Water-Based Ozone-Decomposing Coating for Chalking Resistance

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Solution Overview

Problem

Coating films containing manganese oxide-based catalysts and activated carbon for ozone decomposition suffer from poor weather resistance due to photocatalysis and oxidative degradation when exposed to sunlight, leading to chalking and degradation of resin components.

Innovation Solution

A water-based paint composition incorporating a manganese oxide-based catalyst, activated carbon, and a water-soluble resin such as acrylic or fluorocarbon resin, with specific content ratios and glass transition temperatures, to enhance weather resistance and prevent chalking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a manganese oxide-based catalyst is included in the coating film for ozone decomposition, then ozone decomposition performance is improved, but weather resistance deteriorates due to photocatalysis and oxidative degradation

Engineering Contradiction:

Improveozone decomposition performanceVSAvoidweather resistance

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

A water-soluble resin selected from acrylic resin, modified acrylic resin, or fluorocarbon resin is introduced as an intermediary binder between the manganese oxide-based catalyst particles and the substrate. This resin binder protects the catalyst particles from direct exposure to sunlight while maintaining their ozone decomposition activity, thereby preventing photocatalytic degradation of the coating film and improving weather resistance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating film is formulated as a composite material system comprising manganese oxide-based catalyst particles dispersed in a water-soluble resin matrix. This composite structure allows the catalyst to maintain its ozone decomposition function while the resin matrix provides protection against weathering, solving the contradiction between catalytic performance and durability

Inventive Principle:

Principle #40Composite materials

2Reliability

If activated carbon is included in the coating film for ozone adsorption, then ozone decomposition performance is improved, but weather resistance deteriorates due to oxidative degradation

Engineering Contradiction:

Improveozone decomposition performanceVSAvoidweather resistance

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The water-soluble resin acts as a protective intermediary that encapsulates the activated carbon particles, shielding them from direct contact with oxygen and sunlight. This prevents oxidative degradation of the activated carbon while allowing it to maintain its ozone adsorption capacity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The activated carbon is integrated into the resin-based composite coating matrix, where it maintains its ozone adsorption function while the resin provides a protective environment that prevents oxidative degradation, thereby improving long-term weather resistance

Inventive Principle:

Principle #40Composite materials

3Productivity

If the coating film is applied to exterior parts exposed to air flow for ozone decomposition, then air purification is improved, but chalking occurs due to photocatalysis of resin degradation

Engineering Contradiction:

Improveair purification efficiencyVSAvoidcoating durability

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The water-soluble resin serves as a mediator that allows air flow and ozone contact while protecting the underlying resin components from photocatalytic degradation by the manganese oxide catalyst, thus maintaining coating durability in high-traffic exterior areas

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent specifies particular types of water-soluble resins (acrylic, modified acrylic, or fluorocarbon resin) with appropriate molecular structures and properties that are inherently more resistant to photocatalytic degradation, changing the chemical parameters of the binder system to improve durability

Inventive Principle:

Principle #35Parameter changes

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 composition achieves high ozone decomposition performance while maintaining durability and resistance to weathering, even when exposed to sunlight, by using a water-soluble resin as a binder to stabilize the coating film.

Implementation Method 1

a manganese oxide-based catalyst as an ozone decomposition catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

activated carbon with ozone adsorption capacity

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 3

at least one water-soluble resin selected from a group consisting of a (meth) acrylic resin, a modified acrylic resin, and a fluorocarbon resin

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20260042928A1Water-based paint composition and hardened coating film thereof, and coated article

Publication Date: 2026.02.12 TOYOTA JIDOSHA KK

AI summary

A water-based paint composition includes a manganese oxide-based catalyst, activated carbon, at least one water-soluble resin selected from a group consisting of acrylic resin, modified acrylic resin, and fluorocarbon resin, a polyacrylate-based dispersant, and a water-based solvent. The water-based paint composition, although including the manganese oxide-based catalyst, allows a coating film to be resistant to chalking and weather.