Reactive Particles for Solvent-Free Cold Spray Coatings
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Solution Overview
Problem
Conventional coating technologies face limitations in applying polymer coatings due to the need for volatile organic compounds (VOCs), specific drying conditions, and difficulties in coating large surfaces under ambient conditions, especially outdoors across varying seasons.
Innovation Solution
The use of reactive particles comprising self-reactive monomers or monomers that polymerize within a matrix polymer, which can be cold sprayed onto a substrate at high velocity to form a polymer coating without the need for solvents or specialized heating, allowing for instantaneous curing and flexible application regardless of temperature or humidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional coating technologies are used, then coating compositions can be applied for decorative and protective purposes, but the process requires volatile organic compounds (VOCs) and specific drying conditions which limits application flexibility
Solution Approach 1:
The patent extracts and removes the volatile organic compounds (VOCs) from the coating composition formulation. The coating is applied as a solid or semi-solid material without solvent carriers, eliminating the harmful VOC emissions entirely while maintaining the coating's functional properties for decorative and protective applications.
Solution Approach 2:
The patent changes the physical state parameter of the coating material from liquid (solvent-based) to solid or semi-solid form. This parameter change eliminates the need for VOC-based carriers and allows the coating to be applied in ambient conditions without requiring controlled drying environments, thereby improving application flexibility.
2Area of stationary object
If conventional coating technologies are used, then coating can be applied to substrates, but specific drying conditions are required which limits coating of large surfaces under ambient conditions
Solution Approach 1:
The patent replaces the thermal drying process (heat-based evaporation of solvents) with a mechanical deposition process. The coating material is applied as solid particles or powder that adhere to the substrate through mechanical means such as spray deposition or electrostatic attraction, eliminating the need for controlled drying conditions and enabling coating of large surfaces in ambient environments.
3Duration of action of stationary object
If reactive monomers are polymerized within matrix polymer particles, then the coating components gain unlimited shelf-life, but the particles must be accelerated to high velocity to initiate polymerization which requires specialized equipment
Solution Approach 1:
The patent incorporates reactive monomers within the matrix polymer particles in advance, preparing them for future polymerization. The monomers are pre-positioned and stabilized within the particle structure, allowing the coating to maintain unlimited shelf-life while remaining ready for instantaneous polymerization upon impact with the substrate during cold spray application.
Solution Approach 2:
The patent utilizes the phase transition and mechanical energy conversion inherent in the cold spray process. The coating particles are accelerated to high velocity and undergo phase transition upon impact with the substrate, converting kinetic energy into the activation energy required for polymerization. This allows the reactive monomers to polymerize instantly upon deposition without requiring additional heating or catalysis equipment.
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
This method eliminates the use of VOCs, provides unlimited shelf-life for the coating components, enables coating of large surfaces in any season, and allows for consecutive applications without dripping or flow issues, resulting in a durable and environmentally friendly polymer coating.
Implementation Method 1
cold spraying a cold spray composition comprising the plurality of reactive particles onto a substrate at a velocity sufficiently high to cause the plurality of reactive particles to deform upon contact with the substrate causing the reactive monomer to polymerize
Implementation Method 2
cold spraying a cold spray composition comprising the plurality of reactive particles onto a substrate at a velocity sufficiently high to cause the plurality of reactive particles to deform upon contact with the substrate
Data Source
AI summary
In an embodiment, a composition comprises a plurality of reactive particles; wherein at least a first portion of the reactive particles comprises a first reactive monomer located in a first matrix polymer; wherein the first reactive monomer comprises a self-reactive monomer or wherein the first reactive monomer can polymerize with a second reactive monomer located in a second matrix polymer of a second portion of the reactive particles to form a coating polymer. In another embodiment, a method of making the plurality of reactive particles, comprises polymerizing a first matrix monomer in the presence of the first reactive monomer; or polymerizing the first matrix monomer to form a plurality of particles and swelling the plurality of particles with the first reactive monomer. In another embodiment, a method comprises cold spraying the plurality of reactive particles.