Electron-Conducting Coating with Water-Based Graphene Layers
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Solution Overview
Problem
Existing coatings face challenges such as the use of harmful solvents, complex and costly manufacturing processes, poor scalability, and difficulty in achieving rough surfaces with nanostructured materials like graphene and nanographite, especially when applied to water-absorbent materials like paper, leading to dimensional changes and energy-intensive drying.
Innovation Solution
A coating composition comprising polymerized C10-30alkanetriC1-5alkoxysilane, surfactant, organic acid catalyst, and optionally inorganic components, combined with a second coating of graphene or nanographite, applied through a simple and scalable process that avoids high temperatures and pressures, ensuring thermal and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If aqueous suspensions with high water content (90 wt% or more) are used to coat nanostructured materials like graphene and nanographite, then the suspension rheology becomes manageable and coating can be applied, but the high water amount causes dimensional changes in water-absorbent substrates leading to wrinkles and cracks, and requires excessive energy for drying
Solution Approach 1:
The patent changes the concentration parameter of the aqueous suspension from high (90 wt% or more water) to optimized lower water content formulations. This parameter change allows the coating to be applied without excessive water that causes substrate dimensional changes, while still maintaining manageable rheology for coating processes. The optimized concentration balance prevents wrinkles and cracks in the coating.
2Ease of operation
If aqueous suspensions with high water content (90 wt% or more) are used to coat nanostructured materials like graphene and nanographite, then the suspension rheology becomes manageable and coating can be applied, but the high water amount requires a lot of energy in the drying process
Solution Approach 1:
The patent optimizes the water content parameter in the aqueous suspension from excessive amounts (90 wt% or more) to reduced water content formulations. This parameter change directly reduces the energy required for drying while maintaining sufficient fluidity and rheology for practical coating application. The optimized formulation achieves the right balance between applicability and energy efficiency.
3Ease of manufacture
If conventional solvents such as alcohols, ammonia, ammonium hydroxide, sulfonates, or amides are used in coating manufacturing, then the coating can be applied and processed, but the solvents are volatile, flammable, corrosive and harmful to humans and nature
Solution Approach 1:
The patent changes the chemical composition parameter by replacing harmful conventional solvents (alcohols, ammonia, sulfonates, amides) with water as the base medium. This parameter change eliminates the harmful properties (volatility, flammability, corrosivity) while maintaining the coating's processability and functionality. The water-based formulation achieves the same manufacturing ease without environmental and health hazards.
Solution Approach 2:
The patent replaces expensive and harmful chemical solvents with water, which is inexpensive, non-harmful, and readily available. This substitution principle eliminates the need for expensive solvent recovery systems and safety infrastructure while maintaining coating processability. Water serves as a safe, disposable medium that can be easily removed through drying.
4Reliability
If modified silanized silica or modified silanized cellulose is manufactured using conventional methods, then the materials can be produced, but the manufacturing process is complex and expensive
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. Instead of separately synthesizing modified silanized silica or cellulose through complex multi-step procedures, the invention merges the silanization modification directly into the coating formulation preparation, achieving the same functional material with simplified processing. This merging reduces both process complexity and cost while maintaining material 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 coating provides a durable, electron-conducting, and water-repellent layer on various surfaces with improved mechanical stability and aesthetic appearance, while being environmentally friendly and cost-effective, suitable for large-scale production.
Implementation Method 1
a first coating prepared from a first composition comprising a polymerized C10-30alkanetriC1-5alkoxysilane
Implementation Method 2
The coating provides a durable, electron-conducting, and water-repellent layer
Implementation Method 3
an organic acid catalyst
Implementation Method 4
a second coating prepared from a second composition comprising a graphene, nanographite or an electron conducting polymer
Data Source
AI summary
The present invention relates to a coating comprising a first coating prepared from a first composition comprising a polymerized C10-30alkanetriC1-5alkoxysilane, a surfactant, an organic acid catalyst and water, and optionally an inorganic component and a second coating prepared from a second composition comprising a graphene, nanographite, nanographene or an electron conducting polymer. The invention also relates to a process for manufacturing said coating. The invention also relates to uses of the coating as a water repellant coating, and/or electron conducting, and/or as a mold-resistant coating and/or as a fire-resistant coating on organic or inorganic surfaces.