Compositions and methods for a high performance protective coating

• US 5,936,022 A
• Filed: 08/29/1997
• Issued: 08/10/1999
• Est. Priority Date: 08/29/1997
• Status: Expired due to Term

• Current Assignee: Freecom BV (Mitsubishi Chemical Group Corp.)
• Original Assignee: Freecom BV (Mitsubishi Chemical Group Corp.)
• Inventors: Freeman, John E.
• Primary Examiner(s): Cain, Edward J.
• Application Number:
  US08/920,580
• Time in Patent Office: 711 Days
• Field of Search: 524/492, 524/493, 524/442, 524/444, 524/445
• US Class Current: 524/442
• CPC Class Codes: C08K 3/00 Use of inorganic substances as compounding ingredients
• CPC Class Codes: C08L 2666/16 Addition or condensation polymers of aldehydes or ketones according to C08L59/00 - C08L61/00; Derivatives thereof
• CPC Class Codes: C09D 163/00 Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins

Abstract

A high performance protecting surface coating, and methods, is disclosed. The coating comprises a resin such as epoxy loaded with inert particles, preferably ceramic, a curing agent for hardening, and a selected additive such as a solvent. The protective coating of the present invention has adhesion strength of at least 2,000 psi and impact resistance of at least 90 inch-lbs.

Claims

1. A high performance surface coating comprising:

at least one resin,

inert particles loaded into said resin to form a mixture of resin and inert particles,

a catalyst, wherein said mixture and said catalyst combine to form a base composition; and

at least one additive added to said base composition to form a final coating composition comprising desired performance characteristics;

wherein said performance characteristics comprise adhesion strength of at least approximately 2,000 psi.

2. The coating of claim 1, wherein said at least one resin comprises epoxy.

3. The coating of claim 1, wherein said at least one resin comprises:

novolac resin, dissolved in 15% MEK by weight of novolac, in the range of from 3.5% to 10% by weight of said base composition,

polyglycol di-epoxide resin in the range of from 0.7% to 2.7% by weight of said base composition, and

silicon dioxide in the range of from 4% to 20% based on the weight of the base composition.

4. The coating of claim 1, wherein said at least one additive comprises a selected solvent to dilute said base composition forming a final coating composition for uniform coverage of said surface.

5. The coating of claim 2, wherein said at least one additive comprises a selected solvent to dilute said base composition forming a final coating composition for uniform coverage of said surface.

6. The coating of claim 3, wherein said at least one additive comprises a selected solvent to dilute said base composition forming a final coating composition for uniform coverage of said surface.

7. The coating of claim 4, wherein said selected solvent comprises isopropanol.

8. The coating of claim 4, wherein said selected solvent comprises methyl-ethyl-ketone.

9. The coating of claim 4, wherein said selected solvent comprises isopropanol and methyl-ethyl-ketone.

10. The coating of claim 1, wherein said catalyst comprises diethylene triamine.

11. The coating of claim 2, wherein said catalyst comprises diethylene triamine.

12. The coating of claim 3, wherein said catalyst comprises diethylene triamine.

13. The coating of claim 4, wherein said catalyst comprises diethylene triamine.

14. The coating of claim 1, wherein said catalyst comprises cyclocaliphatic amine.

15. The coating of claim 2, wherein said catalyst comprises cyclocaliphatic amine.

16. The coating of claim 3, wherein said catalyst comprises cyclocaliphatic amine.

17. The coating of claim 4, wherein said catalyst comprises cyclocaliphatic amine.

18. The coating of claim 1, wherein said inert particles comprise ceramic.

19. The coating of claim 2, wherein said inert particles comprise ceramic.

20. The coating of claim 3, wherein said inert particles comprise ceramic.

21. The coating of claim 4, wherein said inert particles comprise ceramic.

22. The coating of claim 1, wherein said inert particles comprise at least 60% of the weight of said mixture.

23. The coating of claim 2, wherein said inert particles comprise at least 60% of the weight of said mixture.

24. The coating of claim 3, wherein said inert particles comprise at least 65% of the weight of said mixture.

25. The coating of claim 4, wherein said inert particles comprise at least 60% of the weight of said mixture.

26. The coating of claim 1, wherein said inert particles comprise in the range of approximately 80% to approximately 90% of the weight of said mixture.

