KR20210114043A - Systems for electrocoating conductive substrates - Google Patents

Abstract

The present invention includes a tank comprising at least one sidewall and configured to hold an electrodepositable coating composition for receiving a substrate to be coated, and a movable electrode positioned within the tank, wherein the movable electrode does not extend through the sidewall. , to an electrocoating system. Also disclosed herein are methods of coating substrates, systems for coating substrates, and coated substrates.

Description

Systems for electrocoating conductive substrates

The present invention relates to an electrocoating system for electrocoating a substrate. The present invention also relates to a system for coating a substrate, a method for coating a substrate, and a coated substrate.

Electrodeposition as a coating application method involves depositing a film-forming composition on a conductive substrate under the influence of an applied potential. Electrodeposition is gaining popularity in the coating industry because it offers higher coating utilization, superior corrosion resistance and lower environmental pollution compared to non-electrophoretic coating methods. However, some conductive substrates are more difficult to coat by electrodeposition due to several factors including the shape and size of the substrate. For example, it can be difficult to coat the inner and outer surfaces of a substrate having an open pocket shape, such as a container or pipe, using conventional electrocoating systems. Accordingly, there is a need for an electrocoating system capable of coating a wide range of substrates.

An electrocoating system comprising: a tank comprising one or more sidewalls, the tank configured to hold an electrodepositable coating composition for receiving a substrate to be coated, and a movable electrode positioned within the tank, the movable electrode not extending through the sidewall This is disclosed herein.

Also disclosed herein is a method of coating a substrate comprising the step of electrophoretically applying an electrodepositable coating composition to at least a portion of the substrate using the electrocoating system of the present invention. The method comprises the steps of placing a substrate in a tank, wherein the surface of the substrate to be coated is immersed in an electrodepositable coating composition held in the tank; positioning the movable electrode; electrically coupling the movable electrode and the substrate to opposite poles of the power source; and then applying an electric current from the power source to electrodeposit the electrodepositable coating composition on the surface of the substrate.

Substrates coated by the method of the present invention are further disclosed herein.

A pretreatment system comprising the electrocoating system of the present invention for pretreating a substrate prior to treating the substrate in the electrocoating system; a primer system for applying a primer to the substrate prior to treating the substrate in the electrocoating system; and/or a topcoat system for applying a topcoat coating to the substrate after treating the substrate in the electrocoating system.

1A and 1B are top views of an exemplary electrocoating system of the present invention with a movable electrode in a first position in FIG. 1A and a movable electrode in a second position in FIG. 1B; 1C and 1D are side views of an exemplary electrocoating system of the present invention with a movable electrode in a first position in FIG. 1C and a movable electrode in a second position in FIG. 1D.
2A is an illustration of an exemplary electrocoating system of the present invention with an expandable electrode in a first state in a tank with a substrate to be coated. 2B is an illustration of the exemplary electrocoating system of FIG. 2A with the expandable electrode in an expanded state.
3A is a perspective view of an exemplary electrocoating system of the present invention with an expandable electrode present in a tank in a first state; 3A shows a first device having an arm connected to an expandable electrode, and two legs positioned along a set of rails running along either side of the bottom of the tank, and a second device connected to another compartment of the expandable electrode; It further shows a second device also having two arms and two legs positioned along a second set of rails running along both sides of the bottom of the tank. 3B is a top view of the exemplary electrocoating system shown in FIG. 3A , and FIG. 3C is a side view of the exemplary electrocoating system shown in FIG. 3A .
4A is a perspective view of an exemplary electrocoating system of the present invention with the expandable electrode in a partially expanded state. 4B is a top view of the exemplary electrocoating system shown in FIG. 4A , and FIG. 4C is a side view of the exemplary electrocoating system shown in FIG. 4A .
5A is a perspective view of an exemplary electrocoating system of the present invention with the expandable electrode in a fully expanded state. 5B is a top view of the exemplary electrocoating system shown in FIG. 5A , and FIG. 5C is a side view of the exemplary electrocoating system shown in FIG. 5A .
6A is a perspective view of an exemplary electrocoating system of the present invention with an expandable electrode fully wound around a reel and a substrate in a tank. 6B is a perspective view showing an expandable electrode partially inserted through a substrate, wherein the dashed line indicates that the expandable electrode is within the substrate. 6C is a perspective view showing the expandable electrode fully extended through the substrate and secured to the sidewall using anchors, the dashed line indicating that the expandable electrode is within the substrate.
6D is a perspective view of an exemplary expandable electrode with spacers. 5E is an inline view of an exemplary expandable electrode with spacers.
6F is a perspective view of an exemplary electrocoating system of the present invention in which expandable electrodes with spacers are positioned within a substrate residing in a tank.
7A is an illustration of an exemplary electrocoating system of the present invention with an expandable electrode positioned at the bottom of a tank with a substrate to be coated in a first state. 7B is an illustration of the exemplary electrocoating system of FIG. 7A with the expandable electrode in a partially expanded state. 7C is an illustration of the exemplary electrocoating system of FIG. 7A with the expandable electrode in a fully expanded state.

The present invention relates to an electrocoating system for electrocoating a substrate. This specification also discloses a system for coating a substrate, a method of coating a substrate, a substrate coated according to one or more methods described herein, and/or using one or more systems described herein.

electrocoating system

1A and 1B , the present invention includes a tank comprising at least one sidewall 120 and configured to hold an electrodepositable coating composition 900 for receiving a substrate 1000 to be coated. (100) and a movable electrode (200) positioned within the tank (100), wherein the movable electrode (200) does not extend through the sidewall (120). As used herein, the term “movable electrode” refers to an electrode configured to change its position and/or orientation within a tank. The movement may be the actual movement of the movable electrode 200 or may be due to a change in the configuration of the movable electrode 200 . For example, the movable electrode 200 may include an expandable electrode 200 as discussed in more detail below. Alternatively, the movable electrode 200 may comprise means 300 for positioning the movable electrode within the tank, and the means for positioning 300 may move the movable electrode.

