Catalyzed surface composition altering and surface coating...

Solid anti-friction devices – materials therefor – lubricant or se – Lubricants or separants for moving solid surfaces and... – Graphite – coal – or elemental carbon

Reexamination Certificate

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C508S123000, C508S126000, C508S181000, C148S251000, C427S248100, C427S421100, C244S13400A

Reexamination Certificate

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06258758

ABSTRACT:

TECHNICAL FIELD
This invention relates generally to compositions and methods for coating a surface, and more particularly to a compositions and methods for catalytically chemically bonding a material to a surface.
BACKGROUND
As described in U.S. Pat. No. 5,877,128, filed Apr. 26, 1996, entitled, “CATALYZED LUBRICANT ADDITIVES AND CATALYZED LUBRICANT SYSTEMS DESIGNED TO ACCELERATE THE LUBRICANT BONDING REACTION,” which application is incorporated herein by reference, the present state of the arts are defined and illustrated by many disclosures with respect to the composition, formulation, and performance of lubricant additives, lubricant systems containing solid lubricant additives, the composition and formulation of metal coatings, the composition and formulation of catalysts, and the chemistry and performance of lubricants containing solid lubricant additives, all of which bear some relevance to the invention presented herein. Those disclosures employed as references in this patent application are listed hereinafter.
The references, other than United States Patents, are presented as follows:
L. L. Cao, Y. M. Sun, and L. Q. Zheng, “Chemical Structure Characterization of Boundary Lubrication Film Using X-ray Photoelectron Spectroscopy and Scanning Auger Microprobe Techniques,” Wear, 140 (1990), pp. 345-357;
Harold Shaub, John Pandosh, Anne Searle, and Stan Sprague, “Mechanism Studies with Special Boundary Lubricant Chemistry,” Society of Automotive Engineers, Paper 952475, 1995;
Hal Shaub, John Pandosh, Anne Searle, Stan Sprague, and Martin Treuhaft, “Engine Durability, Emissions and Fuel Economy Studies with Special Boundary Lubricant Chemistry,” Society of Automotive Engineers, Paper 941983, 1994;
Keith Perrin, John Pandosh, Anne Searle, Hal Shaub, and Stan Sprague, “Radioactive Tracer Study of Start-Up Wear Versus Steady-State Wear in a 2.3 Liter Engine,” Society of Automotive Engineers, Paper 952474, 1995.
Other useful references are as follows:
Kirk-Othmer, “Concise Encyclopedia of Chemical Technology,” John Wiley & Sons, Inc., 1985, pp. 37 and 292-297;
Jacqueline I. Kroschwitz, “Concise Encyclopedia of Polymer-Science and Engineering,” John Wiley & Sons, Inc., 1990, pp. 31-35 and 156-171;
R. E. Banks, B. E. Smart, and J. C. Tatlow, “Organofluorine Chemistry, Principles and Commercial Applications,” Plenum Press, 1994, pp. 397-401.
The United States Patent Application and the United States Patents which bear particular relevance or are of significant interest with respect to the present patent application are singled out and are cited. See U.S. Pat. Nos. 2,230,654; 2,510,112; 2,993,567; 3,194,762; 3,247,116; 3,314,889; 3,432,431; 3,493,513; 3,505,229; 3,536,624; 3,567,521; 3,592,700; 3,607,747; 3,636,172; 3,640,859; 3,723,317; 3,806,455; 3,909,431; 3,933,656; 3,969,233; 4,029,870; 4,036,718; 4,052,323; 4,127,491; 4,224,173; 4,252,678; 4,349,444; 4,363,737; 4,405,469; 4,465,607; 4,484,954; 4,500,678; 4,584,116; 4,615,917; 4,657,687; 4,770,797; 4,803,005; 4,834,894; 4,857,492; 4,859,357; 4,888,122; 4,892,669; 5,009,963; 5,160,646; 5,227,081; 5,350,727; 5,373,986; 5,447,896; 5,460,661. All of the above references are incorporated herein by reference.
As described in detail in U.S. Pat. No. 5,877,128, it generally has been established, through preexisting research work performed by others, that certain materials, such as Teflon® and polytetrafluoroethylene (“PTFE”), which are different designations for the same chemical composition, can be caused to chemically bond to a surface, such as a metallic surface, when exposed at elevated temperatures.
