Epoxy Polysiloxane Coating Humidity-Independent Cure System

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Solution Overview

Problem

Epoxy siloxane coatings exhibit varying cure rates and concentration requirements that are sensitive to relative humidity, necessitating hardeners with cure rates independent of humidity conditions.

Innovation Solution

The development of an epoxy-polysiloxane polymer coating composition incorporating a polysiloxane, a non-aromatic epoxide resin, and a cure system comprising a polyurethane with a metal catalyst and an alkoxy functional aminosilane, which provides consistent dry hard times across different humidity levels, and alternative to traditional tin catalysts, using silane-terminated polyurethane and organic-based catalysts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional epoxy siloxane coatings use conventional hardeners, then the coatings can be applied to various substrates, but the cure rates vary significantly with relative humidity conditions

Engineering Contradiction:

Improvecure rate consistencyVSAvoidhumidity condition sensitivity

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the chemical parameters of the curing system by introducing a polyurethane-metal catalyst complex with specific metal catalysts (zinc, manganese, zirconium, titanium, cobalt, iron, lead, bismuth, or aluminum) that alter the cure chemistry to become independent of humidity conditions, achieving consistent cure rates across different environmental conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite curing system combining polyurethane with metal catalysts and alkoxy functional aminosilane, where the synergistic interaction between these components produces a curing mechanism that eliminates humidity dependence while maintaining versatility across substrate types

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If traditional tin catalysts are used for curing, then the coating can achieve proper curing, but the catalyst concentration requirements are sensitive to humidity and require precise formulation

Engineering Contradiction:

Improvecatalyst concentration controlVSAvoidhumidity sensitivity

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the catalyst system from traditional tin-based catalysts to metal catalysts (zinc, manganese, zirconium, titanium, cobalt, iron, lead, bismuth, or aluminum) coordinated with polyurethane, which fundamentally alters the curing chemistry to eliminate humidity sensitivity while maintaining manageable catalyst concentration ranges

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive and humidity-sensitive tin catalysts with alternative metal catalysts that are less sensitive to humidity conditions, providing more robust and predictable curing performance across varying environmental conditions

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of time

If higher metal catalyst concentrations are used to accelerate curing, then the dry hard time is reduced, but the catalyst cost and potential harmful effects increase

Engineering Contradiction:

Improvedry hard timeVSAvoidmetal catalyst concentration

Core Design Contradiction:

Loss of timeVSQuantity of substance

Solution Approach 1:

The patent creates a composite catalyst system where polyurethane is coordinated with metal catalysts and alkoxy functional aminosilane, producing a synergistic effect that accelerates curing at lower catalyst concentrations through enhanced catalytic activity from the complex structure

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the catalytic mechanism by introducing polyurethane-metal-alkoxysilane complexes that provide higher catalytic efficiency, allowing reduced catalyst concentrations to achieve the same or faster cure rates compared to traditional single-catalyst systems

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

The cure system achieves dry hard times that are essentially the same at 20% and 60% relative humidity, with faster dry hard times at lower metal catalyst concentrations, offering improved humidity independence and reduced catalyst usage.

Implementation Method 1

a cure system that includes (i) a polyurethane with a metal catalyst and (ii) an alkoxy functional aminosilane

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

an alkoxy functional aminosilane

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Data Source

PatentUS20240002695A1Epoxy polysiloxane coating compositions with polyurethane-metal or organic based curing systems

Publication Date: 2024.01.04 PPG INDUSTRIES OHIO INC

AI summary

Disclosed herein are epoxy-polysiloxane polymer coating compositions suitable for coating surfaces that provide excellent chemical, corrosion, or weather resistance. The epoxy-polysiloxane polymer coating compositions include polysiloxane and non-aromatic epoxide resins, and a cure system, wherein the combined composition reacts to form a cross-linked epoxy-polysiloxane polymer structure. The cure system can include at least a blend of metal or organic catalyst(s) and alkoxy functional aminosilane(s), and may further include a polyurethane, such as a silane terminated polyurethane. The metal catalyst may be coordinated with, or in close proximity to, the polyurethane, thus providing excellent hardening results at very low metal concentrations.