According to the present invention and as shown in the figures, the tank 100 is configured to hold the electrodepositable coating composition 900 . Tank 100 may contain any material known in the art. For example, tank 100 may include plastic, metal with an insulating liner, eg, metal with an inner plastic or fiberglass liner, or metal with an insulating coating. Tank 100 may include any geometric shape. For example, tank 100 may be generally rectangular or generally round or spherical. The tank 100 has a bottom 110 and four sidewalls, such as in the illustrated exemplary rectangular configuration extending upwardly from the bottom 110, to form a cavity in which the electrodepositable coating composition 900 can be retained. The same at least one side wall 120 may be included.

The movable electrode 200 may include any suitable conductive material known in the art, and the movable electrode 200 may include both conductive and non-conductive materials. For example, the movable electrode 200 may include ruthenium oxide as well as any other material described herein that may comprise a substrate. The movable electrode 200 may optionally include or be made of a non-porous material. The term "non-porous" as used herein generally refers to a material that is not permeable to fluids such as water or air.

The movable electrode 200 may have any cross-sectional shape. For example, the movable electrode 200 may have any polygonal shape, such as a triangular, square, rectangular, pentagonal, flat, C-shaped, sector-shaped, annular shape, as well as a generally round shape, for example, a circular or elliptical cross-section. It may have a tubular movable electrode having a shape. The cross-sectional shape of the movable electrode 200 may be determined by, for example, the surface area of the substrate 1000 to be electrocoated, the relative surface area of the movable electrode 200 to the surface area of the substrate 1000 to be coated, the movable electrode during electrocoating. The selection may be based on a number of factors, such as the distance between 200 and the substrate 1000 , and the shape of the substrate 1000 .

The cross-sectional area of the movable electrode 200 is not particularly limited, and may depend on and/or be proportional to the size of the substrate 1000 to be coated. For example, a substrate having a large cross-sectional area may require a movable electrode 200 having a larger cross-sectional area. In addition, the cross-sectional shape of the movable electrode 200 may be selected based on the shape of the substrate 1000 to be coated. For example, the movable electrode 200 may have a cross-sectional shape that mirrors the cross-sectional shape of the substrate 1000 to be coated. Further, the cross-sectional area of the movable electrode 200 may be formed such that the outer surface of the movable electrode 200 is within 4 feet of the surface of the substrate 1000 to be coated. For example, an exemplary movable electrode 200 having a square cross-sectional shape and a cross-sectional area of at least 19.01 ft ² (1.77 m ² ) is an exemplary substrate 1000 having a ^{square cross-sectional shape and a cross-sectional area of 100 ft 2} (9.29 m ^{2 ).} ) can be used to coat

The leading (or trailing) edge of the movable electrode 200 may optionally include one or more protrusions extending from the leading edge of the movable electrode 200 . Projections such as corners or complex geometries of a square or rectangular substrate 1000 may extend more difficult to reach the portion of substrate 1000 to be coated. This may improve the charge density of the electrodepositable coating composition 900 at these corners and improve the charge density of the electrodepositable coating composition 900 at these corners.

The movable electrode 200 may be configured such that there is no point in contact with the substrate 1000 to be coated. As used herein, the term “point of contact” with respect to the movable electrode 200 and the substrate 1000 is intended to be filled with the electrodepositable coating composition 900 between the substrate 1000 and the movable electrode 200 . It means that there is a physical contact between the movable electrode 200 and the substrate 1000 so that there is a void that can exist. The term "point of contact" explicitly excludes electrical communication between components.

The movable electrode 200 may be positioned in the tank 100 such that the entire movable electrode 200 is submerged in the electrodepositable coating composition 900 when the tank 100 is at least partially filled. The movable electrode 200 may be configured such that the movable electrode 200 does not penetrate the bottom 110 or the sidewall 120 of the tank 100 . As used herein, the term “penetration” in reference to the bottom 100 or sidewall 120 of the tank 100 is a movable electrode ( 200 ) does not extend through any opening located in the bottom 110 or the sidewall 120 of the tank 100 .

The movable electrode 200 includes a surface, and the surface may be essentially free of an electrocatalyst. As used herein, the term "electrocatalyst" refers to those used in electrochemical ozone generating systems, such as, for example, lead dioxide.

1 and 2 , the means 300 for positioning the movable electrode 200 inside the tank 100 comprises one or more device(s) 310 positioned outside the tank 100 . The device(s) 310 may include an arm coupled to the movable electrode 200 and configured to position the movable electrode 200 within the tank 100 . The device 310 may have any configuration and may be positioned anywhere outside the tank 100 , as long as the arm is configured to extend into the tank 100 to position the movable electrode 200 . For example, as shown in FIGS. 1A and 1B , the device 310 may include a cart 330 , wherein the cart 330 moves laterally on a rail 350 with respect to the tank 100 . It may be located on the at least one rail 350 to move to. The rail 350 may be located above, next to, or below the tank 100 . For example, in FIGS. 1A and 1B , two rails 350 are positioned on top of opposing sidewalls 120 of tank 100 , each rail 350 and 370 on either side of device 310 . Supports the connected cart (330). The means 300 for positioning the movable electrode 200 in FIGS. 1A and 1B removes the movable electrode 200 from the first position ( FIG. 1A ) by moving the cart 330 along the rail 350 . Move to position 2 (FIG. 1B). The positioning means 300 may include any means known in the art, such as, for example, a rack and pinion, a pneumatic press, a hydraulic press, a chain, or the like, or a combination thereof. The means 300 for positioning the movable electrode 200 may further include means for moving the movable electrode in a direction perpendicular to the tank (not shown). Means for moving in the vertical direction may include any means known in the art, such as, for example, racks and pinions, pneumatic presses, hydraulic presses, chains, etc., or combinations thereof.

