Aqueous Coating Mixer With Silane Emulsion for Low-Bake Adhesion
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Solution Overview
Problem
Existing aqueous coating materials for automotive refinishing and plastic parts face challenges in achieving excellent adhesion and interlayer adhesion properties, particularly in low-bake applications, while maintaining low volatile organic compound (VOC) content and ensuring storage stability.
Innovation Solution
A mixer system producing aqueous coating materials using an aqueous pigment paste and a mixing clear resin component, where the resin component includes an acrylic-based multi-stage emulsion polymer synthesized through radical emulsion polymerization with silane-containing olefinically unsaturated monomers, allowing for low VOC content and improved adhesion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixing technology is used, then mixing capability is maintained, but batch times increase and productivity decreases
Solution Approach 1:
The mixing system employs dynamically adjustable mixing elements that can change their configuration during operation. The mixing elements include adjustable components that allow optimization of mixing intensity and pattern, enabling the system to adapt to different material viscosities and batch requirements, thereby reducing batch times while maintaining mixing quality
Solution Approach 2:
The system allows for parameter changes in the mixing process including variable speed operation and adjustable mixing element positions. By changing operational parameters dynamically, the system achieves more efficient mixing cycles, directly addressing the productivity and batch time contradiction
2Ease of operation
If mixing systems are designed for easy cleaning, then ease of operation improves, but mixing intensity may be compromised
Solution Approach 1:
The mixing system is divided into separable modules with mixing elements that can be easily detached from the mixing chamber. This segmentation allows for simple removal and cleaning of mixing components without disassembling the entire system, maintaining ease of cleaning while preserving the high-intensity mixing capability through optimized element design
Solution Approach 2:
The mixing elements are designed to be extractable from the mixing system, allowing them to be removed for cleaning or replacement. This extraction capability facilitates easy maintenance and cleaning operations while the mixing elements themselves are designed to maintain high mixing intensity during operation
3Productivity
If mixing elements are stationary, then device complexity is reduced, but mixing efficiency and productivity decrease
Solution Approach 1:
The system merges the functions of multiple mixing elements into a coordinated arrangement that works together to enhance mixing efficiency. By combining several mixing elements with different functions (e.g., different geometries, rotation directions) into a single integrated system, productivity is improved without proportionally increasing overall device complexity
Solution Approach 2:
The mixing elements are designed with multi-functionality, capable of performing different mixing tasks through adjustable configurations. This universality allows a single set of mixing elements to handle various material types and viscosity ranges, improving productivity while avoiding the need for multiple specialized mixing systems
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 system achieves excellent adhesion and interlayer adhesion in both refinish and OEM applications, with VOC levels below 250 g/L, enhancing workplace safety and reducing environmental impact while maintaining storage stability.
Implementation Method 1
The mixing system according to one or more embodiments disclosed herein employs a rotor-stator mixing configuration which has proven to be effective in producing homogeneous mixes of liquid materials
Implementation Method 2
The mixing system may also include a heating system configured to heat the liquid materials during mixing
Implementation Method 3
The mixing system may also include a cooling system configured to cool the liquid materials during mixing
Data Source
AI summary
The present invention relates to a mixer system for producing aqueous coating materials comprising, within an aqueous mixing clear component B, an aqueous dispersion comprising an acrylic-based multi-stage emulsion polymer comprising silane functionality. The present invention also relates a method of producing a coating material from the mixer system as well as to a method of producing a coating layer from the prementioned coating material.