Hybrid Coating Dispersion for Multilayer Automotive Compatibility
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Solution Overview
Problem
Existing multilayer automotive coatings face challenges in achieving good compatibility between different coating layers, leading to inferior appearance and increased production time and costs, particularly in integrated paint processes.
Innovation Solution
A polyester-polyurethane-poly(meth)acrylic hybrid dispersion is produced by esterifying polyurethane with specific acid and hydroxyl numbers with polyester, followed by radical polymerization of ethylenically unsaturated monomers, including (meth)acrylic monomers, to create a high solids content coating composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating compositions are used in multilayer coatings, then the coating process can be completed, but the compatibility between different coating layers is poor resulting in inferior appearance
Solution Approach 1:
The invention modifies the chemical composition parameters of the coating binder by incorporating polyester-polyurethane-poly(meth)acrylic hybrid dispersion with specific functional groups. This changes the chemical parameters of the coating formulation to improve interlayer compatibility and appearance quality without compromising the coating process
Solution Approach 2:
The invention uses a composite binder system combining polyester-polyurethane-poly(meth)acrylic hybrid dispersion with additional polymers. This composite material approach creates synergistic effects that enhance layer compatibility and appearance quality across the multilayer coating system
2Ease of operation
If conventional low solids content coating compositions are used, then the formulation is easier to apply, but the drying time increases and production efficiency decreases
Solution Approach 1:
The invention changes the solids content parameter from conventional low levels to at least 40 wt.%, which reduces drying time and improves productivity while maintaining adequate application properties through optimized viscosity and composition
3Device complexity
If conventional coating compositions are used, then the formulation is simpler, but a final stripping process is required increasing production time and costs
Solution Approach 1:
The invention modifies the chemical composition to include specific polyester-polyurethane-poly(meth)acrylic hybrid dispersion that eliminates the need for final stripping. This compositional change reduces production time and costs while the formulation remains practically implementable
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 hybrid dispersion enhances layer compatibility, resulting in superior appearance and reduces the need for a final stripping process, thereby decreasing production time and costs.
Implementation Method 1
by esterifying at least one polyurethane containing carboxyl groups, the at least one polyurethane having an acid number of more than 200 mg KOH/g to 400 mg KOH/g and at least one or more terminal carboxyl groups; with at least one polyester containing hydroxyl groups
Implementation Method 2
polymerizing ethylenically unsaturated monomers at least comprising (meth)acrylic monomers by radical polymerization in the presence of the polyester-polyurethane
Data Source
AI summary
The present invention relates to a polyester-polyurethane-poly(meth)acrylic hybrid dispersion obtainable by esterifying at least one polyurethane containing carboxyl groups, the at least one polyurethane having an acid number of more than 200 mg KOH/g to 400 mg KOH/g and at least one or more terminal carboxyl groups; with at least one polyester containing hydroxyl groups, the polyester having a hydroxyl number of 50 mg KOH/g to 300 mg KOH/g, to obtain a polyester-polyurethane; followed by polymerizing ethylenically unsaturated monomers at least comprising (meth)acrylic monomers by radical polymerization in the presence of the polyester- polyurethane of step (a), wherein one or more solvents are present and/or employed during step (a) and/or (b) and/or added after step (b), thereby obtaining the polyester- polyurethane-poly(meth)acrylic hybrid dispersion. Furthermore, the invention relates to a coating composition comprising a polyester-polyurethane-poly(meth)acrylic hybrid dispersion, a coating layer formed thereof and a thus coated substrate. Moreover, the invention relates to the use of a coating composition comprising a polyester- polyurethane-poly(meth)acrylic hybrid dispersion in automotive coating and a method of making a multilayer coating, wherein at least one coating layer is formed from a coating composition comprising a polyester-polyurethane-poly(meth)acrylic hybrid dispersion.