Non-Cryogenic Powder Coating Grinding via Polymer Parameter Changes
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Solution Overview
Problem
Powder coating compositions with low Tg polymers require cryogenic milling to achieve desired particle sizes, increasing complexity and manufacturing costs.
Innovation Solution
A powder coating composition comprising a first polymer with a number average molecular weight over 1,000 and a Tg of at least 40°C, a second polymer with a Tm of at least 100°C, and a cross-linker, where both polymers have less than 25 wt% fluorine-containing monomeric units, allowing grinding at non-cryogenic temperatures to achieve an average particle size of 15 to 150 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cryogenic milling is used to achieve desired particle size, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer (selecting specific polymer types with controlled molecular weight and composition) to enable grinding at non-cryogenic temperatures while still achieving the desired particle size distribution (40-150 microns average size). This allows the same manufacturing precision to be achieved without the complexity of cryogenic equipment.
2Manufacturing precision
If cryogenic milling is used to achieve desired particle size, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent modifies the polymer parameters (molecular weight, composition, and type) to enable cost-effective grinding at ambient or elevated temperatures. By selecting polymers with specific properties (e.g., lower molecular weight ranges, specific monomer compositions), the process achieves the required particle size (40-150 microns) without incurring the high costs associated with cryogenic milling equipment and operation.
3Ease of manufacture
If grinding temperature is increased above 4°C, then ease of manufacture is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent changes the polymer's physical and chemical parameters (molecular weight, glass transition temperature, composition) to enable grinding at temperatures above 4°C while maintaining particle size precision. The selected polymers have properties that allow them to be ground into the desired 40-150 micron range at elevated temperatures without requiring cryogenic conditions, thus improving ease of manufacture while preserving manufacturing precision.
Data Source
AI summary
A powder coating composition grindable at non-cryogenic temperatures includes: (a) a first polymer having a number average molecular weight (Mn) of more than 1,000 and a Tg of at least 40° C.; (b) a second polymer having a Tm of at least 100° C.; and optionally (c) a cross-linker. The first polymer and the second polymer are different from one another, and each of the first and second polymers have less than 25 wt % fluorine-containing monomeric units, with wt % based on the total weight of the monomeric units in each polymer. Upon grinding at a temperature above 4° C. the coating composition has an average particle size from 15 to 150 microns. Further coating compositions, methods of preparing coating compositions, coating systems, and substrates coated with a powder coating composition are also disclosed.