Waterborne Acid-Epoxy Coating Reducing VOC Emissions
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Solution Overview
Problem
Industrial coating processes face challenges in achieving high-quality, smooth coating finishes with adequate physical properties while minimizing volatile organic compounds (VOCs) emissions, particularly with high-solids solventborne coatings and powder coatings.
Innovation Solution
A two-component waterborne coating system comprising an acid-functional polymer with an acid value of at least 100 dispersed in an aqueous medium and an epoxy-functional compound, where the components are stored separately and mixed only before application, allowing for a controlled reaction to form a coating composition with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-solids solventborne coatings are used to achieve high quality coating finishes, then coating quality and physical properties are improved, but VOC emissions increase
Solution Approach 1:
The invention changes the chemical parameters of the coating system by using water as the primary carrier instead of organic solvents, and by employing a two-component system with acid-functional polymer and epoxy-functional compound that cures to form a crosslinked network. This allows achieving high solids content (80-95% resin solids) while using water instead of VOCs, thus maintaining coating quality while reducing harmful emissions
Solution Approach 2:
The invention creates a composite coating system combining acid-functional polymer and epoxy-functional compound in a two-component formulation. This composite approach enables the coating to achieve both high physical properties through crosslinking and low VOC content through water-based formulation, resolving the contradiction between coating quality and environmental sustainability
2Object-generated harmful factors
If powder coatings are used to reduce VOC emissions, then VOC levels are reduced, but achieving smooth coating finishes with adequate physical properties becomes difficult
Solution Approach 1:
The invention changes the physical state parameter from powder to liquid waterborne formulation, enabling the coating to be applied by conventional liquid application methods (spray, brush, roll) that produce smooth finishes. The chemical composition is changed to include high molecular weight polymers with appropriate glass transition temperatures and crosslinking functionality, allowing achievement of adequate physical properties while maintaining low VOC levels through water-based formulation
3Object-generated harmful factors
If waterborne coatings are used to reduce VOC emissions, then environmental sustainability is improved, but coating physical properties and finish quality may be compromised
Solution Approach 1:
The invention creates a composite crosslinked network structure combining acid-functional polymer and epoxy-functional compound. This composite approach at the molecular level provides enhanced physical properties including improved hardness, chemical resistance, and mechanical strength, while the water-based formulation maintains low VOC emissions. The crosslinking reaction forms a three-dimensional network that significantly enhances coating performance
Solution Approach 2:
The invention changes the chemical composition parameters by selecting specific acid-functional polymers with high acid values (100-200 mg KOH/g) and appropriate molecular weights, combined with epoxy-functional compounds having complementary properties. This precise parameter control enables optimization of both physical properties and environmental performance, achieving high strength and durability while maintaining waterborne formulation with low VOC content
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 system achieves high-quality coatings with enhanced physical properties and reduced VOC emissions, providing a balance between performance and environmental sustainability.
Implementation Method 1
a first component including an acid-functional polymer having an acid value of at least 100, based on total resin solids, dispersed in an aqueous medium; and a second component separate from the first component, where the second component includes an epoxy-functional compound
Data Source
AI summary
A two-component waterborne coating system includes: a first component including an acid-functional polymer having an acid value of at least 100, based on total resin solids, dispersed in an aqueous medium; and a second component separate from the first component. The second component includes an epoxy-functional compound. A method of preparing a two-component waterborne coating system and two-component waterborne coating system kit are also described herein.