The electrocoating system 10 may include means (not shown) for positioning and/or rotating the substrate 1000 . Means for positioning and/or rotating the substrate 1000 may position the substrate 1000 within the tank 100 . Means for positioning and/or rotating the substrate 1000 are captured in the substrate 1000 such that all or substantially all of the surface of the substrate 1000 is in contact with the electrodepositable coating composition 900 contained within the tank 100 . The substrate 1000 may be further rotated and rotated along its length so that the exhausted air escapes. The rotation may be, for example, about 5° with respect to the major axis along the length of the substrate 1000 , for example, about 15° rotation about the major axis along the length of the substrate 1000 . Rotation and/or rotation of the substrate 1000 may occur prior to or during operation of the electrocoating system 10 . In addition, the movable electrode 200 prevents rotation of the substrate 1000 during operation of the electrocoating system 10 to ensure that the movable electrode 200 maintains a constant distance from the surface of the substrate 1000 during operation. It can be configured to mirror.

The means for positioning and/or rotating the substrate 1000 may include a roll over dip (or RoDip) system, wherein the substrate 1000 is positioned on a conveyor above the tank 100 and the conveyor is The substrate 1000 may be immersed (ie, immersed) in the electrodepositable coating composition 900 held within the tank 100 of the electrocoating system 10 by rotating 1000 . The movable electrode 200 can be moved into position while the conveyor rotates the substrate 1000 , and the electrocoating system 10 can optionally be operated with the substrate 1000 being rotated by the RoDip system. Also, the movable electrode 200 may be selectively rotated.

As discussed above, the movable electrode 200 may include an expandable electrode 200 . As shown in FIGS. 2A and 2B for illustrative purposes, the present invention provides a tank 100 configured to hold an electrodepositable coating composition 900 for receiving a substrate 1000 to be coated, and positioned within the tank 100 . It relates to an electrocoating system (10) comprising an expandable electrode (200). The expandable electrode 200 is configured to expand from the first state ( FIG. 2A ) to the expanded state ( FIG. 2B ).

According to the present invention and as shown in FIGS. 2A and 2B , the electrocoating system 10 further includes an expandable electrode 200 positioned within the tank 100 . The expandable electrode 200 may be configured to expand from the first state shown in FIG. 2A to the expanded state shown in FIG. 2B . As used herein, the term “expandable electrode” refers to an electrode having a dimension that can be non-destructively increased in at least one spatial direction. As used herein, terms such as “extend,” “expand,” “extendable,” and the like, refer to an increase in the dimension of a body in at least one spatial direction and refer to a structure (eg, a telescoping mechanism). or a body that increases in length through a change in unwinding mechanism). The term "expandable electrode" does not include a single material that can expand upon application of an external energy force, for example a metal that expands upon application of heat. The configuration of the expandable electrode is not limited as long as the expandable electrode is configured to be extended in length. Some or substantially all of the expandable electrode 200 may include a material that expands by changing the composition of the material, such as, for example, a telescoping section, an accordion-like section, a spring-like section, and the like. Alternatively, the expandable electrode 200 may be rolled and unwound in the tank 100 in a first state, for example, to extend the length of the expandable electrode 200 to an expanded state and similar structures. may comprise a flexible material that may have an extended position within the tank 100 without changing the length of the expandable electrode material itself, such as, for example, in a rope or hose-like configuration.

The expandable electrode may also include a combination of the mechanisms described above including a combination of a telescoping section, an accordion-shaped section, a spring-like section, and a flexible material. Although the expansion of the expandable electrode 200 may be along a generally linear path as in FIGS. 2A and 2B , it is within the scope of the present invention to extend along a non-linear path as well as a branching of the expandable electrode. For example, the expandable electrode 200 may extend in a generally linear path, with multiple branches extending outward from the direction of extension of a major portion of the expandable electrode 200 , for example from a generally vertical direction. can be Alternatively, the expandable electrode may be bifurcated in two or more directions, such as in a fork configuration.

2A and 2B , the expandable electrode 200 may include a stretchable electrode 210 . The telescoping electrode 210 may include a telescoping section 220 that may be nested together when the expandable electrode 200 is not fully expanded. The telescoping compartment 220 may include some or all of the telescoping electrode 210 . Each of the telescoping sections 220 of the telescoping electrode 210 may have a substantially uniform extended length X, the telescoping section 220 increasing the length of the telescoping electrode 210 by at most nX−X. extendable, where n is an integer greater than 1 and equals the total number of telescoping sections 220 . As used herein, the term “extended length” with respect to the telescoping section 220 refers to the maximum amount by which an additional telescoping section 220 can increase the length of the telescoping electrode 210 . The maximum extended length of the stretchable electrode 210 is nX, but the actual extended length can be any length up to nX and greater than X depending on the desired application and the substrate 1000 to be coated by the electrocoating system 10 . . Expanding the telescoping electrodes 210 may include expanding the telescoping sections 220 one at a time such that one telescoping section 220 is not “un-nested” at a time. and the telescoping sections 220 can be moved all at once so that each telescoping section 220 remains partially fitted at the extended length, or a combination of the two can be implemented.

The expandable electrode 200 may be positioned completely fixed within the tank such that the entire expandable electrode 200 is immersed in the electrodepositable coating composition 900 . Expandable electrode 200, as used herein, means that expandable electrode 200 is attached to a portion of tank 100 without additional structures located outside tank 100 to support positioning of expandable electrode 200. When fixed, it is in a completely fixed position within the tank 100 . For example, as shown in FIGS. 2A and 2B , the expandable electrode 200 may be fixedly positioned on the sidewall 120 of the tank 100 and may be extended in a direction away from the sidewall 120 . . Alternatively, as shown in FIGS. 7A , 7B and 7C , the expandable electrode 200 may be positioned at the bottom 110 of the tank 100 and be expanded in a direction away from the bottom 110 . can The configuration of the expandable electrode 200 may vary depending on the application and the substrate 1000 to be coated by the electrocoating system 10 .

