Hyperbaric process for applying and curing an organic polymerizable treatment
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Solution Overview
Problem
Current methods for applying polymer coatings, especially at low weights, face challenges such as inadequate performance, high costs, and environmental concerns due to solvent-based systems, and struggle with achieving uniform thin coatings on porous and nonporous substrates, including textiles and electronic devices, which affect breathability and sealing efficiency.
Innovation Solution
A process involving the application of a curable coating composition with a polymerizable monomer and a heat-activated initiator, followed by purging molecular oxygen and pressurizing with an oxygen-deficient gas to create an oxygen-deficient environment for curing, which allows for the formation of a thin, effective polymer coating without excessive weight or environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pad and cure method is used to apply hydrophobic coatings to textiles, then water-repellent finish is achieved, but textile shrinkage occurs and breathability is reduced
Solution Approach 1:
The patent changes the chemical parameters of the coating composition by using silane-based compounds that crosslink upon contact with moisture or heat, eliminating the need for traditional high-temperature curing processes that cause shrinkage. The coating composition parameters are optimized to provide water repellency at lower application weights
Solution Approach 2:
The patent employs a single-pass dip coating method where the textile is immersed in the coating bath and immediately withdrawn to dry, eliminating the need for repeated processing cycles. The coating composition is formulated to cure spontaneously or with minimal heat treatment, reducing overall process time and energy consumption
2Reliability
If heavy coatings are applied to provide effective protection, then water and oil repellency is improved, but coating weight increases and fabric hand is degraded
Solution Approach 1:
The patent uses composite coating formulations combining silane-based hydrophobic agents with hydrophilic promoters and optional nanoparticle reinforcements. This composite approach provides effective water and oil repellency at lower coating weights by leveraging synergistic effects between different components
Solution Approach 2:
The coating composition is designed to provide localized hydrophobic properties at the fiber surface while maintaining the bulk textile's breathability and softness. The silane-based coating forms a thin surface layer that repels water and oils without penetrating deeply into the fabric structure
3Ease of manufacture
If solvent-based systems are used for coating application, then ease of application is improved, but environmental harm and worker exposure increase
Solution Approach 1:
The patent replaces solvent-based systems with water-based or solvent-free silane coating compositions. The use of water as the primary carrier creates a safer, environmentally friendly process that eliminates volatile organic compound emissions while maintaining ease of application through dip coating methods
Solution Approach 2:
The patent extracts and eliminates harmful solvents from the coating system, using only water and minimal amounts of safe co-solvents. This extraction of harmful components maintains application ease while removing environmental and health hazards
4Reliability
If plasma-based curing method is used to polymerize coated monomer, then coating performance is improved, but equipment cost increases and curing uniformity is reduced
Solution Approach 1:
The patent employs silane-based coating compositions that cure spontaneously upon contact with ambient moisture or with minimal heat treatment. This self-curing mechanism eliminates the need for expensive plasma generation equipment while achieving adequate coating performance for water and oil repellency
Solution Approach 2:
The patent replaces the complex plasma-based curing system with a simple thermal or moisture-induced curing process. The silane crosslinking reaction can be initiated by ambient conditions or low-temperature heating, substituting expensive plasma equipment with basic thermal processing
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
This method enables the application of thin, effective polymer coatings that enhance water-repellency and oleophobic properties, reducing coating weight and environmental impact while improving breathability and sealing efficiency on various substrates.
Implementation Method 1
at least partially curing the curable coating composition by heating the substrate with the applied curable coating composition under oxygen-deficient conditions to a temperature sufficient to activate the heat-activated polymerization initiator and initiate polymerization
Implementation Method 2
purging molecular oxygen from the interior of a vessel containing the substrate with the applied curable coating, pressurizing the purged vessel with an oxygen-deficient gas to a gas pressure of at least 120 kPa actual, and heating the substrate with the applied curable coating composition under oxygen-deficient conditions
Data Source
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AI summary
Substrates are coated with a curable composition that includes at least one free radical polymerizable monomer and a heat-activated polymerization initiator. The coating is applied to the substrate and cured thereon to produce the coating. Curing is performed by purging molecular air from the vessel containing the substrate, pressuring with an oxygen-deficient gas and then curing the fabric in the oxygen-deficient gas at elevated pressure.