ABRASION RESISTANT POLYURETHANE COATING, COATED ARTICLE AND METHOD OF MANUFACTURING THE SAME

• US 20150232695A1
• Filed: 02/19/2014
• Published: 08/20/2015
• Est. Priority Date: 02/19/2014
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Bimanand, Alexander, Li, Ronald
• Granted Patent: US 9,957,414 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C08G 18/2885 containing halogen atoms
• CPC Class Codes: C08K 5/02 Halogenated hydrocarbons C08K5/0091 takes precedence
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09D 175/06 from polyesters
• CPC Class Codes: Y10T 428/264 Up to 3 mils

Abstract

A coated substrate including a 1 to 3 mils thick coating layer has a Bayer abrasion resistance value of less than 1% Haze after 600 cycles. The coating layer includes a reaction product of a coating composition including a polyester diol, a di-isocyanate, and a fluorocarbon-based additive. A method of forming the coating layer on the substrate includes mixing reactants including a polyester diol, a di-isocyanate and a flurocarbon-based additive to form a polyurethane coating composition; depositing the polyurethane coating composition on the substrate; and curing the polyurethane coating composition to form an abrasion resistant coating on the substrate.

Claims

1. A coating composition comprising:

a polyester diol;

a di-isocyanate; and

a fluorocarbon-based additive.

2. The coating composition of claim 1, wherein the fluorocarbon-based additive comprises a functional group reactive with —

OH or —

NCO.

3. The coating composition of claim 1, wherein the fluorocarbon-based additive comprises a hydroxyl functional group.

4. The coating composition of claim 1, wherein the fluorocarbon-based additive comprises a perfluorinated carbon atom and a hydroxyl functional group, an acrylate functional group, or a methacrylate functional group.

5. The coating composition of claim 4, wherein the fluorocarbon-based additive comprises two to twelve perfluorinated carbon atoms.

6. The coating composition of claim 4, wherein the fluorocarbon additive comprises a compound represented by CF₃(CF₂)_nCH₂CH₂OH, CF₃(CF₂)_nCH₂CH₂COOCCH₃, or CF₃(CF₂)_nCH₂CH₂COOCCH₂CH₃, wherein n is an integer.

7. The coating composition of claim 6, wherein n is 5.

8. The coating composition of claim 1, wherein the fluorocarbon-based additive is included in an amount of 0.25% to 2% based on a total weight of the coating composition.

9. The coating composition of claim 1, wherein the polyester diol has a weight average molecular weight of 500 to 2000.

10. The coating composition of claim 1, wherein the polyester diol is included in an amount of 2% to 15% based on a total weight of the coating composition.

11. The coating composition of claim 1, wherein the polyester diol comprises a caprolactone derived monomer terminated with a primary hydroxyl group at both ends.

12. The coating composition of claim 1, further comprising a multifunctional polyol having three or more hydroxyl groups.

13. The coating composition of claim 12, wherein the multifunctional polyol comprises a tetra-functional polyol.

14. The coating composition of claim 1, wherein the polyester diol is included in an amount of 2% to 50% based on a total weight of the polyester polyol.

15. The coating composition of claim 1, wherein the coating composition has a Brookfield viscosity of 80 to 120 cPs.

16. The coating composition of claim 1, wherein the coating composition has an NCO/OH ratio of 1 to 1.5.

17. The coating composition of claim 1, wherein the coating composition has a solids content of 50% to 90%.

18. A coated article, comprising:

a substrate; and

a coating layer on the substrate, the coating layer comprising a polyurethane reaction product of reactants comprising;

a polyester diol,

a di-isocyanate, and

a fluorocarbon-based additive.

19. The coated article of claim 18, wherein the coating layer has a thickness of 25 microns to 75 microns.

20. The coated article of claim 18, wherein the coating layer has a Bayer abrasion resistance value of less than 1% Haze after 600 cycles.

21. The coated article of claim 18, wherein the coating layer has a surface hardness of 60 A to 90 A.

22. A method for manufacturing an abrasion resistant substrate, the method comprising:

mixing reactants comprising a polyester diol, a di-isocyanate and a flurocarbon-based additive to form a polyurethane coating composition;

depositing the polyurethane coating composition on the substrate; and

curing the polyurethane coating composition to form an abrasion resistant coating on the substrate.

23. The method of claim 22, wherein depositing the polyurethane coating composition comprises deposition by a continuous flow coating technique.