U.S. Pat. No. 5,877,128 teaches that these materials, such as PTFE, can be caused to chemically bond to a surface, such as a metallic surface, at relatively low (e.g., ambient) temperatures and atmospheric pressures, when the reactants are appropriately catalyzed. In a preferred embodiment, the catalysts disclosed comprise a transition metal such as platinum or palladium. U.S. Pat. No. 5,877,128 further discloses such applications as lubricating load-bearing wear surfaces, and non load-bearing applications and applications where “non-stick” properties are being sought, for example cookware surfaces, cling, and stain resistant surfaces, etc.
SUMMARY OF THE INVENTION
The concepts of the invention disclosed in the U.S. Pat. No. 5,877,128 were initially generally thought to be most advantageous when used primarily for applications utilizing the lubrication characteristics of the surface coating. However, some of the catalysts claimed, such as platinum and palladium, may be too expensive for some applications. In addition, further investigation has led to the conclusion that the same basic concepts are capable of causing surface coating films of PTFE, fluorine containing species, or other unreacted surface coating materials to be chemically bonded to the surface to be coated for applications utilizing other characteristics of the surface coating. For example, the present invention may provide a multilayered, persistent, solid, and corrosion and wear resistant surface coating on the skin (e.g., body panels) of a vehicle, such as an aircraft, not only to provide lubricated surfaces that would be expected to substantially reduce the drag coefficients of the aircraft, but also that could be designed to provide enduring, environmentally benign aircraft anti-icing capabilities, along with a large number of other beneficial properties. As used herein, “unreacted surface coating materials” are defined as including an individual material or combination of materials which may be employed to undergo a catalytically aided reaction wherein the materials are caused to chemically bond to a surface, and in particular refers to such materials prior to the catalytically aided chemical bonding reaction.
Prior art conventional surface coatings are available primarily as liquids or fusible compositions. Generally, the currently available surface coatings are categorized into two different classes.
The first class includes surface coating systems containing oil-modified alkyds, volatile organic compounds (VOCs), or other polymers containing drying oils, which coatings may be divided into the following subclasses:
(1) architectural surface coatings which require air drying applications to cause curing and adhesion, such as oxidizing alkyd resins;
(2) metal surface coatings which require air-drying or low temperature bake-on applications to cause curing and adhesion, such as alkyd and phenoplast, or nitrocellulose, chlorinated rubber, polystyrene, diisocyanate, or vinyl and epoxy;
(3) premium surface coatings with good color retention, and superior chemical and heat resistance which require air-drying or low temperature bake-on applications to cause curing and adhesion, such as alkyd and aminoplast, or aminoplast and epoxy, or alkyd and silicone; and
(4) surface coatings for use as undercoating or overcoating enamels which require bake-on applications to cause curing and adhesion, such as oil-modified epoxy resins and aminoplast.
The second class includes surface coating systems containing no alkyds or drying oils, which coatings may be divided into the following subclasses:
(1) surface coatings with good chemical resistance which require bake-on applications to cause curing and adhesion, such as vinyl acetals and/or phenolic, allylaminoplast, epoxy, along with 2,4,6-trimethylophenyl ether;
(2) surface coatings primarily for corrosion protection which require only ambient temperature applications to cause curing and adhesion, such as phenoplasts with or without epoxy, vinylacetal or aminoplast;
(3) surface coatings that exhibit chemical and discoloration resistance and exhibit high gloss or clear finishes which require elevated temperatures to cause curing and adhesion, such as polyester and triazine resin, allyl polyester, silicone, thermosetting acrylics, complex amino resins, and other polyesters;
(4) surface coatings for architectural products which require heat or air drying applications to cause curing and adhesion, such as vinyl acetate-chloride, copolymers

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