Stain Resistant Coating Composition Using Segmented Resin Particles
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Solution Overview
Problem
Conventional high-gloss paints and semi-gloss paints provide stain resistance but lack low gloss finishes, making them unsuitable for applications requiring matte or low-sheen surfaces while maintaining washability and stain resistance.
Innovation Solution
A coating composition comprising an aqueous dispersion of a mixture of urethane acrylate resin particles and acrylic resin particles, along with a matting agent, where the urethane acrylate resin particles and acrylic resin particles are distinct and have specific size ratios to achieve improved stain resistance and low gloss levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-gloss paints or semi-gloss paints are used to achieve stain resistance, then stain resistance and washability are improved, but the gloss level becomes too high for applications requiring matte or low-sheen surfaces
Solution Approach 1:
The patent segments the resin system into two distinct components: urethane acrylate resin particles and acrylic resin particles. This segmentation allows each resin type to contribute different properties - the urethane acrylate provides stain resistance while the acrylic contributes to matte finish, resolving the contradiction between gloss level and stain resistance
Solution Approach 2:
The patent creates a composite coating system by combining urethane acrylate resin with acrylic resin in specific ratios (at least 5 wt% urethane acrylate based on total resin solids). This composite approach enables the coating to simultaneously achieve stain resistance from the urethane acrylate and low gloss finish from the acrylic, without requiring high overall gloss
2Ease of operation
If conventional high-gloss formulations are used to achieve washability, then ease of stain removal is improved, but the coating surface becomes glossy rather than matte
Solution Approach 1:
The patent applies local quality by having different resin particles perform different functions at the coating surface. The urethane acrylate resin particles (smaller, 50-150 nm) provide stain resistance and washability, while the acrylic resin particles (larger, 150-500 nm) contribute to the matte appearance. This localized functional differentiation allows the coating to be both washable and non-glossy
3Reliability
If a mixture of different resin particles is used to achieve both stain resistance and low gloss, then both properties are improved, but the formulation complexity increases
Solution Approach 1:
The patent controls formulation complexity by specifying precise parameter ranges: urethane acrylate resin particles at 5-50 wt% of total resin solids, particle sizes of 50-150 nm for urethane acrylate and 150-500 nm for acrylic, and specific ratios where acrylic particles are at least 1.5 times larger than urethane acrylate particles. These defined parameters provide a clear formulation framework that balances performance benefits with manufacturing simplicity
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 composition achieves enhanced stain resistance and low gloss finishes, with the smaller urethane acrylate resin particles filling gaps between larger acrylic resin particles, forming a closely packed film resistant to stain penetration and self-stratifying to create resin-rich domains on the surface, thereby improving washability and stain resistance.
Implementation Method 1
the smaller urethane acrylate resin particles filling gaps between larger acrylic resin particles, forming a closely packed film resistant to stain penetration
Implementation Method 2
self-stratifying to create resin-rich domains on the surface
Data Source
AI summary
A coating composition is prepared from an aqueous dispersion of a mixture of (i) urethane acrylate resin particles; (ii) acrylic resin particles; and (iii) a matting agent. A method of imparting stain resistance to a substrate, comprising applying the coating composition to at least a portion of the substrate.