Electroconductive composite substrates coated with electrodepositable coating compositions and methods of preparing them

Patent metadata

Field	Value
Publication number	US-2015017447-A1
Application number	US-201313940943-A
Country	US
Kind code	A1
Filing date	Jul 12, 2013
Priority date	Jul 12, 2013
Publication date	Jan 15, 2015
Grant date	—

Abstract

The present invention is directed to a coated substrate comprising:
A) an electroconductive composite substrate comprising a resinous matrix reinforced with fibers, and B) a cured coating layer electrophoretically deposited on at least at least a portion of a surface of the substrate, wherein the cured coating layer is deposited from a curable, electrodepositable coating composition comprising:
(1) a resin component containing an active hydrogen-containing, cationic or anionic resin comprising an acrylic, polyester, polyurethane and/or polyepoxide polymer; and (2) a curing agent. The present invention is further directed to a process for coating a plastic, electroconductive substrate comprising electrophoretically depositing on the substrate the curable, electrodepositable coating composition described above, and heating the coated substrate to a temperature less than 250° F. for a time sufficient to cure the electrodeposited coating on the substrate.

First claim

What is claimed is:

1 . A coated substrate comprising:
A) an electroconductive composite substrate comprising a resinous matrix reinforced with fibers, and B) a cured coating layer electrophoretically deposited on at least a portion of a surface of the substrate, wherein the cured coating layer is deposited from a curable, electrodepositable coating composition comprising:
(1) a resin component containing an active hydrogen-containing, cationic or anionic resin comprising an acrylic, polyester, polyurethane and/or polyepoxide polymer; and
(2) a curing agent.

2 . The coated substrate of claim 1 , wherein the resinous matrix comprises polystyrene, polyaniline, polypyrrole, polyepoxide, poly(methyl methacrylate), polyurethane, and/or polycarbonate.

3 . The coated substrate of claim 1 , wherein the fibers are electroconductive.

4 . The coated substrate of claim 3 , wherein the fibers comprise stainless steel fibers, copper fibers, nickel fibers, silver fibers, aluminum fibers, metal plated glass fibers, and/or carbon fibers.

5 . The coated substrate of claim 3 , wherein the electroconductive composite substrate further comprises electroconductive particulate filler distributed throughout the resinous matrix and comprising one or more of zinc, ferrophosphorus, tungsten, carbon, nickel, aluminum, copper, iron, steel, molybdenum disulphide, iron oxide, antimony doped titanium dioxide, nickel-doped titanium dioxide, graphite, silver, and/or aluminum particles.

6 . The coated substrate of claim 3 , wherein the electroconductive composite substrate comprises an electroconductive coating layer deposited on the surface of the substrate.

7 . The coated substrate of claim 6 , wherein the electroconductive coating layer is deposited from (I) a composition comprising:
(a) a halogenated polyolefin; (b) a film-forming polymer different from the polyolefin (a); and (c) an electroconductive pigment; or
(II) a composition comprising:
(A) a resinous binder; and
(B) at least one electroconductive pigment dispersed in the resinous binder;
and wherein the resinous binder (A) comprises (1) a polymer containing reactive functional groups, and (2) a curing agent having functional groups reactive with the functional groups on the polymer (1).

8 . The coated substrate of claim 1 , wherein the electroconductive composite substrate further comprises electroconductive particulate filler distributed throughout the resinous matrix and comprising one or more of zinc, ferrophosphorus, tungsten, carbon, nickel, aluminum, copper, iron, steel, molybdenum disulphide, iron oxide, antimony doped titanium dioxide, nickel-doped titanium dioxide, graphite, silver, and/or aluminum particles.

9 . The coated substrate of claim 1 , wherein the electroconductive composite substrate comprises an electroconductive coating layer deposited on the surface of the substrate.

