Optimizing Hegman Rating in Diluted Polymer Emulsions

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Solution Overview

Problem

Large particle agglomerates in polymer emulsions negatively impact the Hegman rating and chemical/corrosion resistance of coatings, making it challenging to achieve desired coating properties for various end-use applications.

Innovation Solution

A method involving the formation of a concentrated emulsion by feeding a molten polymer resin into a melt kneader with optional surfactant and water, followed by dilution in a mixer where shear work and temperature adjustments are made to optimize the Hegman rating, and additional additives are added as needed to achieve acceptable coating properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If particle agglomerates are present in the polymer emulsion, then the emulsion can be produced with simpler processing, but the Hegman rating of the coating deteriorates and chemical/corrosion resistance decreases

Engineering Contradiction:

Improveemulsion production simplicityVSAvoidHegman rating

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-dispersing the polymer resin in a concentrated emulsion (greater than 60 wt% polymer resin solids) before final dilution. This preliminary concentration step allows for optimized particle distribution and breakdown of agglomerates before the emulsion is diluted to the final concentration (equal to or less than 70 wt% polymer resin solids), thereby improving Hegman rating while maintaining ease of manufacture

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the emulsion production process into two distinct stages: (1) formation of a concentrated emulsion with optimized particle distribution, and (2) subsequent dilution to final concentration. This segmentation allows each stage to be optimized independently - the concentrated emulsion stage focuses on particle dispersion and agglomerate breakdown, while the dilution stage achieves the target Hegman rating without requiring complete re-dispersion of all particles

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If large particle agglomerates are present, then the emulsion production is easier, but the chemical and corrosion resistance of the coating deteriorates due to decreased film integrity

Engineering Contradiction:

Improveemulsion production simplicityVSAvoidchemical and corrosion resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The concentrated emulsion formation stage performs preliminary action by optimizing particle distribution and breaking down large agglomerates before dilution. This ensures that when the emulsion is applied and dries, the polymer particles are properly distributed and bonded, forming an intact film that provides reliable chemical and corrosion resistance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the concentration parameter during processing - starting with a concentrated emulsion (greater than 60 wt% polymer resin solids) and diluting to a final concentration (equal to or less than 70 wt% polymer resin solids). This parameter change optimizes the balance between ease of manufacture and film integrity, as the concentrated stage allows for effective particle distribution while the final concentration ensures proper film formation and protective properties

Inventive Principle:

Principle #35Parameter changes

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 effectively optimizes the Hegman rating and enhances the chemical and corrosion resistance of coatings, ensuring they meet specific end-use requirements by controlling particle size and distribution.

Implementation Method 1

adjusting the shear work in the dilution mixer, wherein the adjusting the shear work may comprise raising or lowering the shear work

Methodology Applied

Scientific EffectShear work: Shear Stress

Implementation Method 2

feeding the concentrated emulsion into a dilution mixer wherein water is continuously or in a single or multi-stage manner added to the concentrated emulsion to dilute the concentrated emulsion

Methodology Applied

Scientific EffectMechanical mixing: Stirring

Implementation Method 3

adjusting the temperature of the concentrated and/or diluted emulsion

Methodology Applied

Scientific EffectTemperature control: Heating

Data Source

PatentUS10851213B2Method for optimizing a hegman rating of a diluted emulsion, a diluted emulsion produced thereby, and a coating made

Publication Date: 2020.12.01 DOW GLOBAL TECHNOLOGIES LLC

AI summary

A method for optimizing a Hegman rating of a diluted emulsion including adjusting the shear work in the dilution mixer, wherein the adjusting the shear work may comprise raising or lowering the shear work; adjusting the temperature of the concentrated and/or diluted emulsion; if not earlier added, adding a basic aqueous solution and/or dispersing agent; adding one or more other additives; and/or adjusting the amount of any additive, basic solution or surfactant solution is provided. Also provided are diluted emulsions produced thereby and coatings made from the diluted emulsions.