Phenolic-Functional Polyester Coatings for Corrosion and Flexibility

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Solution Overview

Problem

Conventional polyester-based coatings for food-contact metal containers face challenges in achieving a balance between corrosion resistance, flexibility, and resistance to crazing, with existing coatings either being too soft or exhibiting poor flexibility and unsuitable crazing.

Innovation Solution

A polyester polymer with phenolic functionality, including phenolic-containing pendant and/or terminal groups, such as derivatives of cardanol or diphenolic acid, is used to create a coating composition that includes a phenolic-functional polyester, an optional crosslinker, and a carrier, which enhances adhesion, corrosion resistance, and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyester-based coatings are formulated to exhibit good corrosion resistance, then corrosion resistance is improved, but flexibility deteriorates and crazing occurs

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines polyester resin with phenolic resin to create a composite coating system. This composite formulation allows the coating to achieve both good corrosion resistance from the polyester component and maintained flexibility from the phenolic component, eliminating the trade-off present in conventional polyester coatings.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the coating by incorporating phenolic resin at specific concentrations (typically 10-50 wt% of total resin). This parameter change transforms the coating properties, enabling simultaneous achievement of corrosion resistance and flexibility without crazing.

Inventive Principle:

Principle #35Parameter changes

2Strength

If polyester-based coatings are formulated to exhibit good fabrication properties and absence of crazing, then flexibility is improved, but corrosion resistance deteriorates

Engineering Contradiction:

ImproveflexibilityVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates a composite coating system combining polyester and phenolic resins. The polyester component provides flexibility and good fabrication properties, while the phenolic component contributes corrosion resistance, achieving a balance that neither resin could provide alone.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional polyester coatings are used, then adhesion is achieved, but corrosion resistance and flexibility balance is insufficient

Engineering Contradiction:

ImproveadhesionVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent formulates a composite coating with polyester and phenolic resins where the polyester component ensures good adhesion to the substrate while the phenolic component enhances corrosion resistance. This composite approach maintains adhesion while improving the corrosion resistance-flexibility balance.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11667810B2Polyester polymer having phenolic functionality and coating compositions formed therefrom

Publication Date: 2023.06.06 SWIMC LLC

AI summary

A polyester polymer is provided that includes at least one pendant phenolic-containing group. In one embodiment, the polyester polymer is combined with an optional crosslinker and an optional carrier to form a coating composition suitable for use in coating articles such as packaging articles. The coating composition typically includes a resole phenolic crosslinker. In one embodiment, the polyester polymer has at least one phenolic-containing group that comprises an adduct of cardanol.