Thermoset Polymer Powder Matting Agent for Coatings
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Solution Overview
Problem
Current matting agents for coatings, such as urea formaldehyde condensation products, waxes, and silicon dioxide particles, face issues like formaldehyde release, increased gloss upon mechanical stress, and viscosity concerns, limiting their suitability and flexibility in coating formulations.
Innovation Solution
A thermoset polymer powder with a particle size D90 of 60 µm or less, obtained through the polymerization of compounds with ethylenically unsaturated polymerizable groups, which is formaldehyde-free, non-meltable, and has a lower density than silicon dioxide, suitable for both aqueous and non-aqueous compositions, and can be used in moisture-curable systems without increasing gloss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If waxes are used as matting agents, then the coating achieves initial matting effect, but the gloss increases after mechanical stress such as rubbing
Solution Approach 1:
The patent uses thermoset polymer particles with specific parameter ranges: particle size D90 of 60 μm or less, density of 0.95-1.20 g/cm³, and crosslinked structure. These parameter changes create a matting agent that maintains its matting effect under mechanical stress without increasing gloss, resolving the contradiction between initial matting and stability under stress.
2Illumination intensity
If inorganic particles based on silicon dioxide are used as matting agents, then the matting effect is achieved, but the density increases and viscosity of liquid compositions increases significantly
Solution Approach 1:
The patent specifies density parameters of 0.95-1.20 g/cm³ for the thermoset polymer particles, which is lower than silicon dioxide. This parameter change allows achieving matting effect with lower density, directly resolving the contradiction between matting effectiveness and density.
Solution Approach 2:
The patent uses organic thermoset polymer particles as an alternative to inorganic silicon dioxide particles. This material substitution creates a composite approach that maintains matting functionality while reducing density and viscosity impact, resolving the contradiction between matting effect and density/viscosity.
3Illumination intensity
If inorganic particles based on silicon dioxide are used as matting agents, then the matting effect is achieved, but the viscosity of liquid compositions increases significantly
Solution Approach 1:
The patent specifies particle size parameters with D90 of 60 μm or less, which optimizes the balance between matting effect and viscosity. This parameter change reduces the viscosity impact compared to larger inorganic particles while maintaining effective matting, resolving the contradiction between matting effect and viscosity.
Solution Approach 2:
The patent substitutes inorganic silicon dioxide particles with organic thermoset polymer particles. This material substitution reduces the viscosity increase in liquid compositions while maintaining matting functionality, resolving the contradiction between matting effect and viscosity.
4Illumination intensity
If urea formaldehyde condensation products are used as matting agents, then the matting effect is achieved, but formaldehyde is released under normal conditions
Solution Approach 1:
The patent eliminates formaldehyde-containing materials from the matting agent formulation. By using thermoset polymers obtained by polymerization of compounds with ethylenically unsaturated polymerizable groups, the invention extracts and removes the harmful formaldehyde component while retaining the matting functionality.
Solution Approach 2:
The patent converts the harmful formaldehyde-release property into a benefit by using alternative thermoset polymer chemistry that does not release formaldehyde. The crosslinked structure of thermoset polymers provides stable matting effect without the harmful byproducts, transforming a harmful chemical process into a safe alternative.
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 thermoset polymer powder effectively addresses the drawbacks of existing matting agents by providing a stable, low-density option that maintains coating properties and reduces gloss upon rubbing, while minimizing viscosity impact, making it suitable for various coating applications.
Implementation Method 1
the polymer is obtainable by polymerization of compounds having one or more ethylenically unsaturated polymerizable groups
Implementation Method 2
Thermoset polymer particles are crosslinked. This means that they contain a three-dimensional network of chemical bonds. Thermoset polymer particles cannot be melted without decomposition.
Data Source
AI summary
The invention relates to a thermoset polymer powder having a particle size D90 of 60 μm or less, determined by laser diffraction, wherein the polymer is obtainable by polymerization of compounds having one or more ethylenically unsaturated polymerizable groups, and wherein the compounds having one or more ethylenically unsaturated polymerizable groups include at least one compound having at least two ethylenically unsaturated polymerizable groups.