Polyester-Polyurea Composition for Thin-Coating Adhesion and Wear Resistance
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Solution Overview
Problem
Formulating polymeric coatings that meet multiple performance attributes, such as adhesion, abrasion resistance, and chemical resistance, while maintaining a thin coat weight is challenging, often resulting in compromised performance.
Innovation Solution
A durable polymer composition comprising a polyester component with specific hydroxyl values and a polyurea component, combined with an isocyanate functional component, to achieve strong adhesion, low linear abrasion, and high chemical resistance in thin coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coating thickness is increased to achieve better performance attributes, then adhesion and abrasion resistance are improved, but the coating weight increases and thin coat requirements are compromised
Solution Approach 1:
The patent changes the chemical parameters of the coating composition by incorporating specific polyester polyols with controlled hydroxyl values (50-300) and polyester-polyol grafted polyurea polymers with hydroxyl values (20-100). This chemical parameter optimization enables thin coatings to achieve adequate performance without increasing thickness
Solution Approach 2:
The patent uses a composite polymer system combining polyester polyols and polyester-polyol grafted polyurea polymers in specific weight ratios (70:30 to 95:5). This composite material approach creates synergistic effects that deliver high performance in thin coating formulations
2Quantity of substance
If the coating thickness is reduced to meet thin coat requirements, then coating weight is minimized, but performance attributes such as adhesion and abrasion resistance are compromised
Solution Approach 1:
The patent optimizes chemical parameters by selecting polyester polyols with hydroxyl values of 50-300 and polyester-polyol grafted polyurea polymers with hydroxyl values of 20-100. These specific parameter ranges enable thin coatings to achieve adequate performance without increasing thickness
Solution Approach 2:
The patent uses polyester-polyol grafted polyurea polymers containing multiple carbodiimide moieties (average of 4 to 10 per polymer) to provide concentrated reactive functionality. This excessive action in terms of functional group density compensates for the reduced coating thickness
3Reliability
If a coating composition is optimized for one performance attribute, then that attribute is maximized, but other performance attributes are compromised
Solution Approach 1:
The patent creates a multi-functional polymer system where polyester polyols provide base coating properties and polyester-polyol grafted polyurea polymers provide crosslinking and performance enhancement. This universal system simultaneously delivers adhesion, abrasion resistance, chemical resistance, and low gloss in thin coatings
Solution Approach 2:
The patent employs a composite system of polyester polyols and polyester-polyol grafted polyurea polymers that work synergistically to provide multiple performance attributes simultaneously, avoiding the need to compromise any single attribute
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 performance in thin coatings with a dry film thickness of 2 mils or less, passing tests for adhesion, abrasion, and chemical resistance, including low gloss and resistance to sunscreen and insect repellent.
Implementation Method 1
an isocyanate functional component suitable for crosslinking the polymer system
Implementation Method 2
a polyurea component having a polyester-polyol grafted polyurea
Data Source
AI summary
The present application relates to a resin or polymer system suitable for two-component compositions, and a resin or polymer system configured for durable coatings with only thin coating weights. The resins and polymer systems of this invention provide high performance extremely thin, low gloss coatings with excellent adhesion, abrasion, scratch and chemical resistance The resins include a polyester component with one or more polyester polyols having a hydroxyl value of about 50 to about 300 and a polyurea component with one or more polyester polyol grafted polyurea polymers having a hydroxyl value of about 20 to about 100. These resin or polymer systems and two-component solvent borne coating compositions including such resin or polymer systems are surprisingly capable of achieving strong adhesion, excellent linear abrasion, and high chemical resistance all at the same time in a dry film thickness of about 2 mil or less, in some instances, about 1.2 mils or less, and in other instances, even about 1 mil or less.