Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From reactant having at least one -n=c=x group as well as...
Reexamination Certificate
2001-09-21
2003-05-06
Gorr, Rachel (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From reactant having at least one -n=c=x group as well as...
C528S071000, C524S591000, C524S840000, C428S423100, C427S385500, C525S452000, C525S459000, C525S460000
Reexamination Certificate
active
06559265
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to a curable polyurethane material, coatings prepared therefrom, and methods of making the same.
BACKGROUND OF THE INVENTION
Coating formulations find use in various industries including the coating and/or painting of motor vehicles. In these industries, and in the automotive industry in particular, considerable efforts have been expended to develop coating compositions with improved performance properties. In the automotive industry, for example, numerous approaches have been advanced to achieve improved chip resistance and corrosion protection. These efforts have included, for example, applying up to 6 or more individually applied coating layers over the substrate by one or more coating methods.
These coatings may be applied by either electrophoretic or non-electrophoretic coating methods. Electrodeposition has become increasingly important in the coatings industry because, by comparison with non-electrophoretic coating means, electrodeposition offers higher paint utilization, outstanding corrosion protection, low environmental contamination, and a highly automated process. Generally, cationic electrodeposited coatings provide better corrosion resistance than anionic electrodeposited coatings. Non-electrophoretic coatings, such as sprayable coatings, however, are still widely used throughout the coatings industry because of the relatively low equipment and operating costs associated therewith.
Such efforts have resulted in increased protection of the surface of the substrate and reduced paint loss through chipping when the substrate of the vehicle is hit with solid debris such as gravel and stones. By reducing the difference in impact energy between multiple coating layers, it is believed that chip resistance of the overall coating can be improved, especially for coatings in which the respective coating layers have excessive differences in hardness. It is believed that reducing the hardness differential can lessen delamination between the coating layers such as between the undercoat, an intermediate coat, and a topcoat or an undercoat and an intermediate coat.
In U.S. Pat. No. 5,047,294, this differential is said to be reduced by applying a crosslinked polyurethane resin filler composition between coating layers to improve intercoat adhesion. The filler composition includes a water-dispersible polymer derived from polyisocyanates, high and low molecular weight polyols, compounds reactive with the isocyanate, and monofunctional or active hydrogen-containing compounds. Anhydrides of carboxylic acids, such as trimellitic acid, are disclosed as useful to form the high molecular weight polyol. The coating formulation is typically applied as an intermediate coat between the primer and the topcoat to even out irregularities present in the primer, and improve the overall stone-chip resistance of the coating.
In U.S. Pat. No. 5,674,560, a chip resistant polyolefin type of primer is spray applied over a cationic or anionic electrodeposited coated film before application of a soft intermediate polyester film. The reduction of the differential in impact energy is reportedly maximized when the polyolefin primer is applied over the softer anionic electrodeposited film as opposed to a cationic electrodeposited film.
Even though electrophoretic coatings can provide many advantages over non-electrophoretic coatings, improvements to each are still sought because of the widespread use of both.
Accordingly, the need exists for a polyurethane material useful in coating compositions that can and may be applied to the substrate by electrophoretic and non-electrophoretic coating methods.
SUMMARY OF THE INVENTION
The present invention provides a curable polyurethane material, the polyurethane material formed from components comprising:
(a) at least one polyisocyanate;
(b) at least one active hydrogen-containing material;
(c) at least one polymeric polyamine;
(d) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(e) at least one acid functional material or anhydride having a functional group reactive with isocyanate or hydroxyl groups of other components from which the polyurethane material is formed.
The present invention also provides a curable polyurethane material, the polyurethane material being formed from components comprising:
(a) at least one polyisocyanate;
(b) at least one active hydrogen-containing material that does not include acid functional groups;
(c) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(d) at least one anhydride functional material.
The present invention is also directed to a primer coating composition, a basecoat composition, a clearcoat composition, a monocoat composition, and a multicomponent composite coating including the polyurethane material described above. Where the present invention is a multicomponent composite composition, at least one of the layers comprises the polyurethane material.
The present invention is also directed to a coated substrate having coated layers applied thereover, at least one of the coated layers comprising the polyurethane material of the present invention.
The present invention is also directed to a process for forming an aqueous coating composition containing a polyurethane material, the process comprising,
(a) forming the polyurethane material from components comprising:
(i) at least one polyisocyanate;
(ii) at least one active hydrogen-containing material;
(iii) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(iv) at least one acid functional material or anhydride having a functional group reactive with isocyanate or hydroxyl groups of other components from which the polyurethane material is formed; and
(b) dispersing the polyurethane material in an aqueous solution.
The present invention is also directed to a process for forming an aqueous coating composition containing a polyurethane material, the process comprising,
(a) forming the polyurethane material from components comprising:
(i) at least one polyisocyanate;
(ii) at least one active hydrogen-containing material;
(iii) at least one polyoxyalkylene polyamine;
(iv) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(v) at least one acid functional material or anhydride having a functional group reactive with isocyanate or hydroxyl groups of other components from which the polyurethane material is formed; and
(b) dispersing the polyurethane material in an aqueous solution.
The present invention is also directed to a process for preparing a coated substrate, comprising,
(a) forming a coating on the substrate, the coating being a composition including a curable polyurethane material, the polyurethane material formed from components comprising:
(i) at least one polyisocyanate;
(ii) at least one active hydrogen-containing material;
(iii) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(iv) at least one acid functional material or anhydride having a functional group reactive with isocyanate or hydroxyl groups of other components from which the polyurethane material is formed; and
(b) at least partially curing the coating.
The present invention is also directed to a process for preparing a coated substrate, comprising,
(a) forming a coating on the substrate, the coating being a composition including a curable polyurethane material, the polyurethane material formed from components comprising:
(i) at least one polyisocyanate;
(ii) at least one active hydrogen-containing material;
(iii) at least one polyoxyalkylene polyamine;
(iv) at least one material having at least one primary or secondary amino group and at least one hydroxyl group; and
(v) at least one acid functional material or anhydride having a functional group reactive with isocyanate or hydroxyl groups of other components from which the polyurethane material is
Lamers Paul H.
Martz Jonathan T.
Meyers Lawrence D.
Novak Carolyn A.
Olson Kurt G.
Altman Deborah M.
Gorr Rachel
PPG Industries Ohio Inc.
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