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 uniformity and sealing of nonporous substrates with small cracks or interstices.
Innovation Solution
A method involving the application of a curable coating composition with a polymerizable monomer and heat-activated initiator, followed by purging molecular oxygen, pressurizing with an oxygen-deficient gas, and curing under oxygen-deficient conditions to form a thin, effective polymer coating on substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pad and cure method is used to apply hydrophobic coatings to textiles, then water-repellant finish is achieved, but textile shrinkage occurs and breathability is reduced
Solution Approach 1:
The invention changes the chemical composition parameters of the coating system by using reactive diluents that are incorporated into the polymer network during curing, rather than remaining as separate solvent phases. This eliminates shrinkage caused by solvent evaporation while maintaining water-repellant properties through the hydrophobic nature of the polymer chains and reactive diluents.
Solution Approach 2:
The invention creates a composite coating system combining polymerizable monomers, crosslinking agents, and reactive diluents that work together to provide water repellency without shrinkage. The reactive diluents serve dual functions as both solvents for application and structural components of the cured coating, creating a composite material system that resolves the contradiction between water repellency and dimensional stability.
2Reliability
If heavy coating weights are applied to provide effective protection, then coating performance is improved, but fabric breathability and hand are reduced
Solution Approach 1:
The invention replaces heavy, permanent coating layers with a thin, crosslinked polymer network that provides durable water repellency through chemical bonding rather than physical barrier. The reactive diluents enable low viscosity application at low weights while the crosslinking provides long-term durability, effectively replacing heavy coatings with a lightweight alternative that maintains breathability.
Solution Approach 2:
The invention changes the physical parameters of the coating by using crosslinking chemistry to create a dense, protective network at minimal thickness. The crosslink density and polymer chain architecture are optimized to provide water repellency through surface chemistry rather than bulk thickness, allowing effective protection with minimal coating weight that preserves fabric breathability.
3Ease of operation
If solvent-based systems are used for coating application, then ease of application is improved, but environmental impact and worker exposure increase
Solution Approach 1:
The invention replaces harmful solvent-based systems with a water-based or solvent-free reactive diluent system that creates an inert or benign application environment. The reactive diluents have high boiling points and low volatility, eliminating vapor exposure hazards while maintaining ease of application through appropriate viscosity control and crosslinking chemistry that enables smooth coating formation without traditional organic solvents.
4Reliability
If plasma-based curing is used to polymerize coated monomer, then coating is formed, but equipment cost is high and cure uniformity is poor
Solution Approach 1:
The invention replaces complex plasma-based curing equipment with simple thermal curing or UV irradiation systems. The crosslinking chemistry is designed to proceed under mild conditions that do not require expensive plasma generation equipment, using either heat-activated or photoinitiated crosslinking mechanisms that can be implemented with conventional, cost-effective equipment while achieving uniform coating formation.
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 with improved water-repellency and breathability, reducing waste and environmental impact while ensuring uniform coverage and sealing of substrates, even those with small openings.
Implementation Method 1
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
at least one polymerizable monomer that polymerizes in the presence of free radicals
Implementation Method 3
pressurizing the purged vessel containing the substrate with the applied curable coating with an oxygen-deficient gas to a gas pressure of at least 120 kPa actual
Data Source
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 and temperature.