Phosphorus Acid Binder Coatings for Hiding Efficiency
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Solution Overview
Problem
Current pigmented paints using phosphorus acid functionalized latex binders face issues such as grit formation, high costs, compromised viscosity stability, and reduced hiding efficiency due to uncontrolled reactions and pH effects, necessitating a solution to decrease phosphorus acid monomer concentration without sacrificing hiding efficiency.
Innovation Solution
A process involving a combination of a water-soluble polymer functionalized with sulfonic acid groups and a stable aqueous dispersion of polymer particles functionalized with phosphorus acid groups, both in controlled proportions with TiO2, to improve paint stability and hiding efficiency while reducing phosphorus acid monomer concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phosphorus acid functionalized latex binder is used to improve hiding efficiency, then TiO2 particle spacing is improved, but grit formation occurs due to uncontrolled reaction
Solution Approach 1:
The patent introduces a mediator system comprising carboxylic acid functionalized polymer and phosphorus acid functionalized polymer that act as intermediaries between TiO2 particles and the binder. This mediator controls the interaction between TiO2 and binder, preventing direct uncontrolled reactions that cause grit formation while maintaining the spacing effect that improves hiding efficiency
Solution Approach 2:
The patent changes the chemical parameters by using specific functional groups (carboxylic acid and phosphorus acid) on polymer chains, and controls the concentration ratios of these polymers to optimize both hiding efficiency and prevent grit formation. The parameter optimization involves balancing the concentration of phosphorus acid functionalized polymer to achieve adequate spacing without excessive reactivity
2Manufacturing precision
If phosphorus acid monomer concentration is increased to improve hiding efficiency, then TiO2 spacing is improved, but cost increases and viscosity stability is compromised
Solution Approach 1:
The patent optimizes the concentration parameter of phosphorus acid monomer to a specific range (0.1-5 wt% based on binder weight) and introduces carboxylic acid functionalized polymer as a complementary component. This parameter optimization achieves adequate TiO2 spacing for hiding efficiency while preventing the viscosity instability and cost issues associated with higher phosphorus acid monomer concentrations
Solution Approach 2:
The patent creates a composite binder system combining carboxylic acid functionalized polymer and phosphorus acid functionalized polymer in specific ratios. This composite approach distributes the functional requirements between two components, achieving the desired TiO2 spacing and hiding efficiency while maintaining viscosity stability and reducing reliance on expensive high-concentration phosphorus acid monomers
3Stability of the object's composition
If phosphorus acid monomer concentration is decreased to reduce cost and improve stability, then viscosity stability is improved, but hiding efficiency decreases
Solution Approach 1:
The patent creates a composite system where carboxylic acid functionalized polymer and phosphorus acid functionalized polymer work synergistically. The carboxylic acid component provides structural framework and steric stabilization, while the phosphorus acid component provides controlled adhesion to TiO2. This composite approach maintains hiding efficiency even at lower phosphorus acid monomer concentrations by leveraging the cooperative effect of both polymers
Solution Approach 2:
The carboxylic acid functionalized polymer acts as an intermediary that enhances the effectiveness of lower concentrations of phosphorus acid functionalized polymer. This intermediary provides additional functional groups that contribute to TiO2 spacing and stabilization, allowing the system to achieve adequate hiding efficiency with reduced phosphorus acid monomer content
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 approach enhances paint stability and hiding efficiency, maintaining performance without increasing phosphorus acid monomer levels, thus overcoming the limitations of existing technologies.
Implementation Method 1
the spacing of TiO 2 and its concomitant hiding efficiency can be improved with the aid of emulsion polymer particles adsorbed to the TiO 2 particle surface
Data Source
AI summary
The present invention is a composition comprising a) a stable aqueous dispersion of polymer particles functionalized with structural units of a phosphorus acid monomer or a salt thereof and; b) a water-soluble polymer functionalized with structural units of a sulfonic acid monomer or a salt thereof as well as a method comprising mixing the stable aqueous dispersion of the phosphorus acid functionalized polymer particles with the sulfonic acid functionalized polymer, and TiO2. The composition of the present invention is useful as a coatings formulation that provides improved hiding over phosphorus acid functionalized binders that do not include the water-soluble polymer. Alternatively, the same hiding benefit is seen at lower phosphorus acid concentration when the sulfonic acid functionalized polymer is present.