Water-based Coating Composition for Wallpaper

Solution Overview

Problem

Existing coating compositions for papers and nonwoven fabrics, including wallpapers, often contain environmentally harmful substances like PVC and volatile organic compounds, and lack improved surface characteristics, embossing stability, and water resistance.

Innovation Solution

A water-based synthetic polymer coating composition combining an aqueous dispersion of synthetic polymers with particle sizes ≤ 2 µm and inorganic fillers of similar sizes, providing a high-quality substrate for high-speed digital printing, embossing stability, and water resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If water-based coating compositions are used to replace PVC and melamine resins, then environmental friendliness is improved, but surface characteristics and water resistance are insufficient

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidwater resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent uses composite materials by combining synthetic polymer particles (20-80 wt.-%) with inorganic filler particles (20-70 wt.-%) in a water-based dispersion. This composite structure provides both environmental friendliness (water-based, no PVC/melamine) and improved performance (enhanced water resistance, surface characteristics, and embossing stability through the synergistic combination of organic and inorganic components)

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by严格控制 particle size parameters: synthetic polymer particles ≤ 2 μm and inorganic filler particles ≤ 20 μm with a size ratio of 1:1 to 2:1. This precise parameter control transforms the water-based coating from environmentally friendly but weak to having superior water resistance, surface smoothness, and embossing stability

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If larger filler particle sizes are used, then composition stability decreases and surface roughness increases, but smaller particle sizes improve stability and smoothness

Engineering Contradiction:

Improvestorage stabilityVSAvoidsurface roughness

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The patent applies parameter changes by strictly controlling particle size parameters: synthetic polymer particles ≤ 2 μm and inorganic filler particles ≤ 20 μm with a size ratio of 1:1 to 2:1. This precise parameter control transforms the water-based coating from environmentally friendly but weak to having superior water resistance, surface smoothness, and embossing stability

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional coating compositions are used, then production speeds are limited, but high-speed digital printing requires improved surface characteristics

Engineering Contradiction:

Improveproduction speedVSAvoidsurface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent uses composite materials by combining synthetic polymer particles (20-80 wt.-%) with inorganic filler particles (20-70 wt.-%) in a water-based dispersion. This composite structure provides both environmental friendliness (water-based, no PVC/melamine) and improved performance (enhanced water resistance, surface characteristics, and embossing stability through the synergistic combination of organic and inorganic components)

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by严格控制 particle size parameters: synthetic polymer particles ≤ 2 μm and inorganic filler particles ≤ 20 μm with a size ratio of 1:1 to 2:1. This precise parameter control transforms the water-based coating from environmentally friendly but weak to having superior water resistance, surface smoothness, and embossing stability

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP2860227B1Water-based coating composition

Publication Date: 2017.03.15 HENKEL KGAA

AI summary

The present invention relates to an aqueous coating composition comprising synthetic polymers and inorganic fillers for coating and/or impregnating paper and nonwoven fabrics in general, in particular wallpapers as well as the use of such compositions. The coating composition comprises 20 to 80 wt.-%, preferably 35 to 55 wt.-%, of an aqueous dispersion of one or more synthetic polymers; and 20 to 70 wt.-%, preferably 35 to 55 wt.-%, of an inorganic filler, wherein the particle size d50 of the synthetic polymer particles in the dispersion is ≤ 2 µm and the ratio of the particle size d50 of the synthetic polymer particles and the particle size d50 of the inorganic filler particles is in the range of 2:1 to 1:1.