Multi-component coatings that include polyurea coating layers

• US 20060046068A1
• Filed: 08/25/2005
• Published: 03/02/2006
• Est. Priority Date: 09/02/2004
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Hockswender, Thomas R., Martz, Jonathan T., Barancyk, Steven V., Senkfor, Howard L., Trindade, Jose C., DiMario, Joseph, Brayts, Dan M. Sr., Morales, Joseph
• Granted Patent: US 7,611,772 B2
• Time in Patent Office: Days
• US Class Current: 428/423.100
• CPC Class Codes: C08G 18/0885 using additives, e.g. absorbing agents
• CPC Class Codes: C08G 18/12 using two or more compounds having active hydrogen in the first polymerisation step
• CPC Class Codes: C08G 18/3821 Carboxylic acids; Esters thereof with monohydroxyl compounds
• CPC Class Codes: C08G 18/4854 Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group
• CPC Class Codes: C08G 18/5024 containing primary and/or secondary amino groups
• CPC Class Codes: C08G 18/6685 with compounds of group C08G18/3225 or polyamines of C08G18/38
• CPC Class Codes: C08G 18/725 Combination of polyisocyanates of C08G18/78 with other polyisocyanates
• CPC Class Codes: C08G 18/798 containing urethdione groups
• CPC Class Codes: C08J 2475/00 Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
• CPC Class Codes: C08J 2475/02 Polyureas
• CPC Class Codes: C08J 7/042 with two or more layers, where at least one layer of a composition contains a polymer binder
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C09D 175/02 Polyureas
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

A polyurea composition, a multi-component composite coating and articles formed therefrom, and methods of forming the same are disclosed. The coating composition is formed from a reaction mixture comprising an isocyanate-functional component and an amine-functional component. The ratio of equivalents of isocyanate groups to equivalents of amine groups is greater than 1 while the volume mixing ratio of the isocyanate-functional component to the amine-functional component is capable of being applied to a substrate at 1:1.

Claims

1. A polyurea coating composition, the coating composition being formed from a reaction mixture comprising:

an isocyanate-functional component and an amine-functional component wherein the ratio of equivalents of isocyanate groups to equivalents of amine groups is greater than 1 while the volume mixing ratio of the isocyanate-functional component to the amine-functional component is capable of being applied to a substrate at 1;

1.

2. The coating composition of claim 1, wherein at least 1 percent by weight of the isocyanate-functional component comprises at least one polyisocyanate monomer.

3. The coating composition of claim 1, wherein the ratio of equivalents of isocyanate groups to equivalents of amine groups is 1.01 to 1.10:

1.0.

4. The coating composition of claim 1, wherein the isocyanate-functional component comprises isophorone diisocyanate.

5. The coating composition of claim 1, wherein the amine-functional component comprises a primary amine and/or a secondary amine.

6. The coating composition of claim 7, wherein the amine-functional component comprises 20-80 weight percent primary amine and the balance secondary amine.

7. A multi-component composite coating comprising a first polyurea layer deposited from a first composition, and a second polyurea layer deposited from a second composition, applied over at least a portion of the first polyurea layer, wherein at least one of the first composition and the second composition comprises the coating composition of claim 1.

8. A coated article, comprising:

a substrate; and

the polyurea coating composition of claim 1 deposited on at least a portion of the substrate.

9. The coated article of claim 8, wherein the substrate is a vehicle substrate.

18. The polyurea coating composition of claim 1, wherein the reaction mixture further comprises a clay and, optionally, a silica.

19. The polyurea coating composition of claim 18, wherein the amine component comprises a clay and, optionally, a silica.

20. The polyurea coating composition of claim 18, wherein the clay comprises montmorillonite clays, kaolin clays, attapulgite clays, and/or sepiolite clays.

21. A multi-component composite coating comprising:

at least one first coating formed from a first coating composition applied to at least a portion of at least one major surface of a substrate, wherein the first coating composition comprises at least one crosslinking agent; and

at least one film-forming resin having functional groups reactive with the crosslinking agent;

a second coating composition applied in at least one layer over at least a portion of the first coating to form a second coating thereover, wherein the second coating composition comprises the polyurea composition of claim 1;

and

an adhesion promoting composition, wherein the adhesion promoting composition is included in at least one of the first and second coating compositions, and/or applied as a separate layer over at least a portion of the first coating prior to application of the second coating composition, and wherein the second coating has an ASTMD1876 90°

peel adhesion resistance of at least 5 ft-lbs.

22. The multi-component composite coating of claim 21, wherein the adhesion promoting composition comprises a tertiary amine, a melamine, a urethane acrylate, a metal chelate complex, a polyhydric polymer, and/or a tin-containing compound.

23. The multi-component composite coating of claim 22, wherein the adhesion promoting composition comprises a tertiary amine comprising 1,5-diazabicyclo[4.3.0]non-5-ene, 1,8-diazabicyclo[5.4.0]undec-7-ene, and/or 1,4-diazabicyclo[2.2.2]octane.

26. The coated article of claim 8, wherein the substrate comprises a glass substrate.

27. The coating composition of claim 5, wherein the amine-functional component comprises a secondary amine comprising an acrylate-modified amine and/or a methacrylate-modified amine.

10. A method of forming a polyurea coating on a substrate comprising:

(a) selecting an isocyanate-functional composition and an amine-functional composition such that the ratio of equivalents of isocyanate groups to equivalents of amine groups is greater than 1 while the volume mixing ratio of the isocyanate-functional component to the amine-functional component is capable of being applied to the substrate at 1;

1;

(b) mixing the isocyanate-functional composition and the amine-functional composition in a volume ratio to produce a reaction mixture; and

(c) applying the reaction mixture to a substrate to form a polyurea coating on the substrate.

11. The method of claim 10, wherein at least 1 percent by weight of the isocyanate-functional composition comprises at least one polyisocyanate monomer.

12. The method of claim 10, wherein the mixing is accomplished by impingement, and the applying is performed by spraying.

13. The method of claim 12, wherein the reaction mixture is at least partially cured to form a substantially tack-free polyurea layer, the method further comprising applying a second polyurea layer over the at least partially cured polyurea layer wherein the partially cured polyurea layer is resistant to the second coating.

14. The method of claim 13, wherein the second layer, when cured, exhibits more surface texture than the first coating.

15. The method of claim 10, wherein the substrate is a vehicle substrate.

16. A method of forming a coated article, comprising:

providing a substrate; and

depositing a multilayer composite coating on at least a portion of the substrate to form the coated article, the multilayer composite coating comprising a first polyurea layer deposited from a first composition, and a second polyurea layer deposited from a second composition, applied over at least a portion of the first polyurea layer, at least one of the first composition and the second composition being formed from a reaction mixture comprising;

an isocyanate component; and

an amine component

wherein the ratio of equivalents of isocyanate groups to equivalents of amine groups in the reaction mixture is greater than 1 while the volume mixing ratio of the isocyanate-functional component to the amine-functional component is capable of being applied to a substrate at 1;

1.

17. The method of claim 16, wherein at least 1 percent by weight of the isocyanate-functional component comprises at least one polyisocyanate monomer.

24. The multi-component composite coating of claim 16, wherein the substrate is a vehicle substrate.

25. The multi-component composite coating of claim 24, wherein the second composition is formed from the reaction mixture and the reaction mixture further comprises one or more pigments such that at least a portion of the coated vehicle substrate has a color that substantially corresponds to the color of at least a portion of an associated vehicle body.