Pyrrolidone-Based Spray-Drying Aids for Re-Dispersible Powder Paint

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Solution Overview

Problem

Existing spray drying aids for powder paints, such as formaldehyde condensation products, cause discoloration and formaldehyde emission, and lack environmental friendliness and stability.

Innovation Solution

Using pyrrolidone-based (co)polymers, specifically acrylic acid ester polymers and acrylic-styrene copolymers, as spray drying aids to form a protective shell during the spray-drying process, enhancing re-dispersibility and reducing discoloration and formaldehyde emission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If formaldehyde condensation products are used as spray drying aids, then spray drying performance is improved, but discoloration and formaldehyde emission increase

Engineering Contradiction:

Improvespray drying performanceVSAvoiddiscoloration and formaldehyde emission

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the spray drying aid from formaldehyde condensation products to pyrrolidone-based (co)polymers with specific molecular weight ranges (Mw: 10,000-1,000,000, Mn: 1,000-100,000). This parameter change eliminates formaldehyde emission and discoloration while maintaining spray drying performance through the polymer's protective shell formation capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite pyrrolidone-based (co)polymers combining different polymer components with specific functional groups. This composite structure provides both the spray drying aid function (protective shell formation) and environmental friendliness (no formaldehyde emission, no discoloration), resolving the contradiction between performance and harmful emissions.

Inventive Principle:

Principle #40Composite materials

2Productivity

If conventional spray drying aids are used, then spray drying process is effective, but environmental friendliness and stability are reduced

Engineering Contradiction:

Improvespray drying effectivenessVSAvoidenvironmental friendliness and stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent specifies precise molecular weight parameters for the pyrrolidone-based (co)polymers (Mw: 10,000-1,000,000, Mn: 1,000-100,000) to optimize both spray drying effectiveness and environmental stability. These parameter controls ensure the polymer forms adequate protective shells during spray drying while maintaining long-term stability and environmental friendliness in the final powder paint product.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If spray drying is performed without protective shell formation, then process simplicity is maintained, but re-dispersibility and stability are reduced

Engineering Contradiction:

Improveprocess simplicityVSAvoidre-dispersibility and stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The pyrrolidone-based (co)polymers perform self-service by automatically forming protective shells around dispersion particles during the spray drying process. This self-protective mechanism occurs naturally during spray drying without requiring additional process steps or equipment, thereby maintaining process simplicity while ensuring excellent re-dispersibility and long-term stability of the powder paint.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250313707A1Powder paint comprising a re-dispersible dispersion powder

Publication Date: 2025.10.09 BASF SE

AI summary

The present invention is directed to the use of specific pyrrolidone-based (co)polymer as spray-drying additive (also known as spray drying aid; SDA) in a powder paint comprising at least one re-dispersible dispersion powder (RDP). The present invention is further directed to a powder paint comprising an RDP comprising at least one (co)polymer selected from the group consisting of acrylic acid ester polymer and acrylic-styrene copolymer and at least one pyrrolidone-based (co)polymer, as well as a process of manufacturing a paint.