Abrasion resistant coatings

• US 6,641,629 B2
• Filed: 08/20/2002
• Issued: 11/04/2003
• Est. Priority Date: 12/09/1999
• Status: Expired due to Term

• Current Assignee: Axalta Coating Systems Ip Co Llc (Axalta Coating Systems Ltd.)
• Original Assignee: Valspar Sourcing, Inc. (Sherwin-Williams Company)
• Inventors: Chen, Frank Bor-Her, Safta, Eugen, Muselman, Gregory David, Forrest, Harvey Richard
• Primary Examiner(s): MARCHESCHI, MICHAEL A
• Application Number:
  US10/224,024
• Publication Number:
  US 20030055145A1
• Time in Patent Office: 441 Days
• Field of Search: 512/98, 513/08, 513/09, 513/00, 428/908.8, 428/148, 428/149, 428/151, 428/147, 428/206, 428/211, 428/323, 428/329, 428/457, 428/537.1, 428/537.5, 428/524, 428/525, 428/528, 428/530, 428/142, 428/327, 428/210, 428/503, 428/918, 428/703, 428/704, 427/402, 427/419.1, 427/419.2, 524/430, 524/493, 524/492, 106/204.3, 106/204.01, 106/287.17, 106/287.34
• US Class Current: 51/298
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C09D 7/61 inorganic
• CPC Class Codes: C09D 7/69 Particle size larger than 1000 nm
• CPC Class Codes: D21H 27/28 treated to obtain specific resistance properties, e.g. against wear or weather water-repelling agents D21H21/16
• CPC Class Codes: Y10S 428/918 Material abnormally transparent
• CPC Class Codes: Y10T 428/24364 with transparent or protective coating
• CPC Class Codes: Y10T 428/24405 Polymer or resin [e.g., natural or synthetic rubber, etc.]
• CPC Class Codes: Y10T 428/24413 Metal or metal compound
• CPC Class Codes: Y10T 428/24421 Silicon containing
• CPC Class Codes: Y10T 428/24438 Artificial wood or leather grain surface
• CPC Class Codes: Y10T 428/24893 including particulate material
• CPC Class Codes: Y10T 428/24926 including ceramic, glass, porcelain or quartz layer
• CPC Class Codes: Y10T 428/24934 including paper layer
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/257 Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31866 Impregnated or coated cellulosic material
• CPC Class Codes: Y10T 428/31942 Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31946 : Next to second aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31957 : Wood
• CPC Class Codes: Y10T 428/31964 : Paper
• CPC Class Codes: Y10T 428/31989 : Of wood
• CPC Class Codes: Y10T 428/31993 : Of paper

Abstract

A coating composition for forming abrasion-resistant, high clarity coatings is described. It has been found that a macrocrystalline or single crystal mineral abrasive can be added at high levels, about 5 to about 80 percent by weight, to art-recognized film-forming resin compositions for producing coatings exhibiting exceptional abrasion resistance and clarity. Such a coating composition is useful for application to surfaces including wood, vinyl, tile, rubber modified cement, marble, metal, plastic, and laminated surfaces.

Claims

1. A filled coating composition for forming abrasion-resistant coatings of about 70% clarity or higher as measured by the ASTM®

E430 Standard on a substrate, said coating composition comprising a film-forming resin component and about 5 percent to about 80 percent by weight of a mineral abrasive filler in single crystalline form.

2. The composition of claim 1 wherein the mineral abrasive filler exhibits a Mohs'"'"' hardness of about 6 or greater.

3. The composition of claim 1 wherein the film-forming resin composition comprises a thermosetting resin.

4. The composition of claim 1 wherein the film-forming resin composition comprises a UV-curable resin.

5. The composition of claim 1 wherein the film-forming resin composition comprises a thermoplastic resin.

6. A filled coating composition for forming abrasion-resistant coatings of about 70% clarity or higher as measured by the ASTM®

E430 Standard on a substrate, said coating composition comprising a film-forming resin component and about 5 percent to about 80 percent by weight of a mineral abrasive filler in macrocrystalline form.

7. The composition of claim 6 wherein the mineral abrasive filler exhibits a Mohs'"'"' hardness of about 6 or greater.

8. The composition of claim 6 wherein the film-forming resin composition comprises a thermosetting resin.

9. The composition of claim 6 wherein the film-forming resin composition comprises a UV-curable resin.

10. The composition of claim 6 wherein the film-forming resin composition comprises a thermoplastic resin.

11. A filled coating composition for forming abrasion-resistant coatings of about 70% clarity or higher as measured by the ASTM®

E430 Standard on a substrate, said coating composition comprising a film-forming resin component and about 30 percent to about 80 percent by weight of a mineral abrasive filler in macrocrystalline form.

12. A filled coating composition for forming abrasion-resistant coatings of about 70% clarity or higher as measured by the ASTM®

E430 Standard on a substrate, said coating composition comprising a film-forming resin component and about 30 percent to about 80 percent by weight of a mineral abrasive filler in single crystalline form.

13. An abrasion-resistant filled coating laminate having about 70% clarity or higher as measured by the ASTM®

E430 Standard on a substrate, said laminate comprising at least two coating layers, wherein at least one of said layers comprises a resin component and about 5 percent to about 80 percent by weight of a mineral abrasive filler, where the mineral abrasive filler is in macrocrystalline form or in single crystal form, and at least one of said layers comprises a filled top coat.