a foamed aqueous coating composition with multi-stage copolymer particles having a weight average diameter of 2-20 μm and a core with a glass transition temperature of 20° C. or less, which is crushed to achieve enhanced thickness, add-on, and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If standard coating and crushing processes are used, then coating is applied to substrate, but the coating lacks sufficient thickness and add-on
Solution Approach 1:
The patent changes the physical-chemical parameters of the coating composition by incorporating multi-stage copolymer particles with specific glass transition temperatures (20°C or less). This parameter change allows the coating to achieve greater thickness and add-on when crushed, while still using standard coating and crushing processes without requiring complex manufacturing changes.
Solution Approach 2:
The invention uses composite material structure with multi-stage copolymer particles comprising a core and shell with different properties. The core has Tg of 20°C or less to provide softness and thickness, while the overall particle structure maintains coating integrity. This composite approach enables enhanced thickness and add-on without complicating the manufacturing process.
2Ease of operation
If standard coating and crushing processes are used, then coating is applied to substrate, but the coating lacks sufficient softness
Solution Approach 1:
The patent achieves softer handle by changing the glass transition temperature parameter of the copolymer core to 20°C or less. This parameter change makes the coating material inherently softer and more flexible while maintaining manufacturing consistency through controlled particle synthesis with defined size distribution (2-20 μm weight average diameter).
3Length of moving object
If coating penetration is reduced to preserve substrate properties, then fabric softness is maintained, but coating thickness is insufficient
Solution Approach 1:
By changing the particle size parameter (2-20 μm weight average diameter) and glass transition temperature (20°C or less), the coating achieves greater thickness after crushing without requiring deep penetration into the substrate. The foam structure combined with these parameter changes allows the coating to build up thickness on the surface while preserving substrate properties.
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 process results in crushed foam coatings with higher thickness, add-on, and a softer touch compared to conventional coatings, while maintaining a smooth appearance and improved performance in wash durability, dry clean durability, and flexibility.
Implementation Method 1
wherein said multi-stage copolymer particles comprise a core having a glass transition temperature (Tg) of 20° C. or less
Data Source
AI summary
Provided is a process for producing a coating on a substrate comprising one or more steps of crushing a dried layer of a foamed aqueous coating composition, wherein the aqueous coating composition comprises a collection of multi-stage copolymer particles having a weight average diameter of 2-20 μm, wherein said multi-stage copolymer particles comprise a core having a glass transition temperature (Tg) of 20° C. or less. Also provided is a coated substrate made by that process.