Liquid Silicone Coating for Barrel Evaporation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coatings for wooden barrels used in aging distilled beverages are either difficult to apply, prone to damage, or restrict oxygenation, leading to excessive evaporation and loss of the aged beverage, known as the 'angels' share', which results in volume loss ranging from 2% to 10% per year.
Innovation Solution
A liquid silicone coating composition that acts as a vapor barrier, comprising a vulcanized polymer with a silane crosslinking agent and transition metal catalysts, which is moisture-cured and applied easily to the barrels, reducing evaporation rates while maintaining oxygen permeance and durability for up to 21 years.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a semi-permeable water emulsion of polyvinyl chloride coating is applied to the barrel exterior, then evaporation of the distilled liquid is prevented, but particles of evaporated compounds accumulate and get absorbed into the internal membrane, resulting in loss of permeability over time
Solution Approach 1:
The patent changes the chemical composition and physical properties of the coating material from polyvinyl chloride water emulsion to a cross-linked silicone polymer system. This parameter change results in a coating that maintains permanent porosity and does not absorb evaporated alcohol compounds, thereby maintaining permeability over time while still reducing evaporation loss.
Solution Approach 2:
The invention uses a composite coating system consisting of silicone polymer base material with added cross-linking agents and catalysts. This composite structure creates a durable, porous network that allows vapor transmission while preventing the coating from degrading or absorbing alcohol compounds, resolving the permeability loss issue.
2Loss of substance
If varnish or other coating materials with highly restrictive permeability are used, then evaporation is decreased, but oxygenation is reduced, making them impractical
Solution Approach 1:
The silicone coating provides different permeability characteristics for different substances: it has low permeability to liquid water and alcohol vapors (reducing evaporation loss) while maintaining high permeability to oxygen gas (allowing necessary oxygenation). This selective local quality resolves the contradiction between preventing evaporation and maintaining oxygenation.
Solution Approach 2:
The cross-linked silicone polymer coating maintains a porous structure that allows gas molecules like oxygen to pass through while providing a vapor barrier to liquid and alcohol vapors. The porosity enables oxygenation while the hydrophobic nature of silicone reduces evaporation, simultaneously addressing both requirements.
3Loss of substance
If prefabricated plastic bags or films are wrapped around the barrel, then evaporation rate is reduced, but the films are hard to apply and have limited durability
Solution Approach 1:
The invention replaces the mechanical wrapping system (plastic bags and films that require manual application and adjustment) with a chemical coating system that is applied as a liquid and cures in place. This substitution eliminates the need for complex application machinery and manual adjustment, greatly improving ease of manufacture and application.
Solution Approach 2:
The silicone coating formulation includes self-leveling and self-curing properties. After application, the coating automatically levels itself to provide uniform coverage and then cures through moisture or catalyst-driven cross-linking without requiring additional intervention. This self-service characteristic simplifies the application process and improves durability.
4Loss of substance
If a coating is applied to reduce evaporation, then the angels' share is reduced, but the coating may deform or break down when barrels are moved or rolled
Solution Approach 1:
The coating formulation includes cross-linking agents and catalysts that create a cross-linked polymer network structure before the barrel is put into service. This preliminary cross-linking action provides the coating with enhanced mechanical strength, abrasion resistance, and flexibility, preventing deformation and breakdown during barrel handling and rolling operations.
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 coating effectively reduces evaporation rates by up to 40% while ensuring minimal impact on the sensory profile of the aged beverage, maintaining proper oxidative reactions and durability, thus addressing the 'angels' share issue without compromising the aging process.
Implementation Method 1
a polymer vulcanized with a silane crosslinking agent that is oxime-functional, acetoxy-functional, or alkoxy-functional
Implementation Method 2
an OH-terminated polysiloxane that exhibits moisture curing, condensation reactions when in the presence of water vapors and silane crosslinkers
Implementation Method 3
reducing the evaporation rate without significantly altering the expected taste and smell of the aged distilled alcoholic beverage
Implementation Method 4
a liquid coating composition of matter that works as a vapor barrier when applied to wooden barrels
Implementation Method 5
a transition metal catalyst that provides a reaction crosslink density that allows for minimal transport of ethanol vapors and water vapors after curing
Implementation Method 6
a transition metal catalyst that provides a reaction crosslink density with minimal impact on the rate of oxygen gas transport rate after curing
Data Source
AI summary
A liquid coating composition of matter for application to wooden barrels or casks used in distilling, the composition of matter includes a polymer vulcanized with a silane crosslinking agent that is oxime-functional, acetoxy-functional, or alkoxy-functional, an OH-terminated polysiloxane that exhibits moisture curing, condensation reactions when in the presence of water vapors and silane crosslinkers, a low to medium molecular weight polysiloxane that exhibits low-permeance after curing via moisture-cure, condensation reaction, a transition metal catalyst that provides a reaction crosslink density that allows for minimal transport of ethanol vapors and water vapors after curing, a second transition metal catalyst that provides a reaction crosslink density with minimal impact on the rate of oxygen gas transport rate after curing, and inorganic polymers with a siloxane backbone that exhibits no leaching, migration or notable reaction with a liquid alcohol and water mixture upon curing.