Multicolor Coating via Phase Separation
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Solution Overview
Problem
Existing decorative effect coating compositions typically require multiple applications or products to achieve multi-colored and multi-shaded appearances, limiting consumer flexibility and creativity in achieving desired decorative effects.
Innovation Solution
The development of initially solid-colored coating compositions that utilize tinting colorants incompatible with other components, which separate, concentrate, and float to the surface during the drying process, creating a multi-colored and/or multi-shaded appearance in a single application, with the option to enhance patterns through applied shear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple applications of different coating composition products are used to achieve multi-colored appearances, then color variety is improved, but application complexity and time consumption increase
Solution Approach 1:
The patent combines multiple colorant systems (aqueous colorants and non-aqueous colorants) into a single coating composition formulation. This merging allows the coating to produce multi-colored appearances through internal phase separation rather than requiring multiple separate applications, thereby reducing application time while maintaining color variety.
Solution Approach 2:
The coating composition is pre-formulated with incompatible colorant systems that will automatically separate into distinct phases during the drying process. This preliminary preparation of the colorant mixture eliminates the need for multiple sequential applications, as the multi-color effect is generated automatically from a single applied coat.
2Adaptability or versatility
If multiple applications of different coating composition products are used to achieve multi-colored appearances, then color variety is improved, but process complexity increases
Solution Approach 1:
The patent merges multiple colorant systems and functional components into a single integrated coating composition. This unified formulation simplifies the application process by eliminating the need to handle, store, and apply multiple different products, thereby reducing process complexity while achieving multi-colored results.
Solution Approach 2:
The single coating composition performs multiple functions: it provides the base coating functionality, contains both aqueous and non-aqueous colorants for multi-color effects, and enables phase separation to create decorative patterns. This multi-functionality eliminates the need for separate products for each function, simplifying the overall process.
3Productivity
If known multi-color coating compositions are used to provide multi-colored decorative effects in a single application, then application efficiency is improved, but customization flexibility is reduced
Solution Approach 1:
The coating composition allows for local variation in color expression through controlled phase separation. Different regions of the applied coating can exhibit different color patterns and intensities depending on local drying conditions, substrate characteristics, and shear history, enabling customization while maintaining single-application efficiency.
Solution Approach 2:
The coating composition utilizes dynamic phase separation processes that can be influenced by external factors such as shear application, drying rate, and temperature. This dynamic behavior allows the same base formulation to produce varied decorative effects, providing customization flexibility without requiring multiple pre-formulated products.
4Adaptability or versatility
If tinting colorants incompatible with other components are used, then color differentiation and decorative effect are improved, but coating formulation stability is reduced
Solution Approach 1:
The patent carefully controls formulation parameters such as pH, ionic strength, and surfactant concentration to stabilize the incompatible aqueous and non-aqueous colorant systems during storage. By adjusting these parameters, the formulation maintains stability in the applied state while enabling the desired phase separation and color differentiation to occur during drying.
Solution Approach 2:
The patent uses surfactants and other intermediary substances to mediate between the incompatible aqueous and non-aqueous colorant systems. These intermediaries prevent premature coalescence and instability during storage, while allowing the colorants to separate into distinct phases during the drying process, thus maintaining both formulation stability and color differentiation.
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
Enables the creation of complex decorative effects in a single application, reducing the need for multiple coats and products, while allowing for customizable patterns and enhanced color differentiation, as demonstrated by measurable color differences (ΔE values) ranging from 1 to 200.
Implementation Method 1
a portion of the tinting colorant(s) is incompatible with the remaining components of the coating compositions and thus separates, concentrates, flocculates, and/or floats from an applied coating composition to the exterior-facing surface
Implementation Method 2
a portion of the tinting colorant(s) is incompatible with the remaining components of the coating compositions and thus separates, concentrates, flocculates, and/or floats from an applied coating composition
Data Source
AI summary
The disclosure is generally related to a coating composition, and more particularly to a decorative effect coating composition capable of producing a multicolored and/or multishaded appearance in a single application. The multicolor effect arises through multiple tinting colorants that are substantially immiscible and which separate into separate layers upon application. The color difference between the two layers should be at least about 0.25 delta E units. Additional decorative effects may be applied through shearing the surface with a putty knife or other instrument while the coating composition is still in the liquid or simi-liquid state.