Thermoplastic coating formulations for high-velocity sprayer application and methods for applying same

Patent metadata

Field	Value
Publication number	US-11390773-B2
Application number	US-202117151810-A
Country	US
Kind code	B2
Filing date	Jan 19, 2021
Priority date	Aug 1, 2018
Publication date	Jul 19, 2022
Grant date	Jul 19, 2022

Abstract

Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer are presently disclosed, along with tunable coatings made from the disclosed formulations, and methods for delivering such tunable thermoplastic polymer coatings to substrates.

First claim

What is claimed is:

1. A method for delivering a thermoplastic polymer coating material to a substrate surface, said method comprising:
directing an amount of at least one tunable thermoplastic polymer powder feedstock to a high-velocity cold sprayer to form a tunable thermoplastic polymer spray formulation, said tunable thermoplastic polymer powder feedstock selected from the group consisting of: nylon, polyether ether ketone, polyether ketone, polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, polyetherimide, and combinations thereof;
directing the thermoplastic polymer spray formulation from the high-velocity cold sprayer to a substrate surface; and
forming a tuned thermoplastic polymer coated substrate surface.

2. The method of claim 1 , concurrently with the step of directing an amount of at least one tunable thermoplastic polymer powder feedstock to the high-velocity cold sprayer further comprising:
directing an amount of a conductive powder feedstock to the high-velocity cold sprayer to form a tunable conductive thermoplastic polymer spray formulation, said conductive powder feedstock selected from the group consisting of: titanium, nickel alloy, copper, carbon black, graphene powder, carbon nanotubes, and combinations thereof;
directing the tunable conductive thermoplastic polymer spray formulation from the high-velocity cold sprayer to the substrate surface to form a conductive thermoplastic polymer coating material; and
forming a conductive thermoplastic polymer coated substrate surface, said conductive thermoplastic polymer coating material having a resistivity ranging from about 1×10e 5 to about 1×10e 8 ohm-m.

3. The method of claim 1 , before the step of directing an amount of at least one tunable thermoplastic polymer powder feedstock to the high-velocity cold sprayer to form a tunable thermoplastic polymer spray formulation, the method further comprising:
mixing the at least one tunable thermoplastic polymer powder feedstock with a conductive powder feedstock to form a tunable conductive thermoplastic polymer feedstock mixture; and
directing an amount of the tunable conductive thermoplastic polymer feedstock mixture to the high-velocity cold sprayer.

4. The method of claim 1 , further comprising:
directing an amount of a first thermoplastic polymer powder feedstock to the high-velocity cold sprayer, the first thermoplastic polymer powder feedstock selected from the group consisting of: nylon, polyetheretherketone, polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, polyetherimide, and combinations thereof;
directing an amount of a second thermoplastic polymer powder feedstock to the high-velocity cold sprayer, the second thermoplastic polymer powder feedstock selected from the group consisting of: nylon, polyetheretherketone, polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, polyetherimide, and combinations thereof; and
wherein the first thermoplastic polymer powder feedstock is different from the second thermoplastic polymer powder feedstock.

5. The method of claim 4 , concurrently with the steps of directing an amount of a first thermoplastic polymer powder feedstock to the high-velocity cold sprayer, and directing an amount of a second thermoplastic polymer powder feedstock to the high-velocity cold sprayer directing further comprising:
directing an amount of a conductive powder feedstock to the high-velocity cold sprayer to form a tunable conductive thermoplastic polymer spray formulation, said conductive powder feedstock selected from the group consisting of: titanium, nickel alloy, copper, carbon black, graphene powder, carbon nanotubes, and combinations thereof.

6. The method of claim 5 , further comprising:
directing the conductive powder feedstock to the high-velocity cold sprayer at an amount ranging from about 1% to about 9% by volume of the tunable conductive thermoplastic polymer spray formulation.

7. The method of claim 5 further comprising:
directing the tunable conductive thermoplastic polymer spray formulation from the high-velocity cold sprayer to a substrate surface; and
forming a conductive thermoplastic polymer coating on the substrate surface, said conductive thermoplastic polymer coating having a resistivity ranging from about 1×10e 5 to about 1×10e 8 ohm-m.

8. The method of claim 5 , further comprising:
varying comparative amounts of the at least one thermoplastic polymer powder and the conductive powder to form a tunable conductive thermoplastic polymer coating on the substrate surface, said tunable conductive thermoplastic polymer coating having a predetermined resistivity ranging from about 1×10e 5 to about 1×10e 8 ohm-m.

9. The method of claim 4 , before the steps of directing a first thermoplastic polymer powder feedstock to the high-velocity cold sprayer, and directing an amount of a second thermoplastic polymer powder feedstock to the high-velocity cold sprayer directing further comprising:
mixing the first thermoplastic polymer powder feedstock and the second thermoplastic polymer powder feedstock with a conductive powder feedstock to form a tunable conductive thermoplastic polymer feedstock mixture; and
directing an amount of the tunable conductive thermoplastic polymer feedstock mixture to the high-velocity cold sprayer to form a tunable conductive thermoplastic polymer spray formulation.

Assignees

• Boeing Co

Inventors

• Song Weidong

Classifications

• C23C4/04 Primary

  characterised by the coating material · CPC title

• B05D1/04

  involving the use of an electrostatic field {(B05D1/025 and B05D1/14 take precedence)} · CPC title

• B05B7/205

  the material to be sprayed being originally a particulate material · CPC title

• B05C5/002

  the work consisting of separate articles (B05C5/0208 takes precedence) · CPC title

• C08K2003/0881

  Titanium · CPC title