Phosphorous-Containing Emulsion Polymer Coating for Stain Repellency
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Solution Overview
Problem
Existing aqueous coating compositions with high pigment volume concentration (PVC) face challenges in achieving effective hydrophilic stain repellency without increasing wax content, which can lead to higher costs and compromised performance in gloss, washability, and freeze-thaw stability.
Innovation Solution
An aqueous coating composition comprising an emulsion polymer made from specific ratios of phosphorous-containing monomers, including phosphorous-containing (meth)acrylates and surfactants, combined with a wax emulsion and pigment, which enhances hydrophilic stain repellency even at high PVC levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more wax is added into the coating composition to improve hydrophilic stain repellency at high PVC, then hydrophilic stain repellency is improved, but cost increases and other performances such as gloss, washability, and freeze-thaw stability are compromised
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by incorporating phosphorous-containing monomers (specifically phosphorous-containing (meth)acrylates) into the emulsion polymer. This chemical parameter change enables the binder itself to provide hydrophilic stain repellency through phosphorous-containing groups, replacing the need to increase wax content. The phosphorous-containing monomers are used in specific amounts (0.1-10 wt% based on total monomers) to achieve optimal performance without excessive wax addition.
Solution Approach 2:
The patent creates a composite binder system combining emulsion polymer with phosphorous-containing monomers and wax emulsion. The phosphorous-containing (meth)acrylates copolymerize with other monomers to form a composite polymer structure that integrates stain repellency functionality into the binder matrix, while working synergistically with reduced amounts of wax emulsion (0.5-5 wt% based on total composition) to achieve effective hydrophilic stain repellency without the drawbacks of high wax content.
2Quantity of substance
If PVC of coating composition is increased to 55% or more, then pigment loading and coverage are improved, but hydrophilic stain repellency deteriorates
Solution Approach 1:
The patent modifies the binder's chemical composition by incorporating phosphorous-containing monomers, which fundamentally changes the surface properties of the coating film. This parameter change in the binder chemistry enables the system to maintain high hydrophilic stain repellency even when PVC increases to 55% or higher, overcoming the typical deterioration that occurs with high pigment loading.
Solution Approach 2:
The patent applies local quality by concentrating phosphorous-containing groups at the coating film surface through the use of phosphorous-containing (meth)acrylates. These phosphorous-containing groups migrate to or remain at the surface, creating a localized region with high stain repellency properties that protects the entire coating film, including areas with high pigment concentration.
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 a hydrophilic stain repellency score of 7 or higher, maintaining performance without the need for increased wax content, thus optimizing cost and functionality.
Implementation Method 1
an emulsion polymer prepared by polymerization of at least two types of phosphorous-containing monomers
Implementation Method 2
a phosphorous-containing surfactant or a salt thereof... wherein the phosphorous-containing surfactant has the structure of formula (I)
Implementation Method 3
Wax tends to migrate to the surface of dry coating films and reduces the surface tension, thereby improving stain repellency
Data Source
AI summary
An aqueous coating composition comprising:(A) an emulsion polymer prepared by polymerization of at least two types of phosphorous-containing monomers at a specific ratio, (B) a wax emulsion, (C) a pigment. The aqueous coating composition can provide coatings with good hydrophilic stain repellency.