Low-Gloss Flexible Clear Coat Silica Flattener Formulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current clear coat systems for vehicles often limit low-gloss finishes to black colors and high-gloss finishes, with two coat systems lacking a flexible option that balances weatherability and appearance across various colors.

Innovation Solution

A low-gloss, flexible clear coat formulation incorporating a base resin, cross-linker, silica-based flattener, and flattener enhancing agents, which provides 90° flexibility and a 60° gloss finish between 22 to 34 gloss units when cured, enhancing weatherability and durability while maintaining a low-gloss appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a clear coat is applied in a two coat system to improve weathering performance, then weatherability is improved, but the finish is limited to high gloss only

Engineering Contradiction:

ImproveweatherabilityVSAvoidgloss finish options

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical-chemical parameters of the clear coat formulation by incorporating specific flattening agents (silica-based flatteners at 5-20 parts by weight per 100 parts by weight of base formula) and flattener enhancing agents (0.25-5 parts by weight per 100 parts by weight of base formula). This enables the clear coat to achieve low-gloss finishes (22-34 gloss units at 60°) while maintaining weathering performance and flexibility (90° bend capability)

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite clear coat system by combining base resin, cross-linker, silica-based flattener, and flattener enhancing agents in specific proportions. This composite formulation achieves the unexpected combination of low-gloss appearance, flexibility, and weathering resistance that neither traditional high-gloss clear coats nor monocoat systems could provide

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a monocoat system is used to achieve low-gloss appearance, then low-gloss finish is achieved, but weathering performance is limited and restricted to black color paints

Engineering Contradiction:

Improvelow-gloss appearanceVSAvoidweathering performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent segments the paint system into two distinct coats: a basecoat layer that provides color and a separate clear coat layer that provides weathering protection and low-gloss finish. This segmentation allows each layer to be optimized independently - the basecoat for color variety and the clear coat for durability and appearance control

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clear coat formulation serves multiple functions simultaneously: it provides weathering protection, achieves low-gloss finish (22-34 gloss units), and delivers flexibility (90° bend capability). This multi-functionality eliminates the need to choose between monocoat simplicity and two-coat performance

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If traditional clear coats are used to provide weathering protection, then durability is improved, but flexibility is compromised and cracking may occur

Engineering Contradiction:

ImprovedurabilityVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent modifies the chemical composition parameters of the clear coat by incorporating specific ratios of base resin to cross-linker, along with flattening agents. This chemical parameter optimization enables the cured clear coat to achieve both durability and exceptional flexibility (90° bend capability without cracking), resolving the traditional trade-off between strength and flexibility

Inventive Principle:

Principle #35Parameter changes

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 solution offers a flexible and weather-resistant low-gloss finish suitable for various colors, improving the durability and appearance of vehicle surfaces by preventing cracking and maintaining a desired gloss level under environmental conditions.

Implementation Method 1

a low-gloss, flexible clear coat may include a base formula that includes a base resin and a cross-linker. The low-gloss, flexible clear coat may further include a silica-based flattener, wherein the silica-based flattener comprises from 5 parts by weight per 100 parts by weight of the base formula to 20 parts by weight per 100 parts by weight of the base formula. The low-gloss, flexible clear coat may further include one or more flattener enhancing agents

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentUS9962736B2Low-gloss, flexible clear coats, articles of manufacture having low-gloss, two coat paint systems, and methods for applying the same

Publication Date: 2018.05.08 TOYOTA JIDOSHA KK

AI summary

Low-gloss flexible clear coast can include a base formula that includes a base resin and a cross-linker, a silica-based flattener, wherein the silica-based flattener comprises from 5 parts by weight per 100 parts by weight of the base formula to 20 parts by weight per 100 parts by weight of the base formula, one or more flattener enhancing agents, wherein the one or more flattener enhancing agents comprise 0.25 parts by weight per 100 parts by weight of the base formula to 5 parts by weight per 100 parts by weight of the base formula, and possess 90° flexibility and a 60° gloss finish from 22 gloss units to 34 gloss units.