Process for the preparation of resin-inorganic fibers composite and the obtained resin-inorganic fibers composite for coating

Patent metadata

Field	Value
Publication number	US-11236205-B2
Application number	US-201816487430-A
Country	US
Kind code	B2
Filing date	Feb 20, 2018
Priority date	Feb 20, 2017
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

The present disclosure is directed to a process for the preparation of resin-inorganic fibers composite and the obtained resin-inorganic fibers composite for coating. The process comprises the step of providing inorganic fibers bearing one or more monomer functional groups reactive with a monomer component; and reacting resin-forming monomer components with the inorganic fibers bearing one or more monomer functional groups reactive with a monomer component, to obtain the resin-inorganic fibers composite, wherein the resin is selected from the group consisting of alkyd resin, polyester resin and a combination thereof. The present disclosure is also directed to a coating composition containing the composite and a coating formed from the coating composition.

First claim

What is claimed:

1. A coating composition, comprising a composite made by a process comprising the steps of
providing inorganic fibers bearing one or more monomer functional groups reactive with a monomer component; and
reacting resin-forming monomer component with the inorganic fibers bearing one or more monomer functional groups reactive with a monomer component, to obtain the resin-inorganic fibers composite,
wherein the resin is selected from the group consisting of alkyd resin, polyester resin and a combination thereof, and the coating composition is solvent borne.

2. A coating formed from the coating composition according to claim 1 , which does not exhibit significant blushing when it is subjected to bending or folding one or more times.

3. A coating formed from the coating composition according to claim 1 , which has a pencil hardness of at least 2H, as measured according to ASTM D3363.

4. A coating formed from the coating composition according to claim 1 , which is capable of resisting scratch loading of greater than 250 g, as measured according to ASTM D2197.

5. A coating formed from the coating composition according to claim 1 , which has a film thickness retention ratio of 90% or more, when it is subjected to brushing with an aqueous medium containing sand particles having a particle size of 300-400 mesh by wet abrasion scrub tester REF 903 available from Sheen, England 500 cycles.

6. The coating composition according to claim 1 , wherein the step of providing inorganic fibers bearing one or more monomer functional groups reactive with a monomer component comprises surface modifying the inorganic fibers with a coupling agent bearing one or more functional groups reactive with a monomer component.

7. The coating composition according to claim 6 , wherein the coupling agent comprises a silane coupling agent, a titanate coupling agent, an aluminate coupling or a mixture thereof.

8. The coating composition according to claim 6 , wherein the coupling agent comprises silane compound having the formula:

in which
each X 1 is independently —Cl, —OCH 3, —OCH 2 CH 3, —OC 2 H 4 OCH 3, —OSiMe 3, or —OCOCH 3 ; and
Y 1 is an alkyl group substituted with —Cl, —NH 2, —SH, —OH, epoxy, —N 3, γ-methacryloxypropyl or isocyanate group.

9. The coating composition according to claim 6 , wherein the coupling agent comprises a silane compound comprising γ-methacryloxypropyl trimethoxy silane, 3-aminopropyltriethoxysilane, γ-glycidoxypropyl trimethoxysilane or mixtures thereof.

10. The coating composition according to claim 6 , wherein the coupling agent comprises a silane having the formula:

wherein each of X 2, X 3 and X 4 is independently —Cl, —OCH 3, —OCH 2 CH 3, —OC 2 H 4 OCH 3, —OSiMe 3, —OCOCH 3, —H, —CH 3, —C 2 H 5, and —OH with the proviso that at least one of X 2, X 3 and X 4 is not —H, —CH 3, —C 2 H 5, or —OH;
each of Y 2, Y 3 and Y 4 is independently an alkyl group substituted with —Cl, —NH 2, —SH, —OH, epoxy, —N 3, γ-methacryloxypropyl or an isocyanate group; and
each of m 1 , m 2 and m 3 independently is from 0 to 200, with the proviso that at least one of m 1 , m 2 and m 3 is not 0.

11. The coating composition according to claim 7 , wherein the coupling agent comprises a titanate having the formula:
X 5 O (4-n) —Ti—(OY 5 —Y 6 —Y 7 ) n ;
wherein X 5 O is a hydrolyzable short chain alkoxy;
OY 5 is a carboxyl, sulfonic, or phosphate group;
Y 6 is a long chain alkyl group;
Y 7 is a hydroxyl, thiol, amino, or epoxy group; and
n is 2 or 3.

12. The coating composition according to claim 6 , wherein the coupling agent comprises an aluminate comprising distearoyl isopropoxy aluminate, trimethyl aluminate, triisopropyl aluminate, tribenzyl aluminate or a mixture thereof.

13. The coating composition according to claim 6 , wherein the inorganic fibers have an average fiber diameter of from 0.5 micron to 100 microns.

14. The coating composition according to claim 6 , wherein the inorganic fibers have an average fiber diameter of from 1 micron to 50 microns.

15. The coating composition according to claim 6 , wherein the inorganic fibers have a number average aspect ratio of from 1.1:1 to 10:1.

16. The coating composition according to claim 6 , wherein the inorganic fibers have at least 50% by number of the fibers with an aspect ratio of 1.2:1 or greater.

17. The coating composition according to claim 6 , wherein the inorganic fibers comprises glass fibers, silica fibers, boron fibers, ceramic fibers, metal fibers or combination thereof.

18. The coating composition according to claim 1 , wherein the inorganic fibers bearing one or more functional groups reactive with a monomer component are used in an amount of 0.5 wt % to 99.5 wt %, relative to the total weight of resin-forming monomer component.

19. The coating composition according to claim 6 , wherein the coupling agent bearing one or more functional groups reactive with a monomer component is used in an amount of 0.2 to 10 wt %, relative to the weight of the inorganic fibers.

20. The coating composition according to claim 1 , wherein the resin-forming monomer component comprises (a) 20 to 60 wt % of polyols; (b) 20 to 60 wt % of polyacids; (c) 0 to 50 wt % of fatty acids, fatty acid esters or occurring oils; and (d) 0 to 15 wt % of monofunctional acids,
wherein the wt % is relative to the total weight of components of (a), (b), (c), and (d); and wherein the molar equivalent ratio of the polyols to the sum of the polyacids, the fatty acids, fatty acid esters or occurring oils and the monofunctional acids is 1:2 to 2:1.

21. The coating composition according to claim 1 , wherein the process comprises the steps of
(a) surface modifying the inorganic fibers with a coupling agent bearing one or more amine groups, thereby forming amino group-modified inorganic fibers; and then
(b) in the presence of the amino group-modified inorganic fibers, reacting resin-forming monomer component so that the inorganic fibers are covalently bonded to the formed resin, thereby obtaining a resin-inorganic fibers composite.

Assignees

• Swimc Llc
• Guangdong Huarun Paints Co Ltd

Inventors

• Kai Weihua
• Duan Gang
• Zhao Xi
• Fan Shigang

Classifications

• C09D175/14

  Polyurethanes having carbon-to-carbon unsaturated bonds · CPC title

• C08G63/48

  by unsaturated higher fatty oils or their acids; by resin acids · CPC title

• C08K2201/003

  Additives being defined by their diameter · CPC title

• C08K2201/016

  Additives defined by their aspect ratio · CPC title

• C09D187/005

  Block or graft polymers not provided for in groups C09D101/00 - C09D185/04 · CPC title