Solid Pigmented Resin-Crosslinker Mixture for Aqueous Coatings
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Solution Overview
Problem
Aqueous coating compositions pose challenges in handling and preparation due to their high water content, which increases weight, volume, and cost during transportation, and require complex on-site mixing of individual components, making them costly and time-consuming to manufacture.
Innovation Solution
A method of preparing a granular coating feedstock by mixing a crosslinkable resin and curing agent above their melting points, forming a homogeneous molten blend, cooling, and grinding into a solid form, which can be stored and shipped, then dispersed in water with additives to form an aqueous coating composition, reducing the need for on-site mixing and minimizing transportation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If aqueous coating compositions are prepared from individual components at the site, then the coating can be customized and adapted to specific needs, but the preparation process becomes complex, time-consuming, and costly
Solution Approach 1:
The invention segments the coating system into a stable solid feedstock containing resin and pigment particles, and an aqueous medium added at the point of use. This allows the feedstock to be manufactured once with precise formulation (improving adaptability) while simplifying on-site preparation to merely adding water (reducing complexity).
Solution Approach 2:
The resin and pigment particles are pre-mixed and pre-formed into a stable solid feedstock before shipping. This preliminary action of combining components in controlled manufacturing eliminates the need for complex on-site mixing operations, reducing preparation complexity while maintaining formulation flexibility.
2Stability of the object's composition
If aqueous coating compositions are prepared from individual components, then proper dispersion can be achieved, but it requires significant time and specialized equipment
Solution Approach 1:
The resin and pigment particles are pre-dispersed and pre-mixed into a homogeneous solid feedstock during manufacturing. This preliminary dispersion action ensures proper composition stability is achieved in controlled conditions, eliminating the need for time-consuming on-site mixing while maintaining high dispersion quality.
Solution Approach 2:
The invention changes the physical state of the coating components from liquid to solid feedstock form. This parameter change allows the pre-dispersed feedstock to be stored and transported stably, then rapidly reconstituted by adding water at the point of use, significantly reducing preparation time while maintaining dispersion quality.
3Productivity
If aqueous coating compositions are transported in ready-to-use form, then application can begin immediately, but the weight and volume increase due to high water content
Solution Approach 1:
The invention extracts the aqueous medium from the coating formulation during manufacturing and shipping, transporting only the solid feedstock containing resin and pigment particles. This removes the unnecessary weight of water during transportation, then allows immediate application by adding water at the point of use, achieving both reduced transport weight and application readiness.
Solution Approach 2:
The resin and pigment particles are pre-prepared and pre-formed into a stable solid feedstock that can be stored and transported efficiently. This preliminary preparation eliminates the need to transport large volumes of water, reducing transportation weight while enabling immediate coating application when the feedstock is reconstituted with water on-site.
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 approach significantly reduces shipping costs and simplifies the preparation of aqueous coating compositions by introducing the aqueous solvent at the point of use, ensuring safety and environmental protection, and facilitating easier handling and preparation.
Implementation Method 1
mixing a crosslinkable resin and a curing agent at a mixing temperature at or above the melting points of the resin and agent to form a homogeneous molten blend
Implementation Method 2
The molten blend is subsequently cooled to form a solid blend
Data Source
AI summary
A pigmented granular pigmented coating feedstock is prepared by melting a resin, which can be a solid resin based on polymerizable ethylenically unsaturated monomer or epoxy based resin, and a solid or viscous curing agent, blending the molten mass, and cooling to form a solid. The solid blend of resin and curing agent is ground to produce a granular feedstock. The feedstock is readily storable or shippable to a location for coating preparation. Alternatively a solid coating can be ground after shipping. An aqueous coating is made by dispersing the feedstock in water and mixing to form a dispersion. A salting agent and at least one additive can be added to form an aqueous coating composition. An article can be coated with the dispersion, for example, by electrodeposition.