Opacifying Clusters for Low Gloss Paints
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Solution Overview
Problem
Existing paint compositions using large-size extenders face issues with opacity and gloss, as they create regions of low light scattering, leading to undesirable appearances and requiring additional coats, while alternatives like clay-based pigments and vesiculated beads are costly and inconsistent.
Innovation Solution
The development of discrete opacifying cluster particles composed of a latex binder, opaque polymer, and extender pigment particles with a porosity that maintains light scattering efficiency, allowing for improved opacity and reduced gloss without the drawbacks of traditional large-size extenders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If large-size extenders are used to achieve low gloss finish, then gloss is reduced, but opacity decreases due to regions of low light scattering
Solution Approach 1:
The patent divides the extender material into two distinct size categories: small-size extenders (0.5-5 μm) that maintain good light scattering, and large-size extenders (5-50 μm) that provide gloss reduction. By segmenting the extender function into two particle size groups, the patent achieves both opacity and gloss reduction simultaneously, resolving the contradiction between these two properties.
2Illumination intensity
If TiO2 concentration is increased to improve opacity, then opacity increases, but cost increases significantly
Solution Approach 1:
The patent creates a composite extender system combining small-size and large-size extenders in specific proportions (at least 50% small-size and up to 50% large-size by weight). This composite approach allows the small-size extenders to provide light scattering for opacity while large-size extenders provide gloss reduction, eliminating the need to increase TiO2 concentration and thus reducing material costs.
3Difficulty of detecting and measuring
If clay-based pigments are used as alternative extenders, then gloss reduction is achieved, but opacity decreases due to material uptake in pores
Solution Approach 1:
The patent assigns different functional qualities to different particle size regions: small-size extenders (0.5-5 μm) are optimized for light scattering and opacity maintenance, while large-size extenders (5-50 μm) are optimized for gloss reduction. This local quality differentiation ensures that each particle size performs its specialized function effectively, preventing the opacity loss seen in porous clay-based pigments.
4Illumination intensity
If vesiculated beads are used to increase opacity, then opacity improves, but cost increases and synthesis uniformity decreases
Solution Approach 1:
The patent replaces expensive, difficult-to-synthesize vesiculated beads with conventional extender particles of two size ranges that are easier and cheaper to manufacture. The small-size and large-size extender combination provides comparable optical performance (opacity and gloss reduction) without the high production costs and synthesis uniformity issues of vesiculated beads.
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 opacifying clusters enhance opacity and reduce sheen, achieving a matte or eggshell finish with improved optical properties and mechanical integrity, comparable to prior opaque polymers but with the ability to maintain gloss reduction, thus offering a wide range of gloss and sheen values not previously attainable.
Implementation Method 1
increase the opacity of resultant films made using the paint product while maintaining the mechanical integrity and flatness of the resultant film... improve the opacity... efficiency of light scattering within the paint
Implementation Method 2
a porosity of the second polymeric binder defining a binder void volume
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
An opacifying cluster which may be added to a coating composition to provide a coating composition with low gloss and a high level of opacity. The opacifying cluster can include a polymeric latex binder coalescing cluster components into a generally homogeneous particle. The cluster components may include discrete polymeric particles each defining a closed void volume therein, a plurality of inorganic pigment particles, and a plurality of extender pigment particles. The clusters may also include a porosity of the polymeric latex binder thereof defining a binder void volume. Also provided is a paint product including such a pigment cluster.