Method of forming a coating on a substrate

Patent metadata

Field	Value
Publication number	US-12246345-B2
Application number	US-201816050622-A
Country	US
Kind code	B2
Filing date	Jul 31, 2018
Priority date	Jul 31, 2018
Publication date	Mar 11, 2025
Grant date	Mar 11, 2025

Abstract

A method of forming a multilayer coating on a substrate is provided. The multilayer coating exhibits reduced strike-in and mottling. The method includes the steps of providing the substrate including a primer disposed thereon, applying a basecoat composition on the primer, applying a clearcoat composition on the basecoat composition, and curing the basecoat composition and the clearcoat composition to form the multilayer coating on the substrate. The basecoat composition includes a film forming resin, a pigment, and about 5% to about 75% by weight on binder of a cyclic lactone modified branched acrylic polymer having a hydroxyl monomer content of about 1% to 65% by weight, all or part of which has been reacted with a cyclic lactone, and having a weight average molecular weight (Mw) of about 10,000 to about 150,000 g/mol.

First claim

What is claimed is:

1. A three coat two bake method of forming a multilayer coating on a substrate which exhibits reduced strike-in and mottling, said method comprising the steps of:
A. providing the substrate comprising a solvent-borne primer disposed thereon and subsequently baking the primer to cure;
B. applying a solvent-borne basecoat composition directly on the cured primer, wherein the basecoat composition comprises a film forming resin, a pigment, and about 12.5% to 50% by weight on binder of a cyclic lactone modified branched acrylic polymer having a hydroxyl monomer content of about 1% to about 65% by weight, all or part of which has been reacted with a cyclic lactone, and having a weight average molecular weight (Mw) of about 10,000 to about 150,000 g/mol.;
C. applying a solvent-borne clearcoat composition directly on the basecoat composition in a wet on wet process, and subsequently
D. simultaneously curing the basecoat composition and the clearcoat composition by baking to form a basecoat and a clearcoat, respectively, and to form the multilayer coating on the substrate;
wherein the multilayer coating exhibits mottling of less than about 4 measured at 15 degrees from specular reflection,
wherein the primer is free of the cyclic lactone modified branched acrylic polymer;
wherein the primer, the basecoat composition, and the clearcoat composition are each free of a cyclic lactone modified linear acrylic polymer; and
wherein the basecoat composition is free of a branched polyester.

2. The method of claim 1 wherein the multilayer coating exhibits a strike-in of less than about 3.5 measured as a difference in Ln values.

3. The method of claim 2 wherein the cyclic lactone modified branched acrylic polymer is the reaction product of caprolactone, at least one monoacrylic monomer, and at least one di(meth)acrylic monomer.

4. The method of claim 2 wherein the cyclic lactone modified branched acrylic polymer is the reaction product of caprolactone, at least one monoacrylic monomer, at least one di(meth)acrylic monomer, and at least one monomethacrylic monomer, provided that the at least one monomethacrylic monomer does not exceed 30% by weight of a total reaction mixture.

5. The method of claim 2 wherein the cyclic lactone modified branched acrylic polymer comprises caprolactone grafted onto a polymer that is the reaction product of (1) a first acrylate monomer chosen from isobornyl acrylate, butyl acrylate, ethyl hexyl acrylate, cyclohexyl acrylate, and combinations thereof, and (2) a second (meth)acrylate monomer chosen from a hydroxy alkyl (meth)acrylate having 1-4 carbon atoms in the alkyl group, a (meth)acrylic monomer, a di(meth)acrylate monomer, and combinations thereof.

6. The method of claim 1 wherein the cyclic lactone modified branched acrylic polymer is the reaction product of caprolactone and at least two ethylenically unsaturated monomers, wherein at least one of the ethylenically unsaturated monomers has the hydroxyl content and the other of the ethylenically unsaturated monomers has no hydroxyl content.

7. The method of claim 1 wherein the cyclic lactone modified branched acrylic polymer is present in the basecoat composition in an amount from about 15% to about 40% by weight on binder.

