Encapsulated Particle Polyurethane Coating Dissolution Control
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Solution Overview
Problem
Conventional encapsulated particles face issues with inconsistent polyurethane layer thickness, integrity defects, and lack of hardness, leading to accelerated dissolution, waste, and phytotoxicity, necessitating improved moisture resistance, swelling resistance, and more predictable dissolution rates.
Innovation Solution
An encapsulated particle design featuring a core particle coated with a polyurethane layer formed from the reaction product of an isocyanate component and an isocyanate-reactive component, including a graft polyol, which provides improved moisture resistance, reduced manufacturing costs, and enhanced toughness, resulting in a uniform and defect-free coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polyurethane layers are applied about core particles, then encapsulation is achieved, but the polyurethane layer exhibits inconsistent thickness and integrity defects leading to accelerated dissolution
Solution Approach 1:
The patent changes the chemical composition parameters of the polyurethane layer by incorporating specific ratios of polyols (polyester polyol, polyether polyol, poly silicone oxide) and isocyanates, which fundamentally alters the layer's properties to achieve uniform thickness and consistent dissolution rates without relying on precise manufacturing control
Solution Approach 2:
The patent creates a composite polyurethane layer combining multiple polyol components (polyester polyol with specific hydroxyl value, polyether polyol, and poly silicone oxide) with isocyanate, where each component contributes specific properties that collectively achieve both manufacturing tolerance and dissolution rate control
2Reliability
If multiple polyurethane layers are disposed about the core particle to cure defects, then integrity is improved, but the manufacturing process becomes time consuming and expensive
Solution Approach 1:
The patent modifies the chemical parameters of a single polyurethane layer by incorporating poly silicone oxide and specific polyol ratios, which prevents defect formation during manufacturing and eliminates the need for multiple coating passes, thereby maintaining integrity while improving productivity
3Ease of manufacture
If the polyurethane layer is made thinner to reduce cost, then manufacturing cost decreases, but the layer lacks adequate hardness and resiliency leading to breakage
Solution Approach 1:
The patent develops a composite polyurethane system where poly silicone oxide provides hardness and structural integrity, while the polyester and polyether polyols provide flexibility and resiliency, enabling a thinner, more cost-effective layer that maintains adequate strength and prevents breakage
Solution Approach 2:
The patent optimizes the chemical composition parameters including hydroxyl value of polyester polyol (50-200 mg KOH/g), polyether polyol content (10-50 parts by weight), and poly silicone oxide content (5-30 parts by weight) to achieve optimal strength-to-cost ratio
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 solution achieves extended and predictable dissolution rates, improved shelf stability, and reduced manufacturing costs, while enhancing the encapsulated particle's resilience and hydrophobicity, addressing the limitations of conventional encapsulated particles.
Implementation Method 1
The polyurethane layer comprises the reaction product of an isocyanate component and an isocyanate-reactive component
Implementation Method 2
The graft polyol of the isocyanate-reactive component imparts the encapsulated particle with improved moisture resistance
Implementation Method 3
the polyurethane layers include defects, such as cracks, pits, depressions, etc. When a polyurethane layer including such defects is disposed about the core particle, the cracks, pits, and/or depressions allow water and other liquids to permeate the polyurethane layer
Data Source
AI summary
An encapsulated particle comprises a core particle and a polyurethane layer disposed about the core particle. The core particle can be various particles, such as fertilizer, biocides, flame retardants, seeds, etc. The polyurethane layer comprises the reaction product of an isocyanate component and an isocyanate-reactive component. The isocyanate-reactive component comprises a graft polyol having a continuous phase and polymeric particles. A method of forming the encapsulated particle comprises the steps of providing the core particle, applying the isocyanate and isocyanate-reactive components to the core particle, and reacting the isocyanate and isocyanate-reactive components to form the polyurethane layer. The encapsulated particle has excellent physical properties, such as increased water repellency, resiliency and shelf life.