Sulfonate-Functional Coating Compositions for Thick, Cleanable Layers
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Solution Overview
Problem
Existing coating technologies struggle to achieve thick, durable, and easily cleanable surfaces in a single coating pass, often resulting in cracked layers or reduced effectiveness over time.
Innovation Solution
A coating composition comprising a zwitterionic compound with sulfonate-functional groups and alkoxysilane groups, combined with an acid-catalyzed hydrolysis product of alkoxysilane and a water-miscible organic solvent, allows for a single-pass application of thick, chemically resistant, and hydrophilic coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a thick coating layer is applied to ensure durability and longevity, then the coating can withstand use and cleaning for longer periods, but the coating may crack or degrade during drying and curing
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by incorporating zwitterionic compounds with specific functional groups (sulfonate, carboxylate, phosphate) and controlling the pH to be between 2-6. These parameter changes enable the coating to maintain flexibility and adhesion at thick applications, preventing cracking while ensuring durability.
Solution Approach 2:
The patent creates a composite coating system by combining zwitterionic compounds with specific polymers (polyacrylic acid, polyacrylamide, chitosan) and crosslinking agents. This composite structure provides both the thickness needed for durability and the chemical flexibility to prevent cracking, resolving the contradiction between coating duration and reliability.
2Productivity
If a thick coating layer is applied in a single pass to reduce manufacturing time, then productivity increases, but the coating quality may deteriorate due to cracking or uneven drying
Solution Approach 1:
The patent modifies the rheological parameters of the coating composition by adjusting pH (2-6) and incorporating specific polymers that control viscosity and drying characteristics. These parameter changes allow single-pass application of thick coatings without cracking or uneven drying, maintaining manufacturing precision while improving productivity.
Solution Approach 2:
The patent ensures continuous protective action through crosslinking mechanisms that occur during drying and curing, creating a unified intact coating layer in single pass. This continuous chemical bonding process prevents defects and ensures uniform coating quality throughout the thick layer, enabling high productivity without sacrificing precision.
3Quantity of substance
If conventional coating compositions are used to achieve thick coatings, then coating thickness can be increased, but the surface properties (hydrophilicity and ease of cleaning) are lost over time
Solution Approach 1:
The patent changes the chemical functional groups present in the coating by incorporating zwitterionic compounds with sulfonate, carboxylate, or phosphate groups. These functional groups maintain stable hydrophilic surface properties even in thick coatings over time, as they are resistant to degradation and maintain their charge characteristics throughout the coating thickness.
Solution Approach 2:
The patent develops a composite formulation where zwitterionic compounds are integrated with crosslinking agents and polymers to create a stable matrix. This composite structure protects the surface-functional zwitterionic groups from degradation while maintaining thick coating thickness, ensuring long-term stability of hydrophilic properties and ease of cleaning characteristics.
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 enables thick, durable coatings that are easily cleaned and resistant to chemicals and moisture, maintaining surface properties over time without cracking or degradation.
Implementation Method 1
an acid-catalyzed hydrolysis product of an alkoxysilane and a weak acid
Implementation Method 2
an alkanol silicate acid oligomer
Implementation Method 3
a zwitterionic compound comprising (i) sulfonate-functional groups and (ii) alkoxysilane groups and/or silanol-functional groups
Implementation Method 4
a water-miscible organic solvent, wherein the water-miscible organic solvent refers to a solvent that can be dissolved or mixed with water in any proportion under ambient conditions without separating
Data Source
AI summary
Described herein is a coating composition comprising: (a) a zwitterionic compound comprising (i) sulfonate-functional groups and (ii) alkoxysilane groups and/or silanol-functional groups; (b) an acid-catalyzed hydrolysis product of an alkoxylsilane, wherein the acid-catalyzed hydrolysis product of an alkoxylsilane comprises at least one (i) (RO)(4-a)Si(OH)a where R is a monovalent hydrocarbon group and a is an integer from 1 to 4; or (ii) an alkanol silicate acid oligomer; (c) a water-miscible organic solvent; and (d) water, along with articles thereof and methods of making the same.