Nanoparticle Coated Pigment Pre-flake Manufacturing
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Solution Overview
Problem
The manufacturing of pigments, such as special effects pigments, is complex and time-consuming, requiring expensive vacuum processes and large investments in equipment, limiting production throughput.
Innovation Solution
A method of creating a pigment with a pre-flake coated by nanoparticles, where the nanoparticles are present in an amount greater than 40% by volume, using alternating layers of charged nanoparticles and polymers to form a high-volume coating, which can be up to 100% encapsulation, enabling cost-effective and high-throughput production of special effect pigments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum deposition processes are used to create pigment coatings, then coating quality and optical properties are improved, but manufacturing complexity and equipment investment increase significantly
Solution Approach 1:
The patent replaces vacuum deposition (a complex mechanical/physical vapor deposition system) with a chemical solution-based coating process. The nanoparticle coating is applied through wet chemical methods rather than vacuum mechanical processes, eliminating the need for expensive vacuum equipment while achieving comparable coating quality and optical properties.
Solution Approach 2:
The invention changes the fundamental parameter of the coating process from vacuum-based physical deposition to solution-based chemical deposition. This parameter change allows the use of simpler equipment while maintaining coating precision through control of chemical parameters such as nanoparticle concentration, solution pH, and deposition temperature.
2Manufacturing precision
If step-wise coating processes are employed, then coating uniformity and optical performance are improved, but production time and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple step-wise coating operations into a single integrated process. By using a suspension containing multiple nanoparticle types or a core nanoparticle that self-assembles additional layers, the invention achieves uniform multi-layer coating in one step rather than through sequential deposition steps, thereby maintaining coating uniformity while dramatically increasing production throughput.
Solution Approach 2:
The invention performs preliminary preparation of nanoparticle suspensions with controlled composition and properties before the coating step. This pre-prepared suspension contains all necessary components for uniform coating, allowing a single rapid deposition step to achieve what would otherwise require multiple coating steps, thus improving productivity without sacrificing uniformity.
3Illumination intensity
If high nanoparticle volume fraction coatings are applied, then color intensity and optical effects are improved, but coating stability and manufacturing difficulty increase
Solution Approach 1:
The patent introduces a surfactant or stabilizing agent as an intermediary between the high-concentration nanoparticle suspension and the substrate. This intermediary prevents nanoparticle aggregation and settling in the high-volume-fraction coating, maintaining suspension stability and ease of application while enabling the high nanoparticle concentration needed for intense color and optical effects.
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
This approach simplifies the manufacturing process, reduces costs, and enhances production efficiency while achieving high-performance special effect pigments with specific optical and functional properties.
Implementation Method 1
providing a layer of a first charged nanoparticle to the pre-flake; providing a layer of a second charged nanoparticle material to the pre-flake, wherein the second charged nanoparticle is oppositely charged from the first charged nanoparticle
Implementation Method 2
rinsing
Implementation Method 3
providing to the pre-flake alternating layers of a layer of charged polymer and a layer of first charged nanoparticle; providing a layer of charged polymer or other molecules presenting interacting binding sites; providing a layer of a second charged nanoparticle
Data Source
AI summary
A pigment including a pre-flake; and a coating of nanoparticles present on a surface of the pre-flake, wherein the nanoparticles can be present in the coating in an amount greater than about 40% by volume is disclosed. A method of making a pigment is also disclosed.