In-line Paint Mixing Process for Dynamic TiO2 Control
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Solution Overview
Problem
The existing batch processes for paint production, both base system and point-of-sale models, are inefficient due to excessive use of TiO2 and colorants, requiring substantial inventory and labor, and lack flexibility in adjusting TiO2 levels, leading to unnecessary costs and time in preparing final paints.
Innovation Solution
An in-line mixing process that feeds aqueous dispersions of polymer encapsulated TiO2 particles, opacifying pigment-binder hybrid particles, and rheology modifiers from separate storage vessels into a mixing chamber to form a fully blended paint, allowing for efficient and rapid production of various paint types with minimal cleanup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch process is used to produce paint by grinding pigment and extender particles to form a solid dispersion, then the paint can be produced in bulk, but the process requires substantial inventory and uses a fixed amount of TiO2 without flexibility to adjust TiO2 levels
Solution Approach 1:
The patent implements a dynamic formulation system where TiO2 content can be continuously adjusted during the mixing process. The system allows real-time modification of pigment concentration by controlling the addition of TiO2 particles, enabling adaptation to different colorant requirements without requiring separate batch processes for different TiO2 levels.
Solution Approach 2:
The invention changes the fixed TiO2 parameter to a variable parameter that can be adjusted during the formulation process. By controlling the amount of TiO2 added to the mixing chamber, the system can produce paints with different TiO2 concentrations (e.g., 10-30 wt%) to match specific colorant requirements, thereby resolving the contradiction between bulk production and formulation flexibility.
2Adaptability or versatility
If a base system model is used where paint bases are produced and transported to retail outlets, then colorant can be added to meet consumer demands, but excess TiO2 and colorant must be added to balance the excess TiO2, resulting in unnecessary costs and additional time
Solution Approach 1:
The patent performs preliminary formulation by pre-mixing the paint base with the exact amount of TiO2 needed for the final product in the mixing chamber, rather than relying on post-formulation adjustments at the retail outlet. This preliminary action ensures that the TiO2 content is optimized before colorant addition, eliminating the need to add excess TiO2 and colorant later to balance the formulation.
Solution Approach 2:
The system incorporates feedback control where the TiO2 content is monitored and adjusted during the mixing process to match the specific colorant requirements. This feedback mechanism prevents excess TiO2 from being added to the formulation, thereby reducing waste and unnecessary costs associated with balancing excess TiO2 and colorant.
3Adaptability or versatility
If a point-of-sale model is used where cans of paint are made by concurrent dispensing of binder, pigment, and extender components from separate holding tanks, then the process is an improvement on the base system model, but it is still a labor and cost intensive batch process that relies on the speed of dispensing and the time to mix the materials
Solution Approach 1:
The patent implements a continuous mixing process where the binder, pigment, and extender components are continuously fed into a mixing chamber and mixed in real-time. This continuous action eliminates the intermittent batch processing steps, reducing the total time required for mixing and stabilization while maintaining the ability to produce various paint types by controlling the composition of the continuous feed.
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 process enables the efficient and rapid production of a wide variety of paints with reduced waste and labor, minimizing the need for excess TiO2 and colorants, and allowing for precise control over paint composition, thereby reducing production costs and time.
Implementation Method 1
an aqueous dispersion of polymer encapsulated TiO2 particles and a rheology modifier from a first pre-paint storage vessel; and an aqueous dispersion of opacifying pigment-binder hybrid particles and a rheology modifier from a second pre-paint storage vessel
Data Source
AI summary
The present invention is a process for preparing one or more paints by flowing and merging pre-paints from pre-paint storage tanks into a mixing chamber and into a paint container.