METHOD FOR COATING SUBSTRATES AND CARRIER SUBSTRATES

• US 20100159239A1
• Filed: 12/28/2006
• Published: 06/24/2010
• Est. Priority Date: 02/20/2006
• Status: Active Grant

• Current Assignee: Evonik Degussa GmbH (Rag-Stiftung)
• Original Assignee: Evonik Degussa GmbH (Rag-Stiftung)
• Inventors: Wille, Martin, Vetter, Michael, Nun, Edwin
• Granted Patent: US 8,652,291 B2
• Time in Patent Office: Days
• US Class Current: 428/354
• CPC Class Codes: B05D 2252/10 Applying the material on both sides
• CPC Class Codes: B05D 7/08 using synthetic lacquers or varnishes
• CPC Class Codes: B05D 7/24 for applying particular liquids or other fluent materials
• CPC Class Codes: B05D 7/52 Two layers
• CPC Class Codes: B32B 21/00 Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane

Abstract

The present invention relates to a method for coating substrates, comprising the steps:

• • a) provision of a substrate,
  • b) application of a composition to a first side of the substrate, the composition containing an inorganic compound and the inorganic compound containing at least one metal and/or semimetal selected from the group consisting of Sc, Y, Ti, Zr, Nb, V, Cr, Mo, W, Mn, Fe, Co, B, Al, In, Tl, Si, Ge, Sn, Zn, Pb, Sb, Bi or mixtures thereof and at least one element selected from the group consisting of Te, Se, S, O, Sb, As, P, N, C, Ga or mixtures thereof,
  • c) drying of the composition applied in step b),
  • d) application of at least one coating to the first side of the substrate to which the composition is applied in step b), the coating containing is a silane of the general formula (Z¹)Si(OR)₃, in which Z¹ is R, OR or Gly (Gly=3-glycidyloxypropyl) and R is an alkyl radical having 1 to 18 carbon atoms and all R may be identical or different, oxide particles selected from the oxides of Ti, Si, Zr, Al, Y, Sn, Zn, Ce or mixtures thereof, a polymer and an initiator, and
  • e) drying of the coating applied in step b),
  • f) application of at least one barrier layer to a second side of the substrate, and
  • g) optional application of at least one layer containing at least one adhesive (adhesive layer) to the barrier layer applied in step f),
    and a coated substrate and coated support substrate obtainable by the abovementioned method.

Claims

1. :

A method for coating substrates, comprising;

a) providing a substrate,

b) applying a composition to a first side of the substrate, the composition comprising an inorganic compound and the inorganic compound comprising at least one metal and/or semimetal selected from the group consisting of Sc, Y, Ti, Zr, Nb, V, Cr, Mo, W, Mn, Fe, Co, B, Al, In, Tl, Si, Ge, Sn, Zn, Pb, Sb, Bi and mixtures thereof, and at least one element selected from the group consisting of Te, Se, S, O, Sb, As, P, N, C, Ga and mixtures thereof,

c) drying of the composition applied in step b),

d) applying at least one coating to the first side of the substrate to which the composition is applied in step b), the coating comprising a silane of the general formula (Z¹)Si(OR)₃, in which Z¹ is R, OR or Gly (Gly=3-glycidyloxypropyl) and R is an alkyl radical having 1 to 18 carbon atoms and all R may be identical or different, oxide particles selected from the oxides of Ti, Si, Zr, Al, Y, Sn, Zn, Ce or mixtures thereof, a polymer and an initiator, and

e) drying of the coating applied in step b),

f) applying at least one barrier layer to a second side of the substrate, and

g) optionally, applying at least one layer comprising at least one adhesive (adhesive layer) to the barrier layer applied in step f).

2. :

The method according to claim 1,

wherein

the substrate in step a) is a flexible and/or rigid substrate.

3. :

The method according to claim 1,

wherein

the substrate in step a) is a knitted fabric, a woven fabric, a mesh, a film, a sheet-like structure and/or a metal sheet.

4. :

The method according to claim 1,

wherein

the substrate in step a) is substantially thermally stable at a temperature greater than 100°

C.

5. :

The method according to claim 1,

wherein

the substrate in step a) is substantially thermally stable under the drying conditions of steps c) and/or e).

6. :

The method according to claim 1,

wherein

the inorganic compound of step b) is selected from the group consisting of TiO₂, Al₂O₃, SiO₂, ZrO₂, Y₂O₃, BC, SiC, Fe₂O₃, SiN, SiP, aluminosilicates, aluminium phosphates, zeolites, partly exchanged zeolites and mixtures thereof.

7. :

The method according to claim 1,

wherein

the inorganic compound of step b) has a particle size of 1 nm to 10 000 nm.

8. :

The method according to claim 1,

wherein

the composition of step b) is a suspension.

9. :

The method according to claim 1,

wherein

the inorganic compound of step b) is obtained by hydrolysis of a precursor of the inorganic compound comprising the metal and/or semimetal.

10. :

The method according to claim 9,

wherein

the precursor of the inorganic compound is selected from the group consisting of metal nitrate, metal halide, metal carbonate, metal alcoholate, semimetal halide, semimetal alcoholate and mixtures thereof.

11. :

The method according to claim 1,

wherein

the composition of step b) comprises an initiator.

12. :

The method according to claim 11,

wherein

the initiator is an acid or base.

13. :

The method according to claim 1,

wherein

the composition of step b) is a sol.

14. :

The method according to claim 1,

wherein

the drying of the composition in step c) is carried out by heating to a temperature between 50°

C. and 1000°

C.

