Elastic Gas Barrier Coatings via Polysulfide Phase Separation
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Solution Overview
Problem
Current barrier coatings that provide low temperature elasticity and good oxygen/nitrogen gas barrier performance are lacking, as materials with low glass transition temperatures are poor gas barriers and compromise substrate flexibility.
Innovation Solution
An elastic gas barrier coating composition comprising a barrier material dispersed in an aqueous media, a polysulfide elastomer, and a curing agent, where the barrier material forms a continuous phase and the polysulfide elastomer forms a discontinuous phase, enhancing both elasticity and gas barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If materials with low glass transition temperature are used to achieve low temperature elasticity, then elasticity is improved, but gas barrier performance deteriorates
Solution Approach 1:
The patent uses a composite coating system consisting of a polysulfide elastomer continuous phase combined with barrier material particles (such as silica, alumina, or metal oxides) dispersed within the elastomer matrix. This composite structure allows the coating to maintain low temperature elasticity through the elastomeric continuous phase while the dispersed barrier particles provide gas barrier functionality, resolving the contradiction between elasticity and gas barrier performance.
Solution Approach 2:
The patent applies different functional properties to different regions of the coating structure: the continuous polysulfide elastomer phase provides flexibility and low temperature elasticity, while the dispersed barrier material particles (localized within the elastomer matrix) provide gas barrier properties. This local differentiation of functions allows simultaneous achievement of both elasticity and gas barrier performance.
2Reliability
If barrier coatings are applied to increase gas barrier properties, then gas barrier performance is improved, but substrate flexibility deteriorates
Solution Approach 1:
The patent employs a flexible polysulfide elastomer as the continuous phase of the coating, which forms a thin film over the substrate that maintains substrate flexibility. The elastomeric nature of the continuous phase ensures that the coating itself is flexible and does not compromise the underlying substrate's elastic properties, while still providing effective gas barrier protection through the combined structure.
Solution Approach 2:
The composite structure with polysulfide elastomer as continuous phase and barrier particles as dispersed phase creates a coating that is both flexible and effective as a gas barrier. The elastomeric matrix maintains flexibility while the dispersed barrier particles provide gas barrier functionality, solving the contradiction between gas barrier performance and substrate flexibility.
3Reliability
If conventional barrier coating materials are used to achieve good gas barrier properties, then gas barrier performance is improved, but low temperature elasticity is lost
Solution Approach 1:
The patent changes the key parameter of glass transition temperature by selecting polysulfide elastomers with low Tg values (typically -50°C to -100°C) as the continuous phase. This parameter change enables the coating to maintain flexibility and elasticity at low temperatures. Simultaneously, the dispersed barrier material particles provide gas barrier functionality, achieving both low temperature elasticity and good gas barrier performance.
Solution Approach 2:
The composite structure combines polysulfide elastomer (providing low temperature elasticity through its low Tg) with barrier material particles (providing gas barrier properties). This composite approach allows the coating to simultaneously achieve both low temperature elasticity and effective gas barrier performance, resolving the contradiction between these two properties.
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 coating achieves elasticity of at least 25% at -40°C and good oxygen permeance, maintaining flexibility and barrier performance across a wide temperature range.
Implementation Method 1
when applied to a substrate and cured to form a coating, the barrier material forms a continuous phase and a polysulfide elastomer forms a discontinuous phase
Implementation Method 2
a curing agent reactive with the polysulfide
Data Source
AI summary
An elastic gas barrier coating composition includes a barrier material dispersed in an aqueous media, a polysulfide, and a curing agent reactive with the polysulfide. When applied to a substrate and cured to form a coating, the barrier material forms a continuous phase and a polysulfide elastomer forms a discontinuous phase. An elastic gas coating is also disclosed that includes a continuous phase with a barrier material and a discontinuous phase with a polysulfide elastomer. Substrates at least partially coated with elastic gas barrier coating compositions are further disclosed.