Water-based coatings for color sampling

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Solution Overview

Problem

Existing low VOC or zero VOC water-based polyurethane coatings for color sampling display products lack mechanical integrity and aesthetic appeal due to viscosity issues and substrate interaction, leading to paper wrinkling and buckling when applied to untreated paper substrates.

Innovation Solution

A radiation-curable acrylic coating composition is applied to untreated paper substrates, forming an interpenetrating network of crosslinks using electron beam radiation, which maintains mechanical integrity and prevents substrate curling, while being substantially free of VOCs and surfactants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If water-based polyurethane coatings are used to reduce VOC content, then environmental compliance is improved, but mechanical performance and chemical resistance deteriorate

Engineering Contradiction:

ImproveVOC contentVSAvoidmechanical performance

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

The patent changes the chemical composition parameters by incorporating crosslinking agents (isocyanates, carboxylic acids, or amines) into the water-based polyurethane system. This transforms the linear polymer structure into a crosslinked network structure, fundamentally altering the mechanical properties and chemical resistance while maintaining water-based formulation and low VOC content.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite coating system by combining water-based polyurethane polymers with crosslinking agents. This composite approach integrates the environmental benefits of water-based formulations with the enhanced mechanical performance of crosslinked structures, achieving both low VOC content and superior mechanical properties.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If pre-crosslinking is achieved by incorporating large amounts of monomers with more than two reactive functional groups, then crosslinking density is improved, but viscosity increases making dispersion difficult

Engineering Contradiction:

Improvecrosslinking densityVSAvoidviscosity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies partial crosslinking by incorporating crosslinking agents in controlled amounts rather than using excessive multi-functional monomers. This partial action approach achieves sufficient crosslinking density for mechanical performance while maintaining manageable viscosity levels that allow for easy water dispersion and processing.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If reactive diluents are used to reduce viscosity, then ease of dispersion is improved, but eye and skin irritation increases requiring extensive industrial hygiene measures

Engineering Contradiction:

Improveease of dispersionVSAvoideye and skin irritation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses water as an intermediary medium to disperse the polyurethane crosslinking system. Instead of relying on reactive diluents that cause irritation, water serves as a safe, non-irritating dispersing medium that maintains low viscosity and enables easy processing while eliminating the need for extensive industrial hygiene measures.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If water-based polyurethane is applied to untreated paper substrates, then ease of application is improved, but substrate integrity deteriorates causing wrinkling and buckling

Engineering Contradiction:

Improveease of applicationVSAvoidsubstrate integrity

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent replaces the mechanical action of water absorption (which causes paper wrinkling) with a chemical crosslinking mechanism. The crosslinked coating structure creates a more stable film that does not rely on water absorption into the paper substrate, thereby preventing wrinkling and buckling while maintaining ease of application to untreated paper surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides a color display product with enhanced mechanical integrity and aesthetic appeal, preventing substrate wrinkling and buckling, and achieving faster curing rates compared to solvent-based methods.

Implementation Method 1

using electron beam radiation to cure the coating composition, preferably an opaque layer of the composition, onto the substrate

Methodology Applied

Scientific EffectElectron beam radiation: Electron Beam

Implementation Method 2

curing the composition by electron beam radiation includes forming an interpenetrating network of crosslinks between the one or more polymers in the coating composition

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentUS20170298573A1Water-based coatings for color sampling

Publication Date: 2017.10.19 AXALTA COATING SYSTEMS IP CO LLC

AI summary

A color sampling display product is provided that includes a radiation-curable water-based coating composition applied to a substrate, and shows mechanical integrity and aesthetic appeal.