Multistage Emulsion Polymer Core-Shell Dispersant Binder
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Solution Overview
Problem
The conventional coating preparation process is complex and time-consuming due to the need for separate dispersants in the grind phase and binders in the letdown phase, as well as the requirement to change agitator blades from high-shear to low-shear, which complicates the addition of components and affects the efficiency of the process.
Innovation Solution
A multistage aqueous emulsion polymer that serves as both a dispersant and a binder, comprising a first polymer core and a second polymer shell, allowing for the simplification of the coating preparation process by eliminating the need to change agitator blades and incorporating the multistage emulsion polymer in the grind phase, which also enhances mechanical stability and solid volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional two-step coating preparation process is used with separate dispersants and binders, then the coating formulation achieves adequate performance, but the process becomes complicated and time-consuming due to multiple addition steps and agitator blade changes
Solution Approach 1:
The patent combines the dispersant and binder functions into a single multistage emulsion polymer. The first polymer core provides dispersant functionality while the second polymer shell provides binder functionality, eliminating the need for separate dispersant and binder components and simplifying the coating preparation process to a single-step procedure
Solution Approach 2:
The multistage emulsion polymer is designed to perform multiple functions simultaneously: it acts as both a dispersant for pigments and extenders in the grind phase and as a binder in the letdown phase. This multi-functionality eliminates the need for separate dispersant and binder additions, improving preparation efficiency while maintaining coating performance
2Stability of the object's composition
If high-shear agitator blades are used in the letdown phase to maintain dispersant functionality, then pigment dispersion is maintained, but the binder functionality is compromised due to excessive shear forces
Solution Approach 1:
The emulsion polymer is segmented into two distinct stages: a first polymer core containing dispersant components and a second polymer shell containing binder components. This segmentation allows each functional component to be optimized independently, with the dispersant core remaining effective under high-shear conditions while the binder shell is protected from excessive shear forces
Solution Approach 2:
Different regions of the emulsion polymer particle have different functional properties: the first polymer core provides dispersant properties optimized for high-shear environments, while the second polymer shell provides binder properties protected from shear degradation. This local quality differentiation resolves the contradiction between maintaining dispersion and preserving binder functionality
3Reliability
If separate dispersant and binder components are used, then each component can be optimized for its specific function, but the overall formulation complexity increases due to multiple components and addition steps
Solution Approach 1:
The patent merges separate dispersant and binder components into a single multistage emulsion polymer formulation. The first polymer core and second polymer shell are synthesized in sequence to create one integrated product that provides both dispersant and binder functions, reducing formulation complexity from multiple components to a single optimized polymer
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 multistage emulsion polymer simplifies the coating preparation process, maintains good mechanical stability, and achieves a higher volume of solids compared to conventional coatings, while ensuring effective dispersing capacity and water resistance.
Implementation Method 1
a multistage aqueous emulsion polymer comprising from 88% to 98% by dry weight, based on total dry weight of the multistage aqueous emulsion polymer, of a first polymer core; and from 2% to 12% by dry weight, based on total dry weight of the multistage aqueous emulsion polymer, of a second polymer shell
Data Source
AI summary
A multistage aqueous emulsion polymer comprising from 88％ to 98％ by dry weight, based on total dry weight of the multistage aqueous emulsion polymer, of a first polymer core; and from 2％ to 12％ by dry weight, based on total dry weight of the multistage aqueous emulsion polymer, of a second polymer shell, wherein the first polymer core and the second polymer shell each independently comprises, as polymerized units, one or more ethylenically unsaturated nonionic monomers, wherein the second polymer shell further comprises, as polymerized units, from 20％ to 60％ by dry weight, based on total dry weight of the second polymer shell, of an acid monomer, wherein said acid monomer is, as polymerized units, from 1.1％ to 4.2％ by dry weight, based on total dry weight of the multistage aqueous emulsion polymer. An aqueous coating composition comprising said multistage aqueous emulsion polymer.