27. The coating of claim 2, wherein said inert particles comprise in the range of approximately 80% to approximately 90% of the weight of said mixture.

28. The coating of claim 3, wherein said inert particles comprise in the range of approximately 80% to approximately 90% of the weight of said mixture.

29. The coating of claim 4, wherein said inert particles comprise in the range of approximately 80% to approximately 90% of the weight of said mixture.

30. A high performance surface coating, said coating comprising:

a resin comprising epoxy;

inert particles comprising ceramic loaded into said resin to form a mixture of resin and inert particles, wherein said inerts comprise at least 65% of the weight of said mixture;

a catalyst comprising diethylene triamine combined with said mixture to form a base composition; and

an additive comprising isopropanol as a selected solvent to dilute said base composition to form a final coating composition having desired performance characteristics, and wherein said performance characteristics comprise adhesion strength of at least approximately 2,000 psi.

31. The coating of claim 30, wherein said inert particles comprise approximately 90% of the weight of said mixture.

32. A method of applying a high performance surface coating to a surface, said coating comprising:

at least one resin;

inert particles loaded into said resin to form a mixture of resin and inert particles;

a catalyst, wherein said mixture and said catalyst combine to form a base composition; and

at least one additive added to said base composition to form a final coating composition having desired performance characteristics, and wherein said performance characteristics comprise adhesion strength of at least approximately 2,000 psi, the method comprising;

preparing said surface to achieve an appropriate anchor profile,

re-suspending all said inert particles in said final coating composition,

applying said final coating composition to said surface, and

curing said coating to achieve a desired finish.

33. The method of claim 32, wherein said inert particles comprise ceramic.

34. The method of claim 32, wherein said desired finish comprises a glossy finish.

35. The method of claim 32, wherein said desired finish comprises a mat finish.

36. A surface coated by the method of claim 32.

37. A method of manufacturing a high performance surface coating, the method comprising:

providing at least one resin;

providing an amount of inert particles;

loading said inert particles into said resin to form a mixture of resin and inert particles;

providing a catalyst to harden said resin;

adding said catalyst to said mixture, wherein said mixture and said catalyst combine to form a base composition;

providing at least one additive; and

adding said at least one additive to said base composition to form a final coating composition having desired performance characteristics of said coating, and wherein said performance characteristics comprise adhesion strength of at least approximately 2,000 psi.

38. The method of claim 37, wherein said inert particles comprise at least 60% of the weight of said mixture.

39. The method of claim 37, wherein said inert particles comprise in the range of approximately 80% to approximately 90% of the weight of said mixture.

40. A surface coated by a coating manufactured according to the method of claim 37.

41. A method of manufacturing a high performance surface coating, the method comprising:

providing at least one resin;

providing an amount of inert particles;

loading said inert particles into said resin to form a mixture of resin and inert particles;

providing a catalyst to harden said resin;

adding said catalyst to said mixture, wherein said mixture and said catalyst combine to form a base composition; and

providing at least one additive;

adding at least one additive to said base composition;

adding novolac resin, dissolved in 15% MEK by weight of novolac, added in the range of from 3.5% to 10% by weight of said base composition,

adding polyglycol di-epoxide resin in the range of from 0.7% to 2.7% by weight of said base composition, and

adding silicon dioxide in the range of from 4% to 20% based on the weight of the base composition to form a final coating composition having desired performance characteristics of said coating, and wherein said performance characteristics comprise adhesion strength of at least approximately 2,000 psi.

42. A surface coated by a coating manufactured according to the method of claim 41.