10 . The coated substrate of claim 9 , wherein the electroconductive coating layer is deposited from (I) a composition comprising:
(a) a halogenated polyolefin; (b) a film-forming polymer different from the polyolefin (a); and (c) an electroconductive pigment; or
(II) a composition comprising:
(A) a resinous binder; and
(B) at least one electroconductive pigment dispersed in the resinous binder;

and wherein the resinous binder (A) comprises (1) at least one polymer containing reactive functional groups, and (2) at least one curing agent having functional groups reactive with the functional groups on the polymer (1).

11 . A process for coating a plastic, electroconductive substrate comprising:
(a) electrophoretically depositing on the substrate a curable, electrodepositable coating composition to form an electrodeposited coating over at least a portion of the substrate, the electrodepositable coating composition comprising a resinous phase dispersed in an aqueous medium, said resinous phase comprising:
(1) a resin component containing an active hydrogen-containing, cationic or anionic resin comprising an acrylic, polyester, polyurethane and/or polyepoxide polymer; and
(2) a curing agent; and
(b) heating the coated substrate to a temperature less than 250° F. for a time sufficient to cure the electrodeposited coating on the substrate.

12 . The process of claim 11 , wherein in step (b), the coated substrate is heated to a temperature less than 225° F.

13 . The process of claim 11 , wherein the electroconductive substrate comprises a resinous matrix reinforced with fibers.

14 . The process of claim 13 , wherein the fibers are electroconductive.

15 . The process of claim 14 , wherein the electroconductive composite substrate further comprises electroconductive particulate filler distributed throughout the resinous matrix and comprising one or more of zinc, ferrophosphorus, tungsten, carbon, nickel, aluminum, copper, iron, steel, molybdenum disulphide, iron oxide, antimony doped titanium dioxide, nickel-doped titanium dioxide, graphite, silver, and/or aluminum particles.

16 . The process of claim 14 , wherein the electroconductive composite substrate comprises an electroconductive coating layer deposited on the surface of the substrate.

17 . The process of claim 16 , wherein the electroconductive coating layer is deposited from (I) a composition comprising:
(a) a halogenated polyolefin; (b) a film-forming polymer different from the polyolefin (a); and (c) an electroconductive pigment; or
(II) a composition comprising:
(A) a resinous binder; and
(B) at least one electroconductive pigment dispersed in the resinous binder;

and wherein the resinous binder (A) comprises (1) at least one polymer containing reactive functional groups, and (2) at least one curing agent having functional groups reactive with the functional groups on the polymer (1).

18 . The process of claim 11 , wherein the electroconductive composite substrate comprises electroconductive particulate filler distributed throughout the resinous matrix and comprising one or more of zinc, ferrophosphorus, tungsten, carbon, nickel, aluminum, copper, iron, steel, molybdenum disulphide, iron oxide, antimony doped titanium dioxide, nickel-doped titanium dioxide, graphite, silver, and/or aluminum particles.

19 . The process of claim 11 , wherein the electroconductive composite substrate comprises an electroconductive coating layer deposited on the surface of the substrate.

20 . The process of claim 19 , wherein the electroconductive coating layer is deposited from (I) a composition comprising:
(a) a halogenated polyolefin; (b) a film-forming polymer different from the polyolefin (a); and (c) an electroconductive pigment; or
(II) a composition comprising:
(A) a resinous binder; and
(B) at least one electroconductive pigment dispersed in the resinous binder;

and wherein the resinous binder (A) comprises (1) at least one polymer containing reactive functional groups, and (2) at least one curing agent having functional groups reactive with the functional groups on the polymer (1).

Assignees

• Ppg Ind Ohio Inc

Inventors

• Moravek Scott
• Peffer Robin M
• Mayo Michael A

Classifications

• C25D13/04 Primary

  with organic material · CPC title

• C25D13/06

  with polymers {(not used, see C09D5/44)} · CPC title

• C08J7/044

  Forming conductive coatings; Forming coatings having anti-static properties · CPC title

• C08J7/043 Primary

  Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50) · CPC title

• C08J7/042

  with two or more layers, where at least one layer of a composition contains a polymer binder · CPC title