Non-dusting Effect Pigment Pellets for Powder Coatings
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Solution Overview
Problem
Powder coatings face challenges with the dispersion and orientation of effect pigments like aluminum flakes and pearlescent pigments due to their susceptibility to bending and breakage under high shear mixing, leading to poor appearance and safety hazards from dust generation, which often results in outsourcing the bonding of fine metallic pigments.
Innovation Solution
A pigment pellet preparation comprising effect pigments dispersed in a thermosetting resin with 3 or more reactive terminal groups, formulated to be non-dusting and available in a pelletized form, allowing safe bonding and incorporation into powder coatings without degradation, reducing manufacturing steps and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If effect pigments are incorporated during extrusion and/or milling steps, then the pigment is mixed into the resin, but the effect pigments are damaged and their appearance suffers
Solution Approach 1:
The effect pigments are pre-dispersed in the thermosetting resin before extrusion, creating a master batch where the pigment is already properly oriented and protected. This preliminary dispersion prevents damage during subsequent processing steps.
Solution Approach 2:
The manufacturing process is divided into separate stages: first creating a pigment-resin master batch with proper pigment orientation, then incorporating this protected pigment into the final powder coating formulation, avoiding direct exposure to high-shear mixing.
2Ease of manufacture
If solvent free effect pigment powder is used, then the powder coating can be made, but a large release of dust is generated causing inhalation hazards and explosion risks
Solution Approach 1:
The effect pigments are encapsulated within a thermosetting resin matrix, forming a protective shell around each pigment particle. This encapsulation prevents dust generation while allowing the pigment to function normally when the coating is applied and cured.
Solution Approach 2:
A composite pigment preparation is created by combining effect pigments with thermosetting resin in a controlled dispersion. This composite form maintains the functional properties of the effect pigment while eliminating the dust hazards associated with loose pigment powder.
3Illumination intensity
If effect pigments with large aspect ratios are used, then the color and appearance are enhanced, but the pigments are very susceptible to bending and breakage under high shear mixing
Solution Approach 1:
The high-aspect-ratio effect pigments are pre-oriented and dispersed in the resin before the extrusion process, establishing their optimal positioning and protecting their structural integrity before they are subjected to any mechanical stress.
Solution Approach 2:
The thermosetting resin acts as an intermediary medium that supports and protects the fragile high-aspect-ratio pigment structures during processing, allowing them to maintain their shape and optical properties without direct mechanical stress.
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 pigment pellet preparation maintains the appearance of effect pigments, eliminates dust-related hazards, and streamlines the manufacturing process by enabling safe and efficient incorporation into powder coatings, reducing cure time and allowing for high formulation flexibility.
Implementation Method 1
The thermosetting resin has 3 or more reactive terminal groups
Implementation Method 2
The effect pigment is dispersed in the thermosetting resin
Data Source
AI summary
A pigment pellet preparation, comprises one or more effect pigment and one or more thermosetting resin. The effect pigment is dispersed in the thermosetting resin. The thermosetting resin has 3 or more reactive terminal groups and has an acid number from about 10 to about 50 mg KOH/g resin. The preparation comprises from about 70% to about 90% by weight of one or more effect pigment and from about 5% to about 35% by weight of one or more thermosetting resin. The pigment and thermosetting resin comprise about 95% or more of the preparation. The pellets have a diameter of about 0.5 mm to about 5 mm and a length of about 1 mm to about 5 cm.