According to the present invention, the electrocoating system 10 may comprise means 300 for positioning the expandable electrode 200 within the tank 100 . The means 300 for positioning the expandable electrode 200 within the tank 100 generally includes a support structure connected to the expandable electrode 200 to provide support positioned at least partially external to the tank 100 . refers to As used herein, the term “at least partially external to the tank” in the context of a structure refers to a structure that is not immersed in the electrodepositable coating composition 900 when the tank 100 is filled to a maximum water level. The means 300 for positioning the expandable electrode 200 within the tank 100 may include one or more device(s) 310 positioned external to the tank 100 , the device(s) 310 . may include an arm connected to the expandable electrode 200 and configured to position the expandable electrode 200 within the tank 100 . Device 310 may have any configuration and may be positioned anywhere outside of tank 100 , as long as the arms extend into tank 100 and are configured to position expandable electrodes 200 . For example, as shown in Figures 3A, 3B, 3C, 4A, 4B, 4C, 5A, 5B, and 5C (collectively “Figures 3-5”), the device ( 310 may include a cart 330 , which may be positioned on at least one rail 350 such that the cart may move laterally on the rail 350 with respect to the tank 100 . . The rail 350 may be located above, next to, or below the tank 100 . For example, in FIGS. 3-5 , two rails 350 and 370 are located at the bottom of opposite sidewalls 120 of tank 100 , respectively, rails 350 and 370 are carts 330 and 340 . ) supports one of the two legs 380 of one cart. The means for positioning the expandable electrode 200 within the tank 100 may also function to at least partially or fully expand the expandable electrode 200 . For example, in FIGS. 3-5 , first cart 330 and second cart 340 are configured to position expandable electrode 200 within tank 100 . 3-5 , the first cart 330 and the second cart 340 each include an arm 320 , the arm 320 of the first cart 330 being the end of the expandable electrode 200 . and the arm 320 of the second cart 340 is attached to the telescoping compartment 220 of the expandable electrode 200 . 3A, 3B and 3C show a perspective view, a top view and a side view, respectively, of a first cart 330 and a second cart 340 positioned in a first (starting) state. 4A , 4B and 4C show a perspective, top view and side view, respectively, of an expandable electrode 200 in a partially expanded state, wherein the second cart 340 is displaced laterally from the first cart 330 . moving away from the , and the expandable electrode 200 is positioned further into the tank 100 compared to the first state. Expanding the expandable electrode 200 into the tank may be caused at least partially or completely by the movement of the second cart 340 when the second cart 340 increases the length of the expandable electrode 200 . . 5A , 5B and 5C show a first cart 330 laterally moved toward a second cart 340 to position the expandable electrode 200 in a more fully expanded state into the tank 100 . A perspective view, a top view and a side view are shown respectively. The means 300 for positioning the expandable electrode 200 may further include means for moving the expandable electrode in a vertical direction relative to the tank (not shown). Means for moving in the vertical direction may include any means known in the art, such as, for example, racks and pinions, pneumatic presses, hydraulic presses, chains, etc., or combinations thereof.

According to the present invention, the electrocoating system 10 may further comprise means 400 for expanding the expandable electrode 200 . The means 400 for expanding the expandable electrode 200 may include any suitable means known in the art. For example, as described above, the expanding means 400 moves the expandable electrode 200 to the expanded state, ie, increases the length of the expandable electrode 200 outside the tank 100 . a positioned device 310 . The means 400 for expanding the expandable electrode 200 to the expanded state may alternatively comprise a drive means, the drive means being a rack and pinion, a pneumatic press, a hydraulic press, a chain, etc., or a combination thereof. may include Such means 400 for expanding the expandable electrode 200 may be used with any suitable configuration of the expandable electrode 200 , such as, for example, a telescoping electrode, an electrode having an accordion-like shape, and the like. The means 400 for expanding the expandable electrode 200 to the expanded state may further include a plurality of means for expanding the expandable electrode 200 . For example, the means 400 for expanding the expandable electrode 200 is a device 310 located outside the tank 100 that moves the expandable electrode 200 to a partially expanded state as described above. may comprise, wherein the electrocoating system 10 comprises additional means 500 for expanding the expandable electrode 200 , for example expanding the expandable electrode 200 to a further or fully expanded state. , racks and pinions, pneumatic presses, hydraulic presses, etc. or combinations thereof.

The means 400 for expanding the expandable electrode 200 may further comprise means for moving the flexible material within the tank. For example, the flexible material may be connected to an extendable arm that may extend the material of the expandable electrode 200 in the tank 100 . Alternatively, the flexible material may be connected to a runner that allows the flexible material of the expandable electrode 200 to be transported into the tank 100 . The flexible material of the expandable electrode 200 is held taut in the tank 100 by any suitable means including, for example, attaching to an anchor (not shown) present on the opposite sidewall 120 of the tank. can be The flexible material of the expandable electrode 200 may be particularly suitable for coating elongated hollow substrates such as, for example, pipes. The flexible material of the expandable electrode 200 may be connected through the length of the pipe and secured to an anchor to hold the expandable electrode 200 at a taut, generally uniform distance from the inner surface of the pipe. In this configuration, as shown in FIGS. 6A, 6B, 6C, and 6F, the expandable electrode 200 can be on a reel 210 positioned inside the tank 100, and the expandable electrode ( 200 may be unwound from the reel 210 and extend through the hollow substrate 1000 . An anchor 220 may be positioned on the sidewall 120 of the tank 100 to secure the expandable electrode 200 in place.