15. :

The method according to claim 1,

wherein

the coating of step d) comprises a second silane of the general formula (Z²)_zSi(OR)_4-z, in which R is an alkyl radical having 1 to 8 carbon atoms and Z² is H_aF_bC_n, a and b being integers, all R may be identical or different, a+b=1+2n, z=1 or 2 and n is 1 to 16, or, where Z¹ is Gly, Z² is Am (Am=3-aminopropyl) with z=1.

16. :

The method according to claim 1,

wherein

the coating of step d) comprises 3-glycidyloxypropyltriethoxysilane and/or 3-glycidyloxypropyltrimethoxysilane as the silane and/or 3-aminopropyltrimethoxysilane and/or 3-aminopropyltriethoxysilane as the second silane.

17. :

The method according to claim 1,

wherein

the coating of step d) comprises tetraethoxysilane as the silane and a silane of the formula (H_aF_bC_n)_zSi(OR)_4-n as the second silane, in which a and b are integers, a+b=1+2n, z is 1 or 2, n is 1 to 16 and all R may be identical or different.

18. :

The method according to claim 1,

wherein

the coating of step d) comprises tetraethoxysilane, methyltriethoxysilane, octyltriethoxysilane and/or hexadecyltrimethoxysilane as the silane and/or 3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctyltriethoxysilane as the second silane.

19. :

The method according to claim 1,

wherein

the coating of step d) comprises, as an initiator, an acid or base.

20. :

The method according to claim 1,

wherein

the surface of the oxide particles present in the coating of step d) is hydrophobic.

21. :

The method according to claim 1,

wherein

organic radicals X_1+2nC_n bonded to silicon atoms are present on the surface of the oxide particles of the coating of step d), n being 1 to 20 and X being hydrogen and/or fluorine.

22. :

The method according to claim 1,

wherein

the polymer of the coating of step d) has a mean mass-average molecular weight of at least 3000 g/mol.

23. :

The method according to claim 1,

wherein

the polymer of the coating of step d) has an average degree of polymerization of at least 50.

24. :

The method according to claim 1,

wherein

the polymer of the coating of step d) is selected from the group consisting of polyamide, polyester, epoxy resins, melamine/formaldehyde condensate, urethane/polyol resin and mixtures thereof.

25. :

The method according to claim 1,

wherein

in step d), the coating is applied to the substrate in an amount such that, after drying in step e), a layer of the dried coating having a layer thickness of 0.05 to 10 μ

m is present on the substrate.

26. :

The method according to claim 1,

wherein

before application of the coating in step b) and/or d), at least one further coating is applied.

27. :

The method according to claim 1,

wherein

after application of the coating in step d), at least one further coating is applied.

28. :

The method according to claim 1,

wherein

the drying of the coating in step e) is carried out by heating to a temperature between 50°

C. and 1000°

C.

29. :

The method according to claim 1,

wherein

the barrier layer in step f) is a layer which has substantially no pores.

30. :

The method according to claim 1,

wherein

the barrier layer in step f) comprises at least one film-forming polymer selected from the group consisting of synthetic resin dispersions, synthetic resin emulsions, polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl acetate, modified polyvinyl acetate, polymaleic anhydride, polyvinyl methyl ether, vinyl methyl ether/maleic anhydride copolymer, polyvinyl butyl ether, vinyl butyl ether/styrene copolymer, polyurethane, melamine/formaldehyde condensate, urea/melamine condensate and mixtures thereof.

31. :

The method according to claim 1,

wherein

the adhesive layer, optionally applied in step g), comprises an adhesive selected from the group consisting of dispersion adhesives, solvent adhesives, starch pastes, synthetic resin glues, cold glues, heat-seal adhesives, hotmelt adhesives, assembly glues, wallpaper pastes, physically setting adhesives, chemically setting adhesives, one-component adhesives, multicomponent adhesives, two-component adhesives, aminoplast adhesives, phenoplast adhesives, contact adhesives, pressure-sensitive adhesives, reaction adhesives, plastisol adhesives, glues, urea resin glues and mixtures thereof.

32. :

A method for applying the coated substrate of claim 1 to a support substrate, comprising;

a) providing a support substrate,

b) optionally, applying at least one layer comprising at least one adhesive (adhesive layer) on at least one side of the support substrate and

c) adhesively bonding the coated substrate to the support substrate, the second side of the coated substrate pointing in the direction of the support substrate and/or pointing in the direction of the optionally applied adhesive layer of the support substrate.

33. :

The method according to claim 32,

wherein

the support substrate in step a) is a flexible or rigid substrate.

34. :

The method according to claim 32,

wherein

the support substrate is selected from the group consisting of a chipboard, raw chipboard, wood board, plastic panel, parquet floor, wood veneer, veneer and combinations thereof.

35. :

The method according to claim 32,

wherein

the optional adhesive layer of step b) comprises an adhesive selected from the group consisting of dispersion adhesives, solvent adhesives, starch pastes, synthetic resin glues, cold glues, heat-seal adhesives, hotmelt adhesives, assembly glues, wallpaper pastes, physically setting adhesives, chemically setting adhesives, one-component adhesives, multicomponent adhesives, two-component adhesives, aminoplast adhesives, phenoplast adhesives, contact adhesives, pressure-sensitive adhesives, reaction adhesives, plastisol adhesives, glues, urea resin glues and mixtures thereof.

36. :

The method according to claim 32,

wherein

the adhesive bonding of the coated substrate to the support substrate in step c) is effected with the use of elevated pressure and/or elevated temperature.

37. :

A coated substrate obtained by the method according to claim 1.

38. :

A coated support substrate obtained by the method according to claim 32.

39. :

The coated support substrate according to claim 38, wherein the coated support substrate is a floor panel and/or veneer.

40. (canceled)