Omniphobic Composition Concentrate One-Pot Synthesis
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Solution Overview
Problem
Current omniphobic composition manufacturing processes are complex and costly, requiring graft and block copolymer components with a two-step/two-pot manufacturing process, which increases time and expense, and existing thermoset omniphobic compositions do not offer a stable, gel-free liquid concentrate for versatile coating applications.
Innovation Solution
A stable, gel-free omniphobic composition concentrate is developed, comprising 2 wt. % to 60 wt. % polyisocyanate and monomer units, 30 wt. % to 85 wt. % polyol and monomer units, and 10 wt. % to 50 wt. % functionalized omniphobic polymer and monomer units, which can be partially reacted to form a polymer suitable for forming a thermoset omniphobic composition when combined with a polyurethane base formulation, allowing for efficient and cost-effective coating production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-step/two-pot manufacturing process with graft and block copolymer components is used, then omniphobic properties are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple manufacturing steps into a single one-pot process, merging the graft copolymerization and block copolymer formation into one simultaneous reaction. This eliminates the need for separate preparation steps, reducing manufacturing complexity while maintaining omniphobic properties through the integrated formation of both copolymer structures.
Solution Approach 2:
The invention segments the copolymer structure at the molecular level rather than through process steps. By designing a copolymer with distinct graft segments and block segments within a single polymer chain, the complex omniphobic structure is achieved through molecular architecture rather than multi-step synthesis, simplifying the manufacturing process.
2Reliability
If a two-step/two-pot manufacturing process is used, then omniphobic composition is formed, but manufacturing time increases
Solution Approach 1:
The patent merges two separate manufacturing steps into a single one-pot reaction process, where graft copolymerization and block copolymer formation occur simultaneously. This consolidation eliminates the time required for intermediate isolation, purification, and re-dissolution steps, significantly reducing total manufacturing time while producing the same omniphobic composition.
Solution Approach 2:
The invention performs preliminary structural design at the molecular level, where the copolymer is synthesized with predetermined graft and block segments that self-organize to provide omniphobic properties. This preliminary molecular architecture eliminates the need for subsequent structural modification steps, reducing manufacturing time.
3Reliability
If existing thermoset omniphobic compositions are used, then coating applications are limited, but versatility is reduced
Solution Approach 1:
The patent creates a universal copolymer composition that can serve multiple coating applications through its dual graft-block structure. The omniphobic copolymer can be formulated into various coating types (paints, varnishes, adhesives) and applied to different substrates, providing versatile functionality while maintaining stable performance across diverse applications.
Solution Approach 2:
The invention enables versatility by allowing parameter adjustments in the copolymer formulation, such as varying the ratio of graft to block segments, changing solvent types, and modifying crosslinking densities. These parameter changes allow the same base copolymer to be adapted for different coating applications while maintaining omniphobic properties and stability.
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 solution provides a stable, clear, and versatile omniphobic composition that can be stored for extended periods, offering excellent water and oil repellency, anti-fingerprint, and anti-graffiti properties without the need for fluorine or a one-pot reaction, reducing production costs and simplifying the coating process while maintaining high clarity and durability.
Implementation Method 1
combining (i) the omniphobic composition concentrate and (ii) a polyurethane base formulation; and curing the omniphobic composition concentrate and the polyurethane base formulation to form a crosslinked reaction product
Implementation Method 2
at least one of a polyisocyanate and monomer units thereof in polymerized form; at least one of a polyol and monomer units thereof in polymerized form
Implementation Method 3
curing the omniphobic composition concentrate and the polyurethane base formulation to form a crosslinked reaction product as the omniphobic composition
Data Source
AI summary
The disclosure relates to an omniphobic composition concentrate including 2 wt. % to 60 wt. % of at least one of a polyisocyanate and monomer units thereof in polymerized form, 30 wt. % to 85 wt. % of at least one of a polyol and monomer units thereof in polymerized form, 10 wt. % to 50 wt. % of at least one of a functionalized omniphobic polymer and monomer units thereof in polymerized form, and up to 60 wt. % of at least one diluent. The omniphobic composition further includes a polymer with monomer units of the polyisocyanate, monomer units of the polyol, and monomer units of the functionalized omniphobic polymer. The omniphobic composition is in the form of a gel-free liquid, and it can be cured with a polyol/polyisocyanate polyurethane base formulation to form a thermoset omniphobic composition.