Resin Emulsion Sealer with Core-Shell Structure
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Solution Overview
Problem
Existing aqueous coating compositions for undercoating face challenges in achieving both high blocking resistance and frost damage resistance while maintaining good film-forming properties and water permeability resistance, often requiring high amounts of film-forming aids or pigments that are environmentally unfavorable.
Innovation Solution
A resin emulsion with emulsion particles having an inner and outer layer, where the inner layer is formed from a polymer with high styrene content and the outer layer from a polymer with a carboxyl group-containing monomer, optimized through emulsion polymerization to achieve a balanced glass transition temperature and monomer composition, enhancing blocking resistance, film-forming property, and water permeability resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a film-forming aid is used in a large amount to achieve good film-forming property, then film-forming property is improved, but environmental protection is compromised and frost damage resistance is insufficient
Solution Approach 1:
The patent changes the glass transition temperature parameter of the resin from high to low (not more than 40°C), which fundamentally alters the film-forming mechanism. This allows the resin to form films at lower temperatures without requiring excessive film-forming aids, thereby improving both film-forming property and frost damage resistance simultaneously
Solution Approach 2:
The patent creates a composite resin system combining specific resin components with glass transition temperatures optimized for both film-forming and frost resistance. This composite approach eliminates the need to choose between film-forming aids and frost protection
2Reliability
If the glass transition temperature of the shell is increased to improve blocking resistance, then blocking resistance is improved, but film-forming property and water permeability resistance deteriorate
Solution Approach 1:
The patent reverses the conventional approach by using low glass transition temperature resin (not more than 40°C) to achieve good film-forming property, while obtaining blocking resistance through alternative mechanisms such as pigment composition and coating structure rather than high glass transition temperature
3Reliability
If a water-soluble polymer with high glass transition temperature is used to improve blocking resistance, then blocking resistance is improved, but frost damage resistance deteriorates
Solution Approach 1:
The patent changes the glass transition temperature parameter to not more than 40°C, which simultaneously improves both blocking resistance and frost damage resistance, eliminating the trade-off present in conventional approaches
4Reliability
If the content of pigment is increased to improve blocking resistance, then blocking resistance is improved, but water permeability resistance deteriorates
Solution Approach 1:
The patent optimizes the resin's glass transition temperature and molecular structure to achieve blocking resistance through the coating film's inherent properties rather than relying on high pigment content, thereby maintaining water permeability resistance
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 resin emulsion composition provides excellent blocking resistance, frost damage resistance, and water permeability resistance, reducing the need for excessive film-forming aids and improving the overall performance of coated films on inorganic building materials.
Implementation Method 1
the inner layer is formed from a polymer (I) which is prepared by emulsion polymerization of a monomer component A containing 85 to 100% by weight of styrene and 0 to 15% by weight of a monomer other than the styrene, and the outer layer is formed from a polymer (II) having a glass transition temperature of not more than 40° C., which is prepared by emulsion polymerization of a monomer component B
Data Source
AI summary
A resin composition for sealers as well as a resin composition for sealers and a paint composition for sealers that contains the resin composition for sealers are useful for sealers to be used with such inorganic building materials as ceramic-based building materials. The resin emulsion for sealers is a resin emulsion which contains emulsion particles having an inner layer and an outer layer. The inner layer is formed with a polymer which is formulated by means of emulsion polymerization of a monomer component containing styrene and a monomer other than the styrene, and the outer layer is formed with a polymer which is formulated by means of emulsion polymerization of a monomer component containing a carboxyl-group-containing monomer and a monomer other than the carboxyl-group-containing monomer.