8. The method of claim 1 wherein the weight average molecular weight (Mw) of the cyclic lactone modified branched acrylic polymer is from about 40,000 to about 50,000 g/mol.

9. The method of claim 1 wherein the cyclic lactone modified branched acrylic polymer has a polydispersity of from about 8 to about 15.

10. The method of claim 1 wherein the cyclic lactone modified branched acrylic polymer has a theoretical glass transition temperature (Tg) of from about 60° C. to about 70° C.

11. The method of claim 1 wherein the basecoat composition comprises a curing agent.

12. The method of claim 1 wherein an electrodeposition coated film is disposed on and in direct contact with the substrate, and the cured primer is disposed on and in direct contact with the electrodeposition coated film.

13. The method of claim 1 , wherein:
the step (B) comprises depositing the solvent-borne basecoat composition in two or more passes on the cured primer; and/or
the step (C) comprises depositing the solvent-borne clearcoat composition in two or more passes on the basecoat composition.

14. The method of claim 1 wherein the cyclic lactone modified branched acrylic polymer is the reaction product of:
(1) the reaction product of 1,6-hexanediol diacrylate; isobornyl acrylate; and
hydroxyethyl methacrylate; in the presence of t-butylperoxy acetate; and
(2) gamma-caprolactone.

15. The method of claim 14 wherein the film forming resin is an acrylic copolymer.

16. The method of claim 1 wherein the film forming resin is an acrylic copolymer.

17. The method of claim 1 wherein the multi-layer coating exhibits a strike-in of less than about 3.5 measured as a difference in Ln values and wherein the cyclic lactone modified branched acrylic polymer is the reaction product of caprolactone and at least two ethylenically unsaturated monomers, wherein at least one of the ethylenically unsaturated monomers has the hydroxyl content and the other of the ethylenically unsaturated monomers has no hydroxyl content.

18. A three coat two bake method of forming a multilayer coating on a substrate which exhibits reduced strike-in and mottling, said method comprising the steps of:
A providing the substrate comprising a solvent-borne primer disposed thereon and subsequently baking the primer to cure;
B. applying a solvent-borne basecoat composition directly on the cured primer, wherein the basecoat composition comprises a film forming resin, a pigment, and about 12.5% to about 50% by weight on binder of a cyclic lactone modified branched acrylic polymer having a hydroxyl monomer content of about 1% to about 65% by weight, and a weight average molecular weight (Mw) of about 10,000 to about 150,000 g/mol and that is a reaction product of:
(1) the reaction product of 1,6-hexanediol diacrylate; isobornyl acrylate; and

hydroxyethyl methacrylate; in the presence of t-butylperoxy acetate; and
(2) gamma-caprolactone;

C. applying a solvent-borne clearcoat composition directly on the basecoat composition in a wet on wet process, and subsequently
D. simultaneously curing the basecoat composition and the clearcoat composition by baking to form a basecoat and a clearcoat, respectively, and to form the multilayer coating on the substrate;
wherein the multilayer coating exhibits mottling of less than or equal to about 3.5 measured at 15 degrees from specular reflection,
wherein the primer is free of the cyclic lactone modified branched acrylic polymer;
wherein the primer, the basecoat composition, and the clearcoat composition are each free of a cyclic lactone modified linear acrylic polymer; and
wherein the basecoat composition is free of a branched polyester.

19. The method of claim 18 wherein the multilayer coating exhibits a smoothness of about 11.6 to about 11.7, a mottling of about 3.1 to about 3.5, and a strike-in of about 2.7 to about 3.5.

Assignees

• Axalta Coating Systems Ip Co

Inventors

• Johnson Jeffery W
• Trindade Delson J
• Huang Yongqing
• Ertem Sedef Piril

Classifications

• B32B27/30

  comprising vinyl {(co)polymers; comprising acrylic (co)polymers} · CPC title

• B05D7/532

  the two layers being cured or baked together, i.e. wet on wet · CPC title

• B32B27/36

  comprising polyesters · CPC title

• C09D5/36

  Pearl essence, e.g. coatings containing platelet-like pigments for pearl lustre · CPC title

• C08L61/28

  with melamine · CPC title