The electrocoating system 10 may further comprise means 600 for retracting the expandable electrode 200 . Any suitable means 600 for retracting the expandable electrode may be used. For example, the means 600 for retracting the expandable electrode 200 may reverse the motion of the means 400 for expanding the expandable electrode 200 , for example reversing the direction of the force of the driving means. may include making In another example, as shown in FIGS. 3-5 , the means 600 for retracting the expandable electrode 200 is a return applying force to at least partially reduce the expansion of the expandable electrode 200 . It may include a chain 610 .

As noted above, the expandable electrode 200 may comprise a flexible material that may have an extended position within the tank 100 without changing the length of the expandable electrode material. In this configuration, as shown in FIGS. 6A , 6B , 6C and 6F , the means 600 for retracting the expandable electrode 200 is a reel 210 for retracting the expandable electrode 200 . It may include a mechanism such as winding the

Retracting the expandable electrode 200 means that when the expandable electrode 200 moves past a portion of the substrate 1000, the expandable electrode 200 applies a charge to a portion of the substrate 1000 and the electrodepositable coating composition ( 900) can occur during electrodeposition.

6D and 6E , the expandable electrode 200 may optionally include a spacer 230 positioned on the expandable electrode 200 . The spacer 230 may be sized and configured in such a way that the expandable electrode 200 is maintained at a constant distance from the inner surface of the substrate 1000 . For example, if substrate 1000 is a round pipe, spacers 230 contact the interior surface of substrate 1000 to hold expandable electrodes equidistant from each portion of the cross-section of the interior surface of substrate 1000 . something to do. 6D, 6E, and 6F, the charged portion 250 of the expandable electrode 200 is charged as the charged portion 250 of the expandable electrode 200 passes through the substrate during electrodeposition. may be positioned at the distal end of the expandable electrode 200 behind the spacer 230 to be applied to the portion of the substrate 1000 . The charged portion 250 of the expandable electrode 200 is formed by the spacer 230 moving past the compartment of the substrate 1000 , and then the charged portion 250 providing electric charge to the portion of the substrate 1000 . It may optionally be positioned behind the spacer 230 to allow electrodeposition of the electrodepositable coating composition 900 . This configuration can prevent the creation of defects in the applied coating while the spacer 230 moves through the first surface 1010 of the substrate 1000 and comes into contact with the first surface.

The electrocoating system 10 may further comprise means 700 for balancing the movable electrode 200 . Any suitable means 700 for balancing may be used. For example, the means for balancing 700 may include mechanical means 700 for balancing the movable electrode 200, such as the spacers 230 described herein, as well as the transferable coating composition 900 . It may include one or more air sacs or low-density materials, such as foam, attached to or located within the body of the movable electrode 200, possibly increasing the buoyancy of the electrode 200. Means 700 for balancing the movable electrode 200 are located on the substrate 1000 , which may result from the length of the movable electrode 200 including the length of the expandable electrode 200 in the expanded state. This is to prevent the movable electrode 200 from sagging. Balancing helps ensure a uniform distance between the surface of the substrate 1000 and the outer surface of the movable electrode 200 so that the substrate 1000 is coated substantially uniformly. Accordingly, the means for balancing 700 improves the uniformity of the charge density of the electrodepositable coating composition 900 during electrocoating, and may result from contact of the movable electrode 200 with the substrate to be coated 1000 . It can help eliminate possible arcs.

The tank 100 is further configured to at least partially contain a substrate 1000 for electrocoating by the electrocoating system 10 . Substrate 1000 may be a grounded electrical conductor and may generally be comprised substantially of a conductive material, such as, for example, a metallic material. The substrate 1000 serves as a counter electrode in electrical communication with the stationary electrode(s) 800 (if present) and the movable electrode(s) 200 . The substrate 1000 may include any cross-sectional shape, or may include a plurality of cross-sectional shapes when the substrate 1000 does not have a uniform cross-sectional shape. The substrate may comprise any dimension. The substrate 1000 may include an open polygonal cross-sectional shape, such as an open-pocket cross-sectional shape. The cross-sectional shape may include a generally rectangular or generally round cross-sectional shape. The substrate may include a first surface 1010 and a second surface 1020 . The first surface 1010 may include the inner surface of the substrate 1000 , and the second surface 1020 may include the outer surface of the substrate 1000 . For example, as shown in FIGS. 2A and 2B , when the substrate 1000 has a generally rectangular cross-sectional shape, the first surface 1010 may include the inner surface of the substrate 1000, and 2 Surface 1020 may include the outer surface of substrate 1000 . Substrate 1000 may include a container, such as an intermodal container, for example. For example, the substrate 1000 may be between 8 feet (2.44 m) and 53 feet (16.15 m), such as about 8 feet (2.44 m), 10 feet (3.05 m), 20 feet (6.10 m), 40 an external length of feet (12.19 m), 45 feet (13.72 m), or approximately 53 feet (16.15 m); an exterior width of about 7 feet (2.13 m) to about 8 feet (2.44 m), eg, 7 feet (2.13 m) or 8 feet (2.44 m); and about 7.5 feet (2.29 m) to about 9.5 feet (2.90 m), for example, 7.5 feet (2.29 m), 8.5 feet (2.59 m), or 9.5 feet (2.90 m). The substrate 1000 may be at least 8 feet (2.44 m), such as at least 10 feet (3.05 m), such as at least 20 feet (6.10 m), such as at least 40 feet (12.19 m), such as For example, it may have a length of at least 45 feet (13.72 m) or, for example, at least 53 feet (16.15 m).

