Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
1999-01-08
2003-02-18
Sellers, Robert E.L. (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S108000, C525S113000, C525S121000, C525S122000
Reexamination Certificate
active
06521706
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to epoxy resin-containing coating compositions suitable for use as adhesives, anti-flutter compositions and coatings e.g. for body panel reinforcement and sound dampening.
BACKGROUND OF THE INVENTION
Automobile manufacturers continue to seek improved adhesives to bond similar or dissimilar materials and/or substrates in the manufacturing of motor vehicles. Improvements in the adhesion, durability and strength of structural adhesives enable the production of motor vehicles with better fit of the adhesively bonded parts. As discussed in U.S. Pat. No. 4,739,019, adhesive compositions prepared from epoxy resins exhibit a number of advantages including good strength, adhesion, corrosion resistance and suitability for formulation at high solids levels. To reduce shrinkage, a thermoplastic polyester that is nonreactive with and insoluble in the epoxy resins and that has a weight average molecular weight of from about 1,000 to about 8,000 is included in the epoxy-based adhesive composition.
Also, improved adhesives could result in additional applications for adhesives in motor vehicles and translate into improvements of other curable epoxy-containing coating compositions that have components similar to that of the adhesives, such as corrosion protection coatings, reinforcement coatings, sound dampening and anti-flutter compositions. Such coatings are lightweight compared to metal to reduce the weight of motor vehicles.
Typically, protective coatings designed to inhibit corrosion are applied to the underbody of motor vehicles. The protective underbody coatings are applied to protect the underlying metal structures of the motor vehicle from corrosion by forming a barrier against water and road salt. To be effective and durable, this barrier needs to withstand impacts from abrasive materials such as sand, rock salt, stones and road debris.
Coatings for reinforcement are applied to the interior surfaces of metal parts of motor vehicles. Such reinforcement coatings require sufficient flexibility so that the coated metal does not dimple when the reinforcement coating is cured.
Underbody and underhood coatings also can be used to dampen or reduce road and engine noise, preventing it from permeating into the passenger compartment of the motor vehicle. Sprayable coatings are preferred to facilitate application. Such coating compositions must be adapted to avoid deterioration of the application equipment, e.g., by abrasion of nozzles, pumps and the like.
Anti-flutter compositions are commonly used to prevent vibrations of doors and deck lids. They are usually applied between reinforcing metal bars and the body panel. By varying the components and amounts of components, these compositions can provide different degrees of expansion and strength from the very soft to the very hard.
For a coating and composition manufacturer making more than one of the aforementioned types of coatings and compositions, it is desirable from a manufacturing standpoint to consolidate the similar types of components that may be present in more than one coating or composition to obtain a platform-type of composition from which numerous types of coatings and compositions can be made. For example, if a combination of a thermosetting polymer and its curing agent provide improved properties in one type of coating, they may also provide similar improvements in another type of coating that may include other additional components.
Versatile curable coating compositions which provide corrosion protection and adhesion in various applications such as protective coatings, adhesives, sound dampening compositions, reinforcement compositions, and anti-fluttering compositions are desirable. Preferably, the curable coating compositions provide a base from which other compositions and coatings can be prepared.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a curable coating composition comprising: (a) at least one epoxy-functional polymer containing at least two epoxide groups per molecule present in an amount ranging from about 55 to about 99 weight percent of total resin solids of the coating composition; (b) at least one thermoplastic polymer which is substantially insoluble in the epoxy-functional polymer present in an amount ranging from about 1 to about 45 weight percent of total resin solids of the coating composition; (c) ground vulcanized rubber particles having an average particle size ranging from about 1 to about 300 microns present in an amount ranging from about 1 to about 70 weight percent of total resin solids of the coating composition; and (d) a curing agent adapted to cure the epoxy-functional polymer.
Another aspect of the present invention is a curable coating composition comprising: (a) at least one epoxy-functional polymer containing at least two epoxide groups per molecule present in an amount ranging from about 40 to about 98.9 weight percent of total resin solids of the coating composition; (b) at least one thermoplastic polymer which is substantially insoluble in the epoxy-functional polymer present in an amount ranging from about 1 to about 59 weight percent of total resin solids of the coating composition; (c) at least one vinyl chloride polymer present in an amount ranging from about 0.1 to about 59 weight percent of total resin solids of the coating composition; (d) ground vulcanized rubber particles having an average particle size ranging from about 1 to about 300 microns present in an amount ranging from about 1 to about 70 weight percent of total resin solids of the coating composition; and (e) a curing agent adapted to cure the epoxy-functional polymer.
Yet another aspect of the present invention is a curable coating composition comprising: (a) at least one monoepoxide polymer present in an amount ranging from about 0.1 to about 5 weight percent of total resin solids of the coating composition; (b) at least one thermoplastic polymer present in an amount ranging from about 1 to about 59 weight percent of total resin solids of the coating composition; (c) at least one vinyl chloride polymer present in an amount ranging from about 0.1 to about 59 weight percent of total resin solids of the coating composition; and (d) ground vulcanized rubber particles having an average particle size ranging from about 1 to about 300 microns present in an amount ranging from about 1 to about 70 weight percent of total resin solids of the coating composition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Generally, the curable coating compositions of the present invention comprise the four principal components (a), (b), (c), and (d) discussed above. Other additional components can be included in the composition depending on its intended application. The relative amounts of the components (a), (b), (c) and (d) in the coating composition also depend in part upon the intended application of the composition, such as protective coatings, sound dampening, adhesion or anti-flutter compositions, and will be discussed in detail below.
As used herein, unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, times and temperatures of reaction, ratios of amounts, values for molecular weight (whether number average molecular weight (“M
n
”) or weight average molecular weight (“M
w
”)), and others in the following portion of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount or range. Also for molecular weights, whether M
n
or M
w
, these quantities are determined by gel permeation chromatography using polystyrene as standards as is well known to those skilled in the art and such as is discussed in U.S. Pat. No. 4,739,019 at column 4, lines 2-45, which incorporated herein by reference in its entirety. The term “equivalent weight” is a calculated value based on the relative amounts of the various ingredients used in making the specified material and is based on the solids
Desai Umesh C.
Palermo Anthony C.
Altman Deborah M.
Cannoni Ann Marie
PPG Industries ohio, Inc.
Sellers Robert E.L.
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