Dry Powder Thermosetting Resin Composition for Electrostatic Spraying
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Solution Overview
Problem
Existing dry powder compositions for bonding agents often require solvents for processing, leading to increased production and shipping costs and environmental concerns, and lack optimal particle size distributions for efficient electrostatic spraying applications.
Innovation Solution
A dry powder composition comprising a thermosetting resin with a specific particle size distribution (Dv90 ≤ 50 μm, Dv50 between 5.1 and 12.5 μm, and a narrow distribution ratio of 1.5 to 4.2) is developed, achieved through jet milling, suitable for electrostatic spraying and fluidized bed dipping, and includes a curative and optional anti-caking additives and anti-corrosive pigments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wet spraying or roller coating processes are used with solvent-based bonding agents, then application flexibility is improved, but production costs and environmental impact worsen due to solvent removal requirements
Solution Approach 1:
The invention changes the physical state parameter of the bonding agent from liquid (solvent-based) to solid (dry powder), eliminating the need for solvent removal processes while maintaining application effectiveness through controlled particle size distribution
Solution Approach 2:
The invention extracts and removes the solvent component from the bonding agent formulation, leaving only the essential thermosetting resin and curative components in dry powder form, thereby eliminating all costs and environmental issues associated with solvent handling
2Manufacturing precision
If particle size is reduced to improve coating uniformity, then coating quality improves, but fluidization performance worsens due to excessive fine particles
Solution Approach 1:
The invention optimizes the particle size distribution parameters within a specific range (Dv10: 3-8 μm, Dv50: 8-15 μm, Dv90: 15-30 μm) to achieve the optimal balance between coating uniformity and fluidization performance, rather than simply minimizing particle size
Solution Approach 2:
The invention creates different particle size zones within the distribution - finer particles (Dv10) for coating uniformity and slightly coarser particles (Dv90) for fluidization - allowing each portion of the distribution to serve its specific function
3Ease of operation
If particles larger than 30 μm are present, then fluidization is improved, but coat weight increases unnecessarily
Solution Approach 1:
The invention sets the Dv90 parameter to 15-30 μm, establishing an upper particle size limit that prevents excessive coat weight while maintaining sufficient particle size for adequate fluidization performance
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 cost-effective, environmentally friendly bonding agent with improved coating uniformity and adhesion performance, suitable for various applications including brake pads and rubber compounds, while maintaining bonding strength and durability.
Implementation Method 1
jet milling, suitable for electrostatic spraying and fluidized bed dipping
Implementation Method 2
electrostatic spraying is a coating method which uses a spray gun to create an electrical charge on powder particles, while the substrate to be coated is grounded (made neutral)
Implementation Method 3
the powder to be used as coating is fluidized using air
Data Source
AI summary
The present invention discloses a dry powder composition comprising a thermosetting resin in particulate form, wherein the dry powder composition has a particle size measured according to ISO 13320 (2009) characterized by a Dv90 of 50 μm or lower, a Dv50 in the range of 5.1 to 12.5 μm, and a ratio ofDv90-Dv10Dv50in the range of 1.5 to 4.2. The present invention also discloses processes for preparing the dry powder using jet milling, and processes of applying the dry powder composition to a metal surface. Furthermore, the present invention discloses the uses of the dry powder composition as a bonding material or as an adhesion promoter in a polymer compound.