Coated articles and methods of making the same

Patent metadata

Field	Value
Publication number	US-10967398-B2
Application number	US-201816222487-A
Country	US
Kind code	B2
Filing date	Dec 17, 2018
Priority date	May 28, 2015
Publication date	Apr 6, 2021
Grant date	Apr 6, 2021

Abstract

During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

First claim

What is claimed is:

1. A coated article, comprising:
a metallic substrate;
a foundation coat bonded to the metallic substrate, wherein the foundation coat comprises:
cross-linked titania or silica nanoparticles; and
a plurality of capsules distributed among the cross linked titania or silica nanoparticles, each capsule including a shell capable of covalently bonding to the cross-linked titania or silica nanoparticles and a healing agent surrounded by the shell, wherein the healing agent is an alcohol based sol gel material comprising titania or silica nanoparticles, and wherein the shell and the healing agent are chemically compatible with the cross linked titania or silica nanoparticles.

2. The coated article of claim 1 , wherein the coated article is free of any electro-deposition coatings.

3. The coated article of claim 1 , wherein the foundation coat is ultraviolet radiation (UV) stable.

4. The coated article of claim 1 , wherein the plurality of capsules is a plurality of first capsules and the coated article further comprises a plurality of second capsules, wherein the first capsules include a resin as a first healing agent, and where the second capsules include a curing agent of the resin as a second healing agent.

5. The coated article of claim 1 , wherein the shell is selected from the group consisting of titania, silicon dioxide, quartz crystal, and silica glass.

6. The coated article of claim 1 wherein the shell has a thickness of greater than or equal to about 1/20th to less than or equal to about ⅕th of a diameter of the capsule.

7. The coated article of claim 1 wherein the metallic substrate comprises a material selected from the group consisting of steel, aluminum, magnesium, alloys, and combinations thereof.

8. The coated article of claim 1 wherein the foundation coat is covalently bonded to the metallic substrate, and wherein the covalent bonding between the foundation coat and the metallic substrate ranges from greater than or equal to 60 kJ/mol to less than or equal to about 800 kJ/mol.

9. A method for forming the coated article of claim 1 , the method comprising:
incorporating the plurality of capsules in a sol matrix to form a foundation coat precursor, each capsule including a shell capable of covalently bonding to the sol matrix and a healing agent surround by the shell, and wherein the sol matrix comprises titania or silica nanoparticles suspended in a liquid comprising water, ethanol, or butyl acetate; and wherein the cross-linked titania or silica nanoparticles are compatible with the sol matrix;
applying the foundation coat precursor on the metallic substrate; and
heating the foundation coat precursor and metallic substrate in order to cure the foundation coat precursor and form a foundation coat, wherein the foundation coat is covalently bonded to the metallic substrate.

10. The coating method of claim 9 , wherein applying the foundation coat precursor includes dipping the metallic substrate in a tank containing the foundation coat precursor.

11. The coating method of claim 9 , wherein heating the foundation coat precursor and metallic substrate includes positioning the metallic substrate in an oven after applying the foundation coat precursor on the metallic substrate and heating the coated metallic substrate at a temperature between 200 degrees Fahrenheit and about 320 degrees Fahrenheit for a time between about 15 minutes and about 50 minutes.

12. A precursor of a coating for an article, the precursor comprising:
a sol matrix comprising titania or silica nanoparticles suspended in a liquid comprising water, ethanol, or butyl acetate; and
a plurality of capsules present in the sol matrix, each capsule including a shell that is capable of covalently bonding to the sol matrix and a healing agent surrounded by the shell, wherein the healing agent is an alcohol based sol gel material comprising titania or silica nanoparticles and is compatible with the sol matrix.

13. The precursor of claim 12 , wherein the plurality of capsules comprises a plurality of first capsules and a plurality of second capsules, wherein the first capsules include a resin as a first healing agent and the second capsules include a curing agent of the resin as a second healing agent.

14. The precursor of claim 13 , wherein the resin of the first capsule is a vinyl terminated polydimethylsiloxane (PDMS) resin and the curing agent of the second capsules is a polyisocyanate resin.

15. The precursor of claim 12 , wherein the sol matrix has a nanoparticle concentration of 25 wt. % and the plurality of capsules has a nanoparticle concentration of 40 wt. %.

16. The precursor of claim 12 , wherein the sol matrix has an amount of the capsules ranging from about 1 wt. % to about 40 wt. % of a total wt. % of the sol matrix.

17. The precursor of claim 12 , wherein the shell is selected from the group consisting of titania, silicon dioxide, quartz crystal, and silica glass.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Fan Hua-Tzu
• Arinez Jorge F
• Plazas Torres Alejandro Hernan

Classifications

• C23C18/1241

  Metallic substrates · CPC title

• C09D183/04 Primary

  Polysiloxanes · CPC title

• B05D7/14 Primary

  to metal, e.g. car bodies (involving a chemical reaction between the metal and the coating C23) · CPC title

• C23C28/00

  Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D · CPC title

• C23C18/1254

  Sol or sol-gel processing · CPC title