The first surface 1010 of the substrate 1000 may have a surface area that varies based on the length of the substrate 1000 . The first surface 1010 of the substrate 1000 is at least 285ft ² (26.48m ^2), for example, at least 340ft ² (31.59m ^2), for example, at least 600ft ² (55.74m ^2), for example the , at least 1,145 ft ² (106.37 m ² ), such as at least 1,275 ft ² (118.45 m ² ), such as at least 1,490 ft ² (138.43 m ² ). The first surface 1010 of the substrate 1000 can have more than 285ft ² (26.48m ²⁾ to 1,890ft ² (175.59m ²⁾ surface area. The surface area in relation to the container may vary along the length of the substrate 1000 . For the first surface of the example, eight feet substrate 1000. The first surface 1010 285ft ² (26.48m ²⁾ to 400ft ² may have a surface area (37.16m ^2), 10 piteu base 1000 of 1010 340ft ² (31.59m ²⁾ to 460ft ² (42.74m ²⁾ the first surface 1010 of the can have a specific surface area, 20 feet base 1000 of the 600ft ² (55.74m ²⁾ to 795ft ² (73.86 m ² ), and the first surface 1010 of the 40 foot substrate 1000 can have a surface area of ^{1,145 ft 2} (106.37 m ² ) to 1,460 ft ² (135.64 m ² ), 45 ft first surface 1010 of the substrate 1000 is 1,275ft ² (118.45m ²⁾ 1,620ft ² to the first surface (1010 (150.50m ²⁾ have a surface area, and 53 feet base 1000 of ) may have a surface area of 1,490ft ² (138.43m ²⁾ to 1,890ft ² (175.59m ^2).

The second surface 1020 of the substrate 1000 may have a surface area that varies based on the length of the substrate 1000 . The second surface 1020 of the substrate 1000 is, for at least such as at least ^{330ft 2 (30.66m 2), 380ft} 2 (35.30m 2), for example, at least 675ft ² (62.71m ^2), for example, have a surface area of at least 1,250 ft ² (116.13 m ² ), such as at least 1,390 ft ² (129.14 m ² ), such as at least 1,630 ft ² (151.43 m ^{2 ).} The second surface 1020 of the substrate 1000 may have a 330ft ² (30.66m ²⁾ to 1,750ft ² (162.58m ²⁾ more surface area. The surface area in relation to the container may vary along the length of the substrate 1000 . For example, the second surface 8 of the foot base 1000, second surface 1020 is 330ft ² (30.66m ²⁾ to 440ft ² (40.88m ²⁾ may have a surface area of more than 10 feet base 1000 of 1020 380ft ² (35.30m ²⁾ to 520ft ² (48.31m ²⁾ a second surface 1020 of may have a specific surface area, 20 feet base 1000 of the 675ft ² (62.71m ²⁾ to 865ft ² (80.36 m ² ), the second surface 1020 of the 40 foot substrate 1000 can have a surface area of ^{1250 ft 2} (116.13 m ² ) to 1,575 ft ² (146.32 m ² ), 45 ft. the second surface 1020 of the substrate 1000 is 1,390ft ² (129.14m ²⁾ to 1,750ft ² may have a surface area of (162.58m ^2), 53 feet of the second surface 1020 of the substrate 1000 It may have a surface area of 1,630ft ² (151.43m ²⁾ to 2,030ft ² (188.59m ^2).

Substrate 1000 may have a cross-sectional area of at least 40 ft ² (3.72 m ² ), such as at least 45 ft ² (4.18 ^{m 2} ), such as at least 50 ft ² (4.65 ^{m 2} ), and may have a cross-sectional area of ^{at least 100 ft 2} (9.30 m 2 ). m ^2), for more than, for example, below, 85ft ² (7.90m ²⁾ for example, may be up to 81ft ² (7.53m ^2). Substrate 1000 may be 40 ft ² (3.72 m ² ) to 100 ft ² (9.30 m ² ), such as 45 ft ² (4.18 ^{m 2} ) to 85 ft ² (7.90 m ² ), such as 50 ft ² (4.65 m) ² ) to 81 ft ² (7.53 m ² ). As used herein, the term “cross-sectional area” with respect to the substrate 1000 refers to the maximum cross-sectional area of the substrate measured perpendicular to the longest axis of the substrate 1000 . With respect to the containerized substrate 1000 , the cross-sectional area is the width multiplied by the height.

The substrate 1000 may include any conductive material. For example, the substrate 1000 may include a metallized material such as a metal, a metal alloy, and/or a nickel plated plastic. Additionally, the substrate 1000 may include a non-metallic conductive material including, for example, a composite material such as carbon fiber or a material comprising conductive carbon. Metals or metal alloys are, for example, cold rolled steel, hot rolled steel, zinc metal, steel coated with zinc compounds or zinc alloys, for example electrogalvanized steel, hot-dip galvanized steel, galvanized steel, nickel-plated steel and zinc alloy plated steel. The substrate 1000 may include an aluminum alloy. Non-limiting examples of aluminum alloys include 1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, 7XXX or 8XXX series, as well as clad aluminum alloys and cast aluminum alloys. The substrate 1000 may include a magnesium alloy. The substrate 1000 used in the present invention may further comprise alloys of these materials, as well as other suitable non-ferrous metals such as titanium or copper.

When the substrate 1000 is positioned at least partially within the tank 100 , the electrocoating system 10 may be configured such that the movable electrode 200 can be moved to a position generally closer to the substrate 1000 . have. For example, as discussed above, the distance between the outer surfaces of the movable electrode 200 may be a distance of no more than 4 feet from the surface of the substrate 1000 to be coated. For example, where the substrate 1000 includes a cavity, such as a container or pipe, the movable electrode 200 may be positioned (or expanded) within the cavity of the substrate 1000 to be coated.

The electrocoating system 10 may further include at least one power source (not shown) to provide an electric current to the electrocoating system 10 . The power source may optionally include a rectifier. A power source is electrically coupled to the movable electrode 200, the substrate 1000, and, if present, the stationary electrode 800, one pole of the power source coupled to the substrate and the other pole of the power source moving coupled to the movable electrode 200 and, if present, the fixed electrode(s) 800 , so that the substrate 1000 may be coupled to the movable electrode 200 and, if present, to the fixed electrode(s) 800 . Let it act as a counter electrode. For example, if the electrodepositable coating composition 900 is a cationic electrodepositable coating composition, the substrate 1000 serves as the cathode and the movable electrode 200, and the fixed electrode 800, if present, is the anode. , and the polarity is reversed for the anionic electrodepositable coating composition. The power source provides electrical current to the electrocoating system 10 such that the movable electrode 200 and, if present, the stationary electrode 800, provide sufficient charge to the electrodepositable coating composition 900 for electrocoating purposes. . Specifically, when the power source provides electrical current to the electrocoating system 10, the electrodepositable coating composition 900 is charged by the movable electrode 200 and, if present, the stationary electrode 800, and vice versa. It is dragged and deposited on the used substrate 1000 . The same or substantially equal charge distribution throughout the electrically charged electrodepositable coating composition 900 around the substrate 1000 provided by the electrocoating system 10 of the present invention is generally the entire surface of the substrate 1000 . The electrocoating process is enhanced by providing a substantially uniform coating thickness of the electrodepositable coating composition 900 deposited thereon. For example, without limiting the invention, the current provided to the power source may be from about 25 volts to about 600 volts or more, but is not limited thereto. The electrocoating system 10 may further include any additional or other electrical circuitry required or necessary to perform the purposes stated herein.

As noted above, the electrocoating system 10 may further include at least one fixed electrode 800 optionally positioned within the tank 100 to provide an additional charge to the electrodepositable coating composition 900 . have. The fixed electrode 800 may comprise any suitable conductive material known in the art. For example, the stationary electrode 800 may include a conductive pipe section electrically coupled to a power source. The fixed electrode(s) 800 may be film-free, substantially film-free, or substantially film-covered. The electrocoating system 10 may include a plurality of fixed electrodes 800 , the fixed electrodes 800 being substantially uniformly deposited along the length of the substrate 1000 on which the electrodepositable coating composition 900 is to be electrocoated. It may be located along the length of the tank 100 as possible. For example, the fixed electrode 800 may be positioned equidistant along the length of the tank 100 . The electrocoating system 10 may include a ratio of the total bonding surface area of the fixed electrode(s) 800 to the surface area of the second surface 1020 of the substrate 1000 from 1:7 to 1:1, such as 1: 6 to 1:2, eg, 1:5 to 1:3, eg, 1:4.

Without wishing to be bound by any theory, using only the stationary electrode 800 in the electrocoating system allows the electrodepositable coating composition 900 over the entire surface of the substrate 1000 without also the absence of the movable electrode 200 . It is believed that it will not provide sufficient charge to the electrodepositable coating composition 900 to allow this uniform deposition. For example, the fixed electrode 800 may have an electrical charge sufficient to deposit a coating on the surface of the substrate 1000 positioned proximate the fixed electrode 800 , eg, the second surface 1020 of the substrate 1000 . may provide the electrodepositable coating composition 900, but not provide sufficient charge to deposit a continuous coating on another portion of the substrate, for example, the first surface 1010 of the substrate 1000. have. The electrocoating system 10 of the present invention may substantially or completely cover the first surface 1010 of the substrate 1000 , for example, the electrocoating system may cover the first surface 1010 of the substrate 1000 . At least 70%, such as at least 75%, such as at least 80%, such as at least 85%, such as at least 90%, such as at least 95%, such as at least 95% of the total surface area, such as , such that at least 97%, such as at least 99%, such as 100%, are coated with the coating deposited from the electrodepositable coating composition 900 .

In accordance with the present invention, the electrocoating system 10 may be free of an ion exchange membrane, such as an ion exchange membrane to which an electrocatalyst is applied on a surface.

The electrodepositable coating composition 900 may include any electrodepositable coating composition known in the art. As used herein, the term “electrodepositable coating composition” refers to a composition that can be deposited on an electrically conductive substrate under the influence of an applied potential. For example, as noted above, the electrodepositable coating composition 900 may include a cationic or anionic electrodepositable coating composition.

Electrodepositable coating compositions typically include a film-forming binder. The film-forming binder may include an ionic salt group-containing film-forming polymer and optionally a curing agent.

According to the present invention, the ionic salt group-containing film-forming polymer may comprise a cationic salt group-containing film-forming polymer. Cationic salt group-containing film-forming polymers can be used in cationic electrodepositable coating compositions. As used herein, the term “cationic salt group-containing film-forming polymer” refers to a polymer comprising at least partially neutralized cationic groups, such as sulfonium and/or ammonium groups, which impart a positive charge to the polymer. As used herein, the term "polymer" includes, but is not limited to, oligomers and both homopolymers and copolymers. The cationic salt group-containing film-forming polymer may comprise active hydrogen functional groups. As used herein, the term "active hydrogen functional group" refers to isocyanates as determined by the Zerevitinoff test described in JOURNAL OF THE AMERICAN CHEMICAL SOCIETY, Vol. Refers to a group that reacts and includes, for example, a hydroxyl group, a primary or secondary amino group, and a thiol group. Cationic salt group-containing film-forming polymers comprising active hydrogen functional groups may be referred to as active hydrogen-containing, cationic salt group-containing film-forming polymers.

Examples of polymers suitable for use as the cationic salt group-containing film-forming polymer in the present invention include alkyd polymers, acrylic polymers, polyepoxide polymers, polyamide polymers, polyurethane polymers, polyurea polymers, polyether polymers and poly ester polymers, and the like.

Cationic salt groups can be incorporated into the cationic salt group-containing film-forming polymer as follows: The film-forming polymer can be reacted with a cationic salt group former. By “cationic salt group former” is meant a material that can be acidified before, during or after reaction with epoxy groups on the film-forming polymer to react with epoxy groups present and form cationic salt groups. Examples of suitable materials include primary or secondary amines which may be acidified after reaction with an epoxy group to form an amine salt group, or a tertiary amine which may be acidified prior to reaction with an epoxy group and form a quaternary ammonium salt group after reaction with an epoxy group amines such as Examples of other cationic salt group formers are sulfides, which can be mixed with an acid prior to reaction with the epoxy group and form a ternary sulfonium salt group upon subsequent reaction with the epoxy group.

More specific examples of suitable active hydrogen-containing, cationic salt group-containing film-forming polymers include, for example, U.S. Pat. No. 4,031,050 (3 columns, lines 27 to 5 columns, line 50), U.S. Pat. Nos. 4,452,963 (5 columns) , line 58 to column 6, line 66), and as described in US Pat. No. 6,017,432 (column 2, line 66 to column 6, line 26), the portions of which are incorporated as described herein. amine adducts, such as those of polyglycidyl ethers of polyphenols, such as bisphenol A, and primary and/or secondary amines. The portion of the amine that reacts with the polyepoxide may be the ketimine of the polyamine described in U.S. Pat. No. 4,104,147 (column 6, line 23 to column 7, line 23), the cited portions being incorporated as described herein. have. Also described in U.S. Pat. No. 4,432,850 (2 columns, lines 60 to 5 columns, line 58), the cited portions being incorporated as described herein, the non-gelled polyepoxide-polyoxyalkylenepolyamine resins Suitable. Also, U.S. Pat. No. 3,455,806 (2 columns, lines 18 to 3 columns, line 61) and U.S. Pat. No. 3,928,157 (2 columns, lines 29 to 3 columns, line 21) (portions cited in both documents are as disclosed herein) Cationic acrylic resins such as those described in incorporated) may be used.

In addition to the amine salt group-containing resin, the cation salt group-containing film-forming polymer may include a quaternary ammonium salt group-containing resin. As used herein, “quaternary ammonium salt group” _{refers to a group comprising a quaternary ammonium cation of the formula NR 4} ⁺ , wherein each R group is independently an alkyl or aryl group, and a counter anion. An example of such a resin is one formed by reacting an organic polyepoxide with a tertiary aminate. Such resins are disclosed in U.S. Patent Nos. 3,962,165 (column 2, lines 3-11, line 7); 3,975,346 (column 1, line 62 to column 17, line 25) and US Pat. No. 4,001,156 (column 1, line 37 to column 16, line 7), the portions of which are incorporated herein by reference.

Examples of other suitable cationic resins include ternary sulfonium salt group-containing, such as those described in US Pat. No. 3,793,278 (column 1, line 32 to column 5, line 20), the portions of which are incorporated as described herein. contains resin. In addition, cationic resins that cure via the transesterification mechanism described in European Patent Application No. 12463B1 (page 2, line 1 to page 6, line 25), which are incorporated as described herein, may be used.

Other suitable cationic salt group-containing film-forming polymers include those capable of forming photolysis resistant electrodepositable coating compositions. Such polymers include cationic amine salt groups derived from pendant and/or terminal amino groups disclosed in U.S. Patent Application Publication No. 2003/0054193A1 (paragraphs [0064] to [0088]), the portions of which are incorporated as described herein. containing polymers. Also, polyhydric phenols essentially free of aliphatic carbon atoms to which two or more aromatic groups are bonded as described in U.S. Patent Application Publication No. 2003/0054193 A1 (paragraphs [0096] to [0123]), the portions of which are incorporated as described herein. Active hydrogen-containing, cationic salt group-containing resins derived from polyglycidyl ethers of

Active hydrogen-containing, cationic salt group-containing film-forming polymers can be made cationic and water-dispersible by at least partial neutralization with an acid. Suitable acids include organic and inorganic acids. Non-limiting examples of suitable organic acids include formic acid, acetic acid, methanesulfonic acid and lactic acid. Non-limiting examples of suitable inorganic acids include phosphoric acid and sulfamic acid. "Sulfamic acid" means sulfamic acid itself or a derivative thereof, such as having the formula:

wherein R is hydrogen or an alkyl group having 1 to 4 carbon atoms. Mixtures of the acids mentioned above may also be used in the present invention.

The degree of neutralization of the cationic salt group-containing film-forming polymer may vary depending on the particular polymer involved. However, sufficient acid must be used to sufficiently neutralize the cationic salt group-containing film-forming polymer so that the cationic salt group-containing film-forming polymer can be dispersed in the aqueous dispersion medium. For example, the amount of acid used may provide at least 20% of the total theoretical neutralization amount. It is also possible to use an excess of acid in excess of that required for 100% total theoretical neutralization. For example, the amount of acid used to neutralize the cationic salt group-containing film-forming polymer can be ≧0.1% based on the total amines in the active hydrogen-containing, cationic salt group-containing film-forming polymer. Alternatively, the amount of acid used to neutralize the active hydrogen-containing, cationic salt group-containing film-forming polymer is ≤ 100%, based on total amines in the active hydrogen-containing, cationic salt group-containing film-forming polymer. can be The total amount of acid used to neutralize the cationic salt group-containing film-forming polymer can range between any combination of the values recited in the preceding sentence, inclusive of the recited values. For example, the total amount of acid used to neutralize the active hydrogen-containing, cationic salt group-containing film-forming polymer can be from about 20% to about 80%, based on the total amines in the cationic salt group-containing film-forming polymer. may be, for example, 20%, 35%, 50%, 60% or 80%.

The cationic salt group-containing film-forming polymer is present in the cationic electrodepositable coating composition at least 40% by weight, such as at least 50% by weight, such as at least, based on the total weight of resin solids of the electrodepositable coating composition. It may be present in an amount of 60% by weight, and may be present in an amount of 90% by weight or less, such as 80% by weight or less, such as 75% by weight or less. The cationic salt group-containing film-forming polymer is included in the cationic electrodepositable coating composition, for example, in an amount of 40% to 90% by weight, for example, 50% by weight, based on the total weight of the resin solids of the electrodepositable coating composition. to 80% by weight, for example from 60% to 75% by weight. As used herein, "resin solid" refers to an ionic salt group-containing film