In-press process for coating composite substrates
First Claim
1. a process for manufacture of an in-press coated composite substrate, said process comprising the steps of forming a coating composition laminate comprising a layer of a primer coating composition comprising a water dispersible thermosetting or thermoplastic polymer, said primer coating layer being formed as a chemically crosslinked polymer matrix, and a layer of a top coat composition including a thermoplastic or thermosetting polymer latex composition;
- contacting the primer coating layer with a surface of a compressible mat comprising fibers or particles and a resin binder composition;
compressing the mat and the coating laminate between heated metal surfaces in a press; and
releasing the compressed, polymer coated composite substrate from the press.
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Accused Products
Abstract
An improved process for manufacture of polymer coated composite substrates is described. a coated composite substrate is prepared in the press by applying a layer of a primer coating composition to the surface of a compressible mat comprising fibers and/or particles and a resin binder. The primer coating composition is formulated preferably as a fast setting polymer latex capable of forming a chemically crosslinked polymer matrix when applied to the surface of a compressible mat. a thermosetting top coat composition can be applied directly over the wet primer coating composition before heat-processing the mat to improve surface quality and release characteristics. Compressing and heating the coated mat produces a primed composite substrate directly out of the press.
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Citations
36 Claims
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1. a process for manufacture of an in-press coated composite substrate, said process comprising the steps of
forming a coating composition laminate comprising a layer of a primer coating composition comprising a water dispersible thermosetting or thermoplastic polymer, said primer coating layer being formed as a chemically crosslinked polymer matrix, and a layer of a top coat composition including a thermoplastic or thermosetting polymer latex composition;-
contacting the primer coating layer with a surface of a compressible mat comprising fibers or particles and a resin binder composition;
compressing the mat and the coating laminate between heated metal surfaces in a press; and
releasing the compressed, polymer coated composite substrate from the press. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 23, 25, 27)
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10. a process for manufacture of an in-press polymer coated composite substrate, said process comprising the steps of
applying a layer of a primer coating composition to the surface of a compressible mat comprising fibers or particles and a resin binder, said primer coating composition comprising a thermosetting polymer or a thermoplastic polymer and formulated to form a chemically crosslinked polymer matrix when applied to the surface of the compressible mat; -
compressing the mat and the primer coating layer between heated metal surfaces in a press to form the polymer coated composite substrate; and
releasing the polymer coated composite substrate from the press. - View Dependent Claims (11, 12, 13, 14, 15, 16, 24, 26, 28, 34)
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17. In a process for manufacture of a polymer coated composite substrate including the step of pressing a compressible mat comprising fibers or particles and a resin binder between heated metal plates in a press to form a compressed composite substrate, the improvement comprising the steps of
applying a polymer-containing primer composition to the surface of the compressible mat before pressing it between the heated metal plates, said polymer-containing primer composition being formulated to provide an ionically crosslinked polymer matrix as it is applied on the surface of the compressible mat; - and thereafter
pressing the matrix coated mat between heated metal plates to form a polymer coated composite substrate. - View Dependent Claims (18, 19, 20, 21, 22, 29, 35)
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30. a process for the manufacture of a coated porous substrate comprising
applying a polymer-containing primer composition to the surface of a porous substrate, said primer composition being formulated to provide an ionically crosslinked polymer matrix as it is applied on the surface; - and
contacting the primer coated surface with a heated metal plate. - View Dependent Claims (31, 32, 33, 36)
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Specification