VOC-Reducing Building Panel Coating Composition

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Solution Overview

Problem

Previous VOC and odor-reducing building panels were limited by their inability to neutralize a variety of volatile organic compounds (VOCs) and odors effectively, with limited duration of effectiveness and susceptibility to degradation due to application methodologies that either degraded the neutralizing agent or restricted the amount applied.

Innovation Solution

A coating composition comprising a blend of ethylene urea, silica gel, porous CaCO3, and a liquid carrier, with specific ratios and additives such as surfactants and rheology modifiers, applied to building panels to enhance VOC and odor neutralization, providing a wider range of odor reduction and longer sustainability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If previous application methodologies were used, then the building panels could be manufactured, but the neutralizing agent was degraded or the amount applied was limited

Engineering Contradiction:

Improveeffectiveness of neutralizing agentVSAvoidapplication methodology

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the physical and chemical parameters of the coating composition, specifically using a water-based liquid carrier instead of organic solvents, and controlling the particle size of silica gel (0.5-120 μm) and porous CaCO3 to optimize both application properties and neutralizing effectiveness. This allows the neutralizing agents to remain stable during manufacturing while achieving adequate application amounts.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite coating composition combining multiple neutralizing agents (ethylene urea, silica gel, porous CaCO3) with specific binders and surfactants. This composite approach enhances the overall performance, allowing the neutralizing agents to work synergistically while maintaining stability during manufacturing and application.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If previous coating compositions were used, then VOC and odor reduction was achieved, but the variety of VOCs and odors that could be neutralized was limited

Engineering Contradiction:

Improverange of VOCs and odors neutralizedVSAvoidextent of neutralization

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent creates a universal coating composition that can neutralize multiple types of VOCs and odors simultaneously. The combination of ethylene urea (effective for aldehydes and ketones), silica gel (effective for polar compounds), and porous CaCO3 (effective for acidic VOCs) provides multi-functional capability, expanding the range of neutralizable substances while maintaining high effectiveness for each type through the synergistic interaction of the components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Duration of action of stationary object

If previous coating compositions were used, then odor reduction was achieved, but the duration of effectiveness was limited

Engineering Contradiction:

Improvesustainability of odor reductionVSAvoidresistance to degradation

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent employs readily available, stable inorganic materials (silica gel, porous CaCO3) and a common chemical compound (ethylene urea) that are inherently resistant to degradation. These materials can be replenished through normal wear and tear cycles, ensuring long-term sustainability without complex degradation mechanisms, thus extending the duration of effectiveness.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The water-based liquid carrier creates a stable, inert environment for the neutralizing agents, protecting them from premature degradation. The composition is designed to resist chemical breakdown under various environmental conditions (humidity, temperature variations), thereby extending the functional lifetime of the coating and maintaining odor reduction effectiveness over extended periods.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 coating composition effectively neutralizes a broader range of VOCs and odors, including complex odors, with improved sustainability and resistance to moisture variations, making it suitable for diverse climates and environments.

Implementation Method 1

porous CaCO3, with a surface area ranging from about 120 m2/g to about 160 m2/g

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

silica gel, with a particle size ranging from about 0.5 μm to about 120 μm

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS11944953B2Method of forming VOC and odor reducing building panels

Publication Date: 2024.04.02 AWI LICENSING LLC

AI summary

Described herein are methods of forming a VOC and odor-reducing building panel. The methods include providing a substrate; applying a wet-state coating to a major surface of the substrate, the wet-state coating comprising carrier comprising water; and drying the wet-state coating, thereby evaporating at least 95 wt. % of the carrier to form a dry-state coating.