One-Part Polymerizable Coating via Solvent Evaporation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing polymerizable formulations for coatings require two parts, making them difficult to apply as a spray and leading to wasted material, poor adhesion, and increased viscosity, which complicates substrate preparation and environmental exposure.
Innovation Solution
A one-part, storage-stable polymerizable formulation with an ethenically unsaturated polymerizable compound and a free radical initiator, stabilized by an organic solvent, allowing for consistent viscosity and penetration into substrates without prior preparation, and forming a corrosion barrier upon solvent evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two part polymerizable formulation is used to initiate polymerization reaction, then coating formation is achieved, but the formulation must be applied on a timetable consistent with cure rate and viscosity increases, and spray application is precluded
Solution Approach 1:
The patent combines the polymerizable compound and polymerization initiator into a single one-part formulation that remains stable during storage and application. The formulation allows spray application before polymerization begins, then cures after application to form the coating, eliminating the need for separate mixing of two parts.
Solution Approach 2:
The formulation is prepared in advance with all components (polymerizable compound, initiator, and solvent) already combined and stabilized. This preliminary preparation allows the formulation to be stored and applied via spray without requiring on-site mixing, while still enabling subsequent polymerization to form the coating.
2Reliability
If higher molecular weight polymer precursors are used, then coating protection is improved, but the precursors are unable to permeate well into porous or scaly substrates
Solution Approach 1:
The patent changes the physical state parameter of the polymer precursor by dissolving it in an organic solvent, transforming it from a high-viscosity or solid state that cannot penetrate substrates into a low-viscosity liquid that can permeate porous or scaly surfaces. After application and solvent evaporation, the high molecular weight polymer forms the protective coating.
3Reliability
If a two part formulation is mixed to initiate polymerization, then coating formation is achieved, but any unused formulation is wasted
Solution Approach 1:
The patent merges the polymerizable compound and initiator into a single stable one-part formulation that does not polymerize until after application. This eliminates the need to mix two parts, allowing unused formulation to be stored and reused without degradation or premature curing, thereby preventing material waste.
4Ease of operation
If a one part polymerizable formulation with organic solvent is used, then spray application and storage stability are enabled, but solvent evaporation time is required before polymerization accelerates
Solution Approach 1:
The organic solvent acts as an intermediary that temporarily delays polymerization by keeping the formulation in a stable, low-viscosity state during storage and application. After spray application, the solvent evaporates, removing the delay mechanism and allowing polymerization to accelerate and form the coating. This intermediary enables both spray applicability and eventual coating formation.
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
Enables efficient application and storage of the formulation, improved adhesion, and formation of a protective air and moisture barrier on substrates, including those with existing corrosion layers, without the need for extensive substrate preparation.
Implementation Method 1
stabilized in part through solvent dilution
Implementation Method 2
upon evaporation of the solvent, the rate of polymerization of the compound accelerates
Implementation Method 3
free radical initiated polymerizable formulations
Implementation Method 4
The substrate of the article forms a corrosion barrier even without prior removal of a native corrosion layer
Data Source
AI summary
A one part, storage stable polymerizable formulation is provided that includes an ethenically unsaturated polymerizable compound intermixed with a free radical polymerization initiator and an organic solvent. The organic solvent provides storage stability and upon evaporation of the solvent, the rate of polymerization of the compound accelerates independent of addition of a second part. The formulation includes at least 30 total weight percent solids upon cure. Optional additives to the formulation include at least one of a cure accelerator, a filler, a plasticizer, a colorant, and a cure inhibitor. A process for forming a polymerized coating on an article involves the application of this formulation to the substrate of an article and allowing sufficient time for the solvent to evaporate to form the polymerized coating on the article. The substrate of the article forms a corrosion barrier even without prior removal of a native corrosion layer on a surface of the substrate of the article.