One-Component Epoxy Coating with Ketimine Curing Agent
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Solution Overview
Problem
Existing epoxy coatings require a precise blend ratio of two components, leading to potential errors and failures such as premature rusting or blistering, and they have high volatile organic content (VOC), which is environmentally undesirable.
Innovation Solution
A high solids, one-component epoxy coating composition comprising an epoxy resin with multiple 1,2-epoxy groups, a hydrocarbon compound with a softening point between 50°C to 140°C, an alkoxy-functional and/or silanol-functional silicone, and a ketimine curing agent derived from a polyalkylpolyamine and ketone reaction, providing improved storage stability and low VOC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-component epoxy coating system is used to achieve optimum coating properties, then the coating performance is improved, but the complexity of application increases and the risk of errors (incorrect blend ratio) worsens
Solution Approach 1:
The patent combines the epoxy resin and curative agent into a single one-component system where the curative is incorporated within the resin formulation. This eliminates the need for separate mixing of two components, reducing application complexity while maintaining coating performance through controlled release mechanisms.
Solution Approach 2:
The curative agent is pre-incorporated into the resin formulation during manufacturing, but remains inactive or controlled during storage. The curing reaction is activated only after application, typically through moisture exposure or temperature conditions. This preliminary preparation eliminates blending errors while maintaining storage stability.
2Reliability
If traditional epoxy coating formulations are used to provide good coating properties, then the coating effectiveness is improved, but the volatile organic content (VOC) increases causing environmental harm
Solution Approach 1:
The patent modifies the formulation parameters by using high-solids content epoxy resins and adjusting the curative agent composition to minimize volatile content. The formulation achieves proper curing and coating effectiveness while maintaining low VOC levels through controlled chemistry and reduced solvent dependence.
3Ease of operation
If a one-component epoxy coating composition is used to simplify application and eliminate blending errors, then the ease of operation is improved, but the storage stability may worsen due to potential premature reaction
Solution Approach 1:
The curative agent is pre-incorporated into the resin in an inactive or controlled state during manufacturing. The curing reaction is designed to activate only under specific conditions after application, such as exposure to moisture, temperature changes, or catalytic triggers. This maintains storage stability while enabling one-component application simplicity.
Solution Approach 2:
The patent introduces an intermediary mechanism or substance that controls the timing of the curing reaction. This intermediary prevents premature reaction during storage and transport, while enabling the curing process to proceed after application under controlled conditions, thus maintaining both storage stability and application simplicity.
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 offers excellent storage stability, hot water resistance, corrosion resistance, and adhesion, eliminating the need for precise blending and reducing VOC emissions while maintaining high performance.
Implementation Method 1
a ketimine curing agent comprising a reaction product of reactants comprising a polyalkylpolyamine component and a ketone component
Implementation Method 2
an alkoxy-functional and/or silanol-functional silicone
Implementation Method 3
an alkoxy-functional and/or silanol-functional silicone
Implementation Method 4
a hydrocarbon compound having a softening point of from 50°C to 140°C
Data Source
AI summary
Disclosed are high solids, one-component, storage stable coating compositions that include an epoxy resin comprising more than one 1,2-epoxy groups per molecule; a hydrocarbon compound having a softening point of from 50°C to 140°C; an alkoxy-functional and/or silanol-functional silicone; and a ketimine curing agent comprising a reaction product of reactants comprising a polyalkyldiamine component and a ketone component. Also disclosed are substrates at least partially coated with a coating deposited from such composition and methods for coating substrates with such compositions.