Urea Crystal Sag Control Composition Stability
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Solution Overview
Problem
Conventional sag control compositions are specific to particular coating resins, require special compounding, and exhibit poor stability due to low urea particle concentrations, leading to inefficiencies and surface defects in coating applications.
Innovation Solution
A sag control composition comprising urea crystals and a non-polymeric organic solvent, with a high loading of urea crystals (at least 8 weight %) and a D50 particle size distribution of 1 to 5 microns, formed using a mixing device to ensure stability and compatibility with various coating resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional sag control compositions are prepared at low concentrations of less than 4 weight % urea particles to maintain low viscosity, then ease of operation is improved, but stability deteriorates with urea particles quickly separating out of solution
Solution Approach 1:
The patent changes the concentration parameter from less than 4 weight % to at least 8 weight % urea particles, and changes the particle size parameter to D50 of 1-5 microns. These parameter changes enable the composition to maintain stability at higher concentrations while controlling viscosity through particle size optimization.
2Reliability
If conventional sag control compositions are prepared with coating resins, then sag control function is achieved, but adaptability deteriorates as they are specific to particular coating resins requiring separate compositions for different resins
Solution Approach 1:
The patent extracts the coating resin from the sag control composition formulation, creating a universal composition that works with any coating resin. The sag control function is achieved through the urea particle suspension mechanism alone, without requiring integration with specific resin systems.
Solution Approach 2:
The patent creates a universal sag control composition that can be used with any coating resin system. The composition comprising urea particles in a solvent serves multiple coating applications without requiring formulation changes, achieving multi-functionality and broad compatibility.
3Manufacturing precision
If conventional sag control compositions require special offsite compounding by external suppliers, then manufacturing precision is improved, but device complexity and productivity deteriorate due to additional compounding steps and facilities
Solution Approach 1:
The patent merges the sag control composition preparation into the standard coating formulation process. The urea particle suspension can be prepared and incorporated using conventional coating equipment without requiring separate offsite compounding facilities, simplifying the overall manufacturing process.
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 excellent stability and compatibility with different coating resins, minimizing surface defects and enabling the formation of smooth, sag-free coating layers with improved durability and appearance.
Implementation Method 1
The urea crystals include the reaction product of a polyisocyanate and a mono-amine
Data Source
AI summary
Sag control compositions, methods of forming sag control compositions, and methods of forming coating systems that include at least one coating layer including urea crystals of such sag control compositions are provided herein. In an embodiment, a sag control composition includes urea crystals and a non-polymeric organic solvent. The urea crystals include the reaction product of a polyisocyanate and a mono-amine. The sag control composition is a stable mixture with a single phase at a temperature of about 21° C. based upon visual observation for a period of at least 10 minutes after forming the mixture.