Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/03—Powdery paints
  • C09D5/032—Powdery paints characterised by a special effect of the produced film, e.g. wrinkle, pearlescence, matt finish
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
  • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
  • B05D7/20—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wires
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/60—Additives non-macromolecular
  • C09D7/63—Additives non-macromolecular organic
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
  • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
  • H01B3/40—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes epoxy resins
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
  • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
  • H01B3/42—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
  • H01B3/421—Polyesters

Definitions

• the present disclosure relates to coating compositions, dielectric coatings formed from the coating compositions, and methods of preparing the dielectric coatings.
• the powder coating composition for preparing the dielectric coating can include: an epoxy functional polymer; a poly-carboxylic acid functional polyester polymer reactive with the epoxy functional polymer and which comprises an acid value of less than 100 mg KOH/g; and optionally a poly-carboxylic acid functional (meth)acrylate polymer reactive with the epoxy functional polymer. It is appreciated that the epoxy functional polymer, poly-carboxylic acid functional polyester polymer, and poly-carboxylic acid functional (meth)acrylate polymer can react to form a hydroxyl functional reaction product.
• the poly-carboxylic acid functional polyester polymer used in the powder coating composition described herein can have an acid value of less than 100 mg KOH/g or less than 80 mg KOH/g.
• the poly-carboxylic acid functional polyester polymer can further have an acid value of at least 20 mg KOH/g, such as at least 40 mg KOH/g, such as at least 60 mg KOH/g.
• the poly-carboxylic acid functional polyester polymer can comprise at least 20 weight %, at least 25 weight %, at least 30 weight %, at least 35 weight %, at least 40 weight %, or at least 50 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the poly-carboxylic acid functional polyester polymer can comprise up to 80 weight % or up to 70 weight % or up to 60 weight % or up to 50 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the poly-carboxylic acid functional polyester polymer can also comprise an amount of from 20 to 80 weight %, such as from 20 to 50 weight %, from 30 to 50 weight %, from 50 to 80 weight %, or from 50 to 70 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the poly-carboxylic acid functional (meth)acrylate polymer can comprise up to 10 weight %, up to 5 weight %, or up to 3 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the poly-carboxylic acid functional (meth)acrylate polymer can also comprise an amount of from 0.05 to 10 weight %, or from 0.1 to 5 weight %, or from 1 to 3 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• Non-limiting examples of suitable epoxy resins are also commercially available from NanYa Plastics under the trade name NPES-903, and from Hexion under the trade names EPONTM 2002 and EPON 2004TM.
• Other non-limiting examples of suitable epoxy functional polymers include Novolac epoxies.
• the epoxy functional polymer such as the diglycidyl ethers of bisphenol A, polyglycidyl ethers of polyhydric alcohols, polyglycidyl esters of polycarboxylic acids, can have an equivalent weight of at least 500 or at least 700.
• the epoxy functional polymer such as the diglycidyl ethers of bisphenol A, polyglycidyl ethers of polyhydric alcohols, polyglycidyl esters of polycarboxylic acids, can also comprise an equivalent weight of up to 1000 or up to 5100.
• the epoxy functional polymer such as the diglycidyl ethers of bisphenol A, polyglycidyl ethers of polyhydric alcohols.
• polyglycidyl esters of polycarboxylic acids can comprise an equivalent weight of from 500 to 5100 or from 700 to 1000.
• the epoxy functional polymer, such as the Novolac cpoxics can comprise an equivalent weight of any of the previously recited ranges or can comprise an equivalent weight of from 125 to 500, such as from 125 to 300, or from 150 to 250.
• the epoxy functional polymer, such as the Novolac epoxies can comprise an equivalent weight of at least 125, such as at least 150.
• the epoxy functional polymer, such as the Novolac epoxies can comprise an equivalent weight of up to 500, such as up to 300, or up to 250.
• equivalent weight refers to the average weight molecular weight of a resin divided by the number of functional groups.
• the equivalent weight of the epoxy functional polymer is determined by dividing the average weight molecular weight of the epoxy resin by the total number of epoxide groups and any other optional functional groups that are not an epoxide. Further, the average weight molecular weight is determined by gel permeation chromatography relative to linear polystyrene standards of 800 to 900,000 Daltons as measured with a Waters 2695 separation module with a Waters 410 differential refractometer (RI detector). Tetrahydrofuran (THF) is used as the eluent at a flow rate of 1 ml min-1, and two PLgel Mixed-C (300x7.5 mm) columns is used for separation.
