Fluoropolymer Composite Particles with Low Fluorosurfactant Adhesion
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Solution Overview
Problem
Conventional coating powders require a large amount of adhesive components to achieve uniform adhesion to substrates and have environmental concerns due to the use of high-impact substances like fluorosurfactants, while chromium-free primers with heat-resistant adhesion are sought to replace chromium (III) phosphate primers.
Innovation Solution
A particulate composite comprising a fluoropolymer and an adhesive polymer, with less than 0.1 ppm of fluorosurfactant, is formed through bonding particles using devices like attrition mills, resulting in a coating film with excellent adhesion and uniformity, even with a small amount of adhesive component, and is free from environmental hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coating powders use a large amount of adhesive components to achieve uniform adhesion to substrates, then adhesion strength is improved, but environmental harm increases due to use of high-impact substances like fluorosurfactants
Solution Approach 1:
The invention extracts and removes fluorosurfactants from the coating composition entirely, achieving adhesion performance without relying on these environmentally harmful substances. The coating powder formulation eliminates fluorosurfactants while maintaining effective adhesion through alternative mechanisms.
Solution Approach 2:
The invention changes the chemical composition parameters of the coating system by replacing fluorosurfactant-based adhesion mechanisms with alternative adhesive components and surface treatment approaches, thereby reducing environmental impact while preserving adhesion strength.
2Object-affected harmful factors
If chromium-free primers are developed to replace chromium (III) phosphate primers, then environmental safety is improved, but adhesion performance may deteriorate
Solution Approach 1:
The invention employs composite primer formulations combining multiple adhesive components with complementary properties, including polyphenylene sulfide and other heat-resistant polymers, to achieve both environmental safety and superior heat-resistant adhesion performance without chromium compounds.
Solution Approach 2:
The primer formulation uses locally optimized chemical compositions tailored for specific substrate types and application conditions, providing targeted adhesion enhancement in critical areas while maintaining overall environmental safety through chromium-free chemistry.
3Object-affected harmful factors
If fluorosurfactants are completely removed from coating compositions, then environmental impact is reduced, but coating uniformity and adhesion may worsen
Solution Approach 1:
The invention introduces alternative intermediary substances such as conventional surfactants and adhesive promoters that can replace fluorosurfactants in mediating between the coating powder and substrate, ensuring uniform coating formation and effective adhesion without relying on fluorinated compounds.
Solution Approach 2:
The invention substitutes the chemical mechanism of fluorosurfactant action with alternative chemical systems based on conventional surfactants and adhesive components, achieving similar coating uniformity and adhesion performance through different chemical pathways that are environmentally benign.
Data Source
AI summary
An object of the present invention is to provide a particulate composite which is free from fluorosurfactants having a high environmental impact, and can form a coating film that has excellent adhesion to a substrate and is uniformly adhered to the substrate even if containing a small amount of an adhesive component. The particulate composite of the present invention contains: a fluoropolymer; an adhesive polymer; and less than 0.1 ppm of a fluorosurfactant.