Multi-layer coatings and related methods

• US 7,354,624 B2
• Filed: 05/18/2005
• Issued: 04/08/2008
• Est. Priority Date: 05/28/2004
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Cheng, Shan, Lin, Chia-Cheng, Colton, James P., Nakajima, Masayuki, Millero, Edward R.
• Primary Examiner(s): Zimmer; Marc S.
• Application Number:
  US11/132,110
• Publication Number:
  US 20050266248A1
• Time in Patent Office: 1,056 Days
• Field of Search: None
• US Class Current: 427/387
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08L 2666/54 Inorganic substances
• CPC Class Codes: C09D 183/02 Polysilicates
• CPC Class Codes: C09D 5/1675 Polyorganosiloxane-containing compositions
• CPC Class Codes: C09D 7/61 inorganic
• 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 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

Multi-layer coatings are disclosed that include (a) a first layer deposited from at least one composition that includes a polymeric composition, and (b) a second layer applied over at least a portion of the first layer in which the second layer is deposited from at least one liquid composition that includes (i) a photocatalytic material, and (ii) a binder that is hydrophilic and comprises an essentially completely hydrolyzed organosilicate. Also disclosed are substrates coated with such multi-layer coatings, methods of applying such multi-layer coatings to a substrate and methods of making a painted surface easy-to-clean.

Claims

1. A method for improving the anti-fouling and/or self-cleaning properties of a painted article, wherein the article comprises a surface having a coating layer deposited from a polymeric composition deposited thereon, the method comprising

(a) applying a liquid composition comprising (i) a photocatalytic material, and (ii) a binder comprising a hydrophilic ungelled essentially completely hydrolyzed organosilicate directly to at least a portion of the coating layer deposited from the polymeric composition;

and

(b) curing the composition applied in step (a) to provide a coating having a dry film thickness of no more than 200 nanometers.

2. The method of claim 1, wherein step (b) comprises air drying the liquid composition at ambient temperature.

3. The method of claim 1 wherein the binder consists of the hydrophilic ungelled completely hydrolyzed organosilicate.

4. The method of claim 1, wherein the coating having a dry film thickness of no more than 200 nanometers is substantially free of Si—

OR groups, where R represents C1to C4 alkyl groups.

5. The method of claim 1, wherein the photocatalytic material is in the form of particles having an average crystalline diameter of 3 to 35 nanometers.

6. The method of claim 1, wherein the photocatalytic material is present in the liquid composition in an amount ranging from 0.1 to 0.75 percent by weight based on the total weight of the composition.

7. The method of claim 1, wherein the organosilicate is present in the liquid composition in an amount ranging from 0.1 to 2 percent by weight calculated as SiO₂, based on the total weight of the composition.

8. The method of claim 1, wherein the dry film thickness is 20 to 60 nanometers.