Process for producing a crushed foam coating
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Solution Overview
Problem
Existing crushed foam coatings lack the desired thickness, add-on, and softness after standard coating and crushing processes, failing to provide superior performance in terms of thickness, mass per unit area, and tactile softness compared to previous coatings.
Innovation Solution
A process involving an aqueous coating composition with multi-stage copolymer particles and binder polymers, where gas is introduced to create a wet foam, applied, dried to 2-20% water content, and then crushed, utilizing GRIN copolymer particles with a core and shell structure and specific glass transition temperatures to enhance thickness and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard coating and crushing processes are used, then the coating can be applied efficiently, but the resulting crushed foam coating lacks sufficient thickness, add-on, and softness
Solution Approach 1:
The patent modifies the physical and chemical parameters of the coating composition by incorporating multi-stage copolymer particles with specific glass transition temperatures (Tg ≤ 20°C for core, Tg ≥ 50°C for shell). This parameter change enables the coating to achieve greater thickness and softer handle after crushing while maintaining application efficiency through controlled foam expansion and drying characteristics.
Solution Approach 2:
The invention uses composite multi-stage copolymer particles with distinct core and shell structures having different Tg values. The core provides softness and thickness upon crushing, while the shell maintains structural integrity during application. This composite structure resolves the contradiction between achieving thick, soft coatings and maintaining efficient standard coating processes.
2Quantity of substance
If standard coating and crushing processes are used, then the process can be completed quickly, but the add-on (mass of coating per unit area) is insufficient
Solution Approach 1:
By changing the compositional parameters of the coating to include multi-stage copolymer particles with specific Tg ranges and controlled particle sizes (2-20 μm), the coating achieves higher add-on after crushing without extending processing time. The controlled foam expansion and particle characteristics enable greater material deposition in the standard drying and crushing cycle.
3Ease of operation
If standard coating and crushing processes are used, then the coating can be applied uniformly, but the resulting coating is not soft to the touch
Solution Approach 1:
The patent applies local quality by creating multi-stage copolymer particles with spatially differentiated properties: the core has low Tg (≤ 20°C) to provide softness upon crushing, while the shell has high Tg (≥ 50°C) to maintain uniformity and structural integrity during application. This local differentiation of material properties within the particle structure enables both tactile softness and coating uniformity after crushing.
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 process results in crushed foam coatings with increased thickness, higher add-on, and a softer handle compared to conventional coatings, while maintaining a smooth appearance and improved durability and flexibility.
Implementation Method 1
introducing gas into the aqueous coating composition to produce a wet foam
Implementation Method 2
drying the layer of wet foam to a water content of 2% to 20% by weight
Data Source
AI summary
Provided is a process for producing a coating on a substrate comprising one or more steps of crushing a dried layer of a foamed aqueous coating composition, wherein the aqueous coating composition comprises a collection of multi-stage copolymer particles having a weight average diameter of 2-20 μm, wherein said multi-stage copolymer particles comprise a core having a glass transition temperature (Tg) of 20°C or less. Also provided is a coated substrate made by that process.