• THF Tetrahydrofuran
• the epoxy functional polymer can comprise one or multiple types of epoxy functional polymers.
• the multiple epoxy functional polymers can have the same or different equivalent weights.
• a first epoxy functional polymer can have an equivalent weight that is greater than an equivalent weight of a second epoxy functional polymer.
• the epoxy functional polymers can also include additional functional groups besides the epoxy functional groups including, but not limited to, any of the previously described functional groups.
• the epoxy functional polymer can be free of any one, or all, of the previously described functional groups besides the epoxy functional groups.
• the carboxylic acid functional polymer(s) and the epoxy functional polymer of the powder coating composition may be reacted to form a reaction product comprising hydroxyl functional groups.
• the reaction product can comprise one or multiple hydroxyl groups.
• the reaction product can comprise multiple pendant hydroxyl groups and, optionally, terminal hydroxyl groups.
• the powder coating composition described herein can also comprise an isocyanate functional crosslinker that is reactive with the previously described reaction product comprising hydroxyl functional groups.
• the isocyanate crosslinker can provide additional properties including, for example, a higher crosslink density for increased chemical and abrasion resistance.
• the isocyanate functional crosslinker can include various types of polyisocyanates. Polyisocyanates that can be used include aliphatic and aromatic diisocyanates as well as higher functional polyisocyanates.
• Non-limiting examples of suitable polyisocyanates include isophorone diisocyanate (IPDI), dicyclohexylmethane 4,4'-diisocyanate (H12MDI), cyclohexyl diisocyanate (CHDI), m-tetramethylxylylene diisocyanate (m-TMXDI), p-tetramethylxylylene diisocyanate (p-TMXDI), ethylene diisocyanate, 1 ,2-diisocyanatopropane, 1,3- diisocyanatopropane, 1 ,6-diisocyanatohexane (hexamethylene diisocyanate or HDI), 1 ,4-butylene diisocyanatc, lysine diisocyanatc, 1,4-mcthylcnc bis-(cyclohcxyl isocyanate), toluene diisocyanatc (TDI), m-x
• the isocyanate functional crosslinker can comprise at least 0.1 weight %, at least 1 weight %, or at least 3 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the isocyanate functional crosslinker can comprise up to 10 weight %, up to 8 weight %, or up to 5 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the isocyanate functional crosslinker can also comprise an amount of from 0.1 to 10 weight %, or from 1 to 8 weight %, or from 3 to 5 weight % of the powder coating composition, based on the total resin solids weight of the powder coating composition.
• the powder coating composition can also include additional materials.
• materials that can be used with the powder coating compositions described herein include plasticizers, anti-oxidants, flow and surface control agents as such waxes (e.g., amide waxes), thixotropic agents, slip aids, catalysts such as metal catalysts (e.g., tin catalysts), antigassing agents such as benzoin, reaction inhibitors, texturizers, and other customary auxiliaries.
• a powder coating composition is completely free of ammonium salt, phosphonium salt, and imidazole curing catalysts if ammonium salt, phosphonium salt, and imidazole curing catalysts are not present in the powder coating composition.
• Example colorants include pigments (organic or inorganic), dyes, and tints, such as those used in the paint industry and/or listed in the Dry Color Manufacturers Association (DCMA), as well as special effect compositions.
• a colorant may include, for example, a finely divided solid powder that is insoluble, but wettable, under the conditions of use.
• a colorant can be organic or inorganic and can be agglomerated or non-agglomerated.
• the coating composition can be substantially free, essentially free, or completely free of a colorant such as a pigment.
• substantially free of a colorant means that the coating composition contains less than 1000 parts per million by weight (ppm) of a colorant based on the total solids weight of the composition, “essentially free of a colorant” means that the coating composition contains less than 100 ppm of a colorant based on the total solids weight of the composition, and “completely free of a colorant” means that the coating composition contains less than 20 pails per billion by weight (ppb) of a colorant based on the total solids weight of the composition.
• the homogenous mixture can be melt mixed in a twin screw extruder with zones set to a temperature of 75°C to 125°C, such as from 85°C to 115°C or at 100°C. [0049] After melt mixing, the mixture is cooled and re-solidified. The re-solidified mixture is then ground such as in a milling process to form a solid particulate curable powder coating composition. The re-solidified mixture can be ground to any desired particle size.
• the coating composition described herein can be applied to a wide range of substrates known in the coatings industry.
• the coating compositions described herein can be applied to automotive substrates, industrial substrates, aerocraft and aerocraft components, marine substrates and components, packaging substrates, electronics, architectural substrates, and the like.
• Specific non-limiting substrates include cars, trucks, ships, vessels, on-shore and offshore installations, storage tanks, windmills, power industry substrates such as nuclear plants, power wires, batteries and battery components, bus bars, metal wires, copper or aluminum conductors, wood flooring and furniture, apparel, housings and circuit boards, glass and transparencies, sports equipment, including golf balls, stadiums, buildings, bridges, and the like.
• Non-metallic substrates include polymeric, plastic, polyester, polyolefin, polyamide, cellulosic, polystyrene, polyacrylic, poly(ethylene naphthalate), polypropylene, polyethylene, nylon, EVOH, polylactic acid, other “green” polymeric substrates, poly(ethyleneterephthalate) (PET), polycarbonate, polycarbonate acrylobutadiene styrene (PC/ABS), polyamide, wood, veneer, wood composite, particle board, medium density fiberboard, cement, stone, glass, paper, cardboard, textiles, leather both synthetic and natural, and the like.
• the coating compositions described herein are particularly beneficial when applied directly to a metallic substrate or a pretreated metallic substrate to form dielectric coatings that provide insulating properties.
• the powder coating composition described herein is cured with infrared radiation to heat the composition from 300°F to 55O°F for 1 to 20 minutes, or from 35O°F to 525°F for 2 to 10 minutes, or from 370°F to 515°F for 5 to 8 minutes.
• the powder coating composition described herein can be cured with multiple types of heat sources such as both convection heating and infrared radiation.
• the powder coating composition described herein can be partially cured with convection heating or infrared radiation, and then completely cured with a different heat source chosen from convection heating and infrared radiation.
• each of the coatings prepared from the compositions were evaluated for dielectric strength, as measured by a Sefelec Dielectrimeter RMG12AC-DC and in accordance with ASTM D 149-09 Hipot test.
• the parameters of the testing were as follows: Voltage limit: 12 kV DC, I m ax Limit: 4.0 mA. 3 seconds ramp, 1 second dwell, 2 second fall.
• the results of the Hipot test are shown in Table 2.
• a curable powder coating composition prepared in Example 1 was applied by electrostatic spray onto aluminum substrates (Q-PANEL aluminum panels having a size of 4 inches by 12 inches with a thickness of 0.64 mm or 0.81 mm). During application, a first layer of 5 mils was applied and then gelled with a shortwave IR oven at 315°F-345°F for 2 minutes. A second layer of 5 mils was then applied and then a full bake with a shortwave IR oven at 415°F- 515°F for 5 minutes.
• the coating prepared from the composition was evaluated for dielectric strength, as measured by a Sefelec Dielectrimeter RMG12AC-DC and in accordance with ASTM D149-09 Hipot test.
• the parameters of the testing were as follows: Voltage limit: 12 kV DC, I m x Limit: 4.0 mA, 3 seconds ramp, 1 second dwell, 2 second fall.
• the results of the Hipot test are shown in Table 3.
• the chips were milled in a Strand mill to obtain a particle size of predominantly 5 to 100 microns with a majority of the particles being from 20 to 60 microns by volume.
• the resulting coating compositions for each of Examples 9-19 were solid particulate powder coating compositions that were free flowing.
• Table 4 1 An O-cresol Novolac type epoxy resin, available from Teda Golone Chemical (Tianjin, China)
• each of the coatings prepared from the compositions of Examples 9-19 were evaluated for dielectric strength, as measured by a Sefelec Dielectric Strength Tester RMG12AC-DC and in accordance with ASTM D 149-09 Dielectric Breakdown Voltage and Dielectric Strength test.
• the parameters of the testing were as follows: Voltage limit 12.0 kV DC, I m ax Limit: 0.5 mA, 20 second ramp, 20 second dwell, and 2 second fall.
• the results of the dielectric strength test are reported in Tables 4-5.
• each of the coatings in Examples 9-19 had a good dielectric strength at a low film thickness.

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• 2023
  • 2023-10-04 CN CN202380068470.9A patent/CN119948117A/zh active Pending
  • 2023-10-04 JP JP2025519634A patent/JP2025535712A/ja active Pending
  • 2023-10-04 WO PCT/US2023/075950 patent/WO2024077067A1/en not_active Ceased
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