Coating system for a porous substrate using an asphalt-containing thermosetting basecoat composition and a thermoplastic top coat composition

• US 6,849,338 B2
• Filed: 01/08/2003
• Issued: 02/01/2005
• Est. Priority Date: 11/29/2000
• Status: Expired due to Fees

• Current Assignee: Pacific Northwest Coatings
• Original Assignee: Pacific Northwest Coatings
• Inventors: Clemens, Leslie G, Clemens, Paul L
• Primary Examiner(s): Ahmed, Sheeba
• Application Number:
  US10/337,820
• Publication Number:
  US 20030113566A1
• Time in Patent Office: 755 Days
• Field of Search: 428/411.1, 428/413, 428/423.1, 428/447, 428/448, 428/451, 428/452, 428/500, 428/515, 428/507, 428/511, 428/537.1, 428/424.2, 428/537.5
• US Class Current: 428/413
• CPC Class Codes: B05D 1/10 Applying particulate materials
• CPC Class Codes: B05D 3/08 by flames
• CPC Class Codes: B05D 7/148 using epoxy-polyolefin systems in mono- or multilayers
• CPC Class Codes: B05D 7/54 No clear coat specified
• CPC Class Codes: C08G 18/003 with epoxy compounds having no active hydrogen with epoxy resins containing active hydrogen C08G18/58
• CPC Class Codes: C08G 18/698 Mixtures with compounds of group C08G18/40
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31573 Next to addition polymer of ethylenically unsaturated monomer
• CPC Class Codes: Y10T 428/31844 Of natural gum, rosin, natural oil or lac
• CPC Class Codes: Y10T 428/31848 Next to cellulosic
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers

Abstract

A coating system comprises a basecoat of an thermosetting asphalt extended, chemically cross linked-urethane/epoxy hybrid basecoat resting on a substrate, preferably a porous substrate such as concrete or wood that off-gas when coated with a thermoplastic material; and a thermoplastic powder coating topcoat overlying at least the base coat. The thermosetting basecoat composition consisting essentially of, in weight percent based on final formulation, and between 10 and 90% of a petroleum asphalt; between 10 and 90%, of a hydroxy-terminated homopolymer; and between 0.1 and 30% of a functional epoxy reactive diluent for reducing the viscosity of the composition; and further up to 5% of a surfactant for improving surface imperfections, up to 5% of an anti-oxidant; and up to 25% of a thickening agent.

Claims

1. A coating system comprising:

a) basecoat of an thermosetting asphalt extended, chemically cross linked-urethane/epoxy hybrid basecoat resting on a substrate that off-gases when coated with a thermoplastic material; and

b) a thermoplastic powder coating topcoat overlying at least the base coat;

c) wherein the thermosetting asphalt extended, chemically cross linked-urethane/epoxy hybrid basecoat comprises, in weight percent based on final formulation;

between 10 and 90% of a petroleum asphalt;

between 10 and 90% of a hydroxy-terminated homopolymer;

between 0.1 and 30% of an epoxy-functional reactive diluent for reducing the viscosity of the composition;

up to 5% of a surfactant for improving surface imperfections;

up to 5% of an anti-oxidant; and

up to 25% of a thickening agent for improved thermal resistance, resiliency, adhesion to the substrate and topcoat, and chemical resistance.

2. The coating system of claim 1, wherein the thermosetting basecoat composition further includes, based on weight percentage, one or more of a catalyst in a range between 0.0001 and 5%, polyols for higher strength, fillers for viscosity adjustment in a range between 0.1 and 75%, functional silanes in a range between 0.001 and 10%, thermal conductivity agents in a range between 0.1 and 75% of the formulation, hollow and/or solid glass filler spheres in a range of between 0.001 and 5%, drying agents ranging up to 20 gram/gram of water present, flame retardants in amounts ranging between 0.1 and 60%, corrosion inhibitors ranging between 0.1 and 50%, antistatic agents ranging between 0.1 and 50%, biostabilizers ranging between 0.1 and 10%, chemical blowing agents ranging between 0.1 and 10%, scent additives ranging between 0.1 and 25%, bittering agents ranging between 0.1 and 25%, pigments ranging between 0.1 and 40%, fluorescent whiting agents ranging between 0.1 and 10%, lubricants ranging between 0.1 and 25%, UV stabilizers ranging between 0.001% and 50%, powdered (−

20 to −

1250 mesh size) thermoplastic materials and between 0.001% and 50% of powdered thermoplastic materials with incorporation of one or more of the following;

fillers, thermal conductivity agents, flame retardants, corrosion inhibiters, antistatic agents, biostabilizers, chemical blowing agents, scent additives, bittering agents and pepper, pigments/effects, fluorescent whiting agents, lubricants, and plasticizers (−

20 to −

1250 mesh size).

3. The coating system of claim 1, wherein the petroleum asphalt ranges between 20 and 70%, the hydroxy-terminated homopolymer ranges between 20 and 70%, and the epoxy-functional reactive diluent ranges between 3 and 25%.

4. The coating system of claim 1, wherein the surfactant, the anti-oxidant, and the thickening agent of the basecoat thermosetting composition range between 0.2 and 3%, 0.2 and 3%, and 0.1 and 10%, respectively.

5. The coating system of claim 1, wherein the substrate is one of wood or concrete.

6. The coating system of claim 1, wherein the hydroxy-terminated polymer is a hydroxy-terminated butadiene polymer.

7. The system of claim 1, wherein an alcohol-silane primer is on the substrate and surrounds at least a portion of the basecoat while leaving a portion of the substrate exposed, the topcoat overlying both the primer and the portion of exposed substrate.

8. The coating system of claim 7, wherein the alcohol primer consisting essentially, in weight percent, of between zero and up to 10% of a silane, a solvent ranging between 80 and 95%, and the balance water.

9. The coating system of claim 8, wherein the silane is one of:

an ionic and anionic silane;

a methanol, organic phosphonium chloride salt and silane monomer;

or any other silane having an active hydrogen.

10. A coating system comprising:

a) basecoat of an thermosetting asphalt extended, chemically cross linked-urethane/epoxy hybrid basecoat resting on a substrate that off-gases when coated with a thermoplastic material; and

b) a thermoplastic powder coating topcoat overlying at least the base coat;

wherein the thermoplastic powder coating topcoat has a topcoat thermoplastic composition comprising, in weight percent, based on final formulation;

between 10 and 90% of a modified ethylene terpolymer;

between 5 and 95% of a polyethylene/methacrylic acid copolymer;

between 5 and 95% of a polyethylene/methacrylic acid copolymer ionomer;

up to 50% of a coloring pigment;

up to 5% of an anti-oxidant;

up to 5% of an ultraviolet stabilizer;

up to 5% of a surfactant for improving surface imperfections; and

up to 25% of a thickening agent.

11. The coating system of claim 10, wherein the topcoat thermoplastic composition is modified, based on weight percent, with the incorporation of one or more of other fillers for viscosity adjustment ranging between 0.1 and 75%, thermal conductivity agents ranging between 0.1 and 75% of the formulation, drying agents ranging up to 20 gram/gram of water present, flame retardants in amounts ranging between 0.1 and 60%, corrosion inhibitors ranging between 0.1 and 50%, antistatic agents ranging between 0.1 and 50%, biostabilizers ranging between 0.1 and 10%, chemical blowing agents ranging between 0.1 and 10%, scent additives ranging between 0.1 and 25%, bittering agents ranging between 0.1 and 25%, pigments ranging between 0.1 and 40%, fluorescent whiting agents ranging between 0.1 and 10%, and lubricants and plasticizers, each ranging between 0.1 and 25%.

12. The coating system of claim 10, wherein each of the modified terpolymer and the polyethylene/methacrylic acid copolymer ranges between 20 and 70%, and the polyethylene/methacrylic acid copolymer ionomer ranges between 5 and 70%.

13. The coating system of claim 10, wherein the surfactant and the thickening agent of the topcoat thermoplastic composition range between 0.2 and 3% and 0.1 and 10%, respectively.

14. The coating system of claim 10, wherein the substrate is one of wood or concrete.