Combined physical and chemical models for estimating service lifetime and degradation of coating materials

Patent metadata

Field	Value
Publication number	US-2025389638-A1
Application number	US-202519245477-A
Country	US
Kind code	A1
Filing date	Jun 23, 2025
Priority date	Jun 25, 2024
Publication date	Dec 25, 2025
Grant date	—

Abstract

Coating materials such as paints, and/or coatings used to protect and improve the aesthetics of a material surface, develop the problem of degradation under environmental exposure. The degradation causes the coating to fail unexpectedly in its required applications. To keep this in check, the service life and change in material properties of a paint/coating need to be predicted before its use. Present disclosure provides system and method that implement a combined model to estimate the service lifetime and predict the chemical and physical changes in a coating material under various weathering conditions. The combined model captures the chemical modifications and physical modifications and affected properties like surface roughness, thickness loss, fracture toughness, gloss loss respectively. Chemical changes and physical changes are estimated correlated to help in estimating the service lifetime and degradation of the coating material.

First claim

What is claimed is:

1 . A processor implemented method, comprising:
receiving, via one or more hardware processors, a plurality of inputs pertaining to a coating material comprising a thickness, a polymer chemistry, a sunlight-Ultraviolet (UV) time series, an oxygen concentration, a moisture concentration, one or more polymer concentration profiles, and a product concentration of polymers; generating, via the one or more hardware processors, (i) a first model and a second model based on the plurality of inputs, wherein the second model is further based on one or more oxygen concentration profiles and number of reactive photons obtained from the first model; combining, via the one or more hardware processors, the first model and the second model to obtain a combined model; and estimating, via the one or more hardware processors, a service lifetime, and a degradation of the coating material using the combined model.

2 . The processor implemented method of claim 1 , wherein the first model is obtained by:
generating a first set of parameters using the plurality of inputs; iteratively performing:
applying, by using a first solver, a first set of governing equations on the first set of parameters to obtain a second set of parameters; and
applying, by using a second solver, a second set of governing equations on the second set of parameters, until an optimized set of parameters is obtained; and
generating the first model using the optimized set of parameters.

3 . The processor implemented method of claim 2 , wherein the second model is obtained by:
performing a Monte-Carlo (MC) simulation technique on the optimized set of parameters and the plurality of inputs to obtain a set of simulation parameters; estimating a pixel damage location, and a MC event time series from the set of simulation parameters; estimating a pore damage time, and a pixel spatiotemporal damage status using the pixel damage location, and the MC event time series; obtaining a first updated pixel spatiotemporal damage region based on an associated pit formation and growth identified in the pore damage time, and the pixel spatiotemporal damage status; and filtering one or more unconnected islands from the first updated pixel spatiotemporal damage region to obtain a second updated pixel spatiotemporal damage region, wherein the second updated pixel spatiotemporal damage region serves as the second model.

4 . The processor implemented method of claim 3 , wherein the combined model is obtained by correlating each of the one or more polymer concentration profiles of the first model with one or more timesteps of the second updated pixel spatiotemporal damage region serving as the second model to obtain the combined model, and wherein the combined model comprises the one or more polymer concentration profiles from the first model, and a time scaling factor and the second updated pixel spatiotemporal damage region serving as the second model.

5 . The processor implemented method of claim 1 , wherein the step of estimating the service lifetime, and the degradation of the coating material using the combined model comprises:
developing a surface profile of the coating material using the status associated with the second model; calculating a thickness loss and a roughness parameter of the coating material based on the surface profile; calculating a gloss loss, a fracture toughness and a contact wetting angle of the coating material using the thickness loss and the roughness parameter; and estimating the service lifetime, and the degradation of the coating material based on the gloss loss, the fracture toughness, and the contact wetting angle.

6 . A system, comprising:
a memory storing instructions; one or more communication interfaces; and one or more hardware processors coupled to the memory via the one or more communication interfaces, wherein the one or more hardware processors are configured by the instructions to: receive a plurality of inputs pertaining to a coating material comprising a thickness, a polymer chemistry, a sunlight-Ultraviolet (UV) time series, an oxygen concentration, a moisture concentration, one or more polymer concentration profiles, and a product concentration of polymers; generate (i) a first model and a second model based on the plurality of inputs, wherein the second model is further based on one or more oxygen concentration profiles and number of reactive photons obtained from the first model; combine the first model and the second model to obtain a combined model; and estimate a service lifetime, and a degradation of the coating material using the combined model.

7 . The system of claim 6 , wherein the first model is obtained by:
generating a first set of parameters using the plurality of inputs; iteratively performing:
applying, by using a first solver, a first set of governing equations on the first set of parameters to obtain a second set of parameters; and
applying, by using a second solver, a second set of governing equations on the second set of parameters, until an optimized set of parameters is obtained; and
generating the first model using the optimized set of parameters.

8 . The system of claim 7 , wherein the second model is obtained by:
performing a Monte-Carlo (MC) simulation technique on the optimized set of parameters and the plurality of inputs to obtain a set of simulation parameters; estimating a pixel damage location, and a MC event time series from the set of simulation parameters; estimating a pore damage time, and a pixel spatiotemporal damage status using the pixel damage location, and the MC event time series; obtaining a first updated pixel spatiotemporal damage region based on an associated pit formation and growth identified in the pore damage time, and the pixel spatiotemporal damage status; and filtering one or more unconnected islands from the first updated pixel spatiotemporal damage region to obtain a second updated pixel spatiotemporal damage region, wherein the second updated pixel spatiotemporal damage region serves as the second model.

9 . The system of claim 8 , wherein the combined model is obtained by correlating each of the one or more polymer concentration profiles of the first model with one or more timesteps of the second updated pixel spatiotemporal damage region serving as the second model to obtain the combined model, and wherein the combined model comprises the one or more polymer concentration profiles from the first model, and a time scaling factor and the second updated pixel spatiotemporal damage region serving as the second model.

10 . The system of claim 6 , wherein the service lifetime, and the degradation of the coating material are estimated using the combined model by
developing a surface profile of the coating material using the pixel spatiotemporal damage status associated with the second model; calculating a thickness loss and a roughness parameter of the coating material based on the surface profile; calculating a gloss loss, a fracture toughness and a contact wetting angle of the coating material using the thickness loss and the roughness parameter; and estimating the service lifetime, and the degradation of the coating material based on the gloss loss, the fracture toughness, and the contact wetting angle.

11 . One or more non-transitory machine-readable information storage mediums comprising one or more instructions which when executed by one or more hardware processors cause:
receiving a plurality of inputs pertaining to a coating material comprising a thickness, a polymer chemistry, a sunlight-Ultraviolet (UV) time series, an oxygen concentration, a moisture concentration, on

Assignees

• Tata Consultancy Services Ltd

Inventors

• Gupta Ambesh
• Maiti Soumyadipta
• Saini Parvesh
• Shrivastava Surabhi
• Kausley Shankar Balajirao
• Rai Beena

Classifications

• G01N33/0096

  Testing material properties on thin layers or coatings · CPC title

• G01N17/004 Primary

  to light · CPC title

• G01N33/32

  Paints; Inks · CPC title

• G16C20/10

  Analysis or design of chemical reactions, syntheses or processes · CPC title

• G16C20/30

  Prediction of properties of chemical compounds, compositions or mixtures · CPC title