Multiphase Waterborne Coatings via Microphase Separation
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Solution Overview
Problem
Current waterborne coatings lack durability and scalability compared to solvent-based alternatives, often being single-phase systems that limit the range of physical properties that can be expressed at the surface, and there is a need for multifunctional coatings that combine multiple dissimilar elements that do not mix or associate with each other.
Innovation Solution
A multiphase waterborne composition is developed, comprising a first-material phase and a second-material phase that are chemically different and covalently bonded, with microphase-separated structures on an average length scale of 1 micron to 100 microns, using fluoropolymers and polyolefins, and containing ionic species to achieve simultaneous expression of multiple properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If waterborne coatings are used as low-VOC alternatives, then environmental impact is reduced and cost is decreased, but durability and performance are worsened
Solution Approach 1:
The patent creates a multiphase waterborne coating system combining water-soluble resin and water-dispersed resin in a single formulation. This composite approach allows the coating to achieve both environmental benefits of waterborne systems and performance characteristics previously only attainable with solvent-based coatings, directly resolving the durability contradiction.
2Device complexity
If single-phase waterborne systems are used, then formulation is simplified, but the range of physical properties that can be expressed at the surface is limited
Solution Approach 1:
The patent segments the coating formulation into two distinct phases: a water-soluble resin phase and a water-dispersed resin phase. Each phase contributes different physical properties to the final coating, enabling the system to express a broader range of surface properties while maintaining a relatively simple single-step application process.
Solution Approach 2:
By combining water-soluble and water-dispersed resins in a composite waterborne formulation, the patent enables the coating to exhibit multiple physical properties simultaneously, such as flexibility from one phase and hardness from the other, thus increasing versatility without proportionally increasing formulation complexity.
3Adaptability or versatility
If multiple dissimilar elements are combined in coating, then multifunctionality is improved, but compatibility and mixing difficulty are worsened
Solution Approach 1:
The patent segments dissimilar resin materials into separate water-soluble and water-dispersed phases, allowing each material to maintain its own properties and compatibility requirements while being part of a unified coating system. This segmentation prevents unwanted interactions between incompatible materials.
Solution Approach 2:
Water acts as an intermediary medium that enables the combination of water-soluble and water-dispersed resins. The water phase allows both dissimilar elements to coexist and be applied together without direct contact that would cause incompatibility issues, while still achieving a unified coating film after water evaporation.
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 multiphase waterborne composition provides durable and robust coatings that can withstand environmental elements on both interior and exterior vehicle surfaces, maintaining commercial scalability and improved compatibility and adhesion, enabling continued performance over the lifetime of the coating.
Implementation Method 1
wherein the first material and/or the second material contains ionic species
Implementation Method 2
wherein the first material is covalently bonded to the second material
Data Source
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AI summary
This invention provides multifunctional coatings containing multiple components that usually do not associate with one another, from deposition of waterborne precursor compositions. Some variations provide a multiphase waterborne composition comprising a first-material phase containing a first material and a second-material phase containing a second material chemically different than, but covalently bonded to, the first material, wherein the first material and/or the second material contains ionic species. The first-material phase and the second-material phase are microphase-separated on an average length scale of phase inhomogeneity from 0.1 to 100 microns. The first and second materials may be selected from hydrophobic materials, hydrophilic materials, hygroscopic materials, oleophobic materials, and/or oleophilic materials, for example. Due to the first-material phase and the second-material phase being microphase-separated, the multiphase waterborne composition possesses a simultaneous combination of properties, rather than a combined average. Precursors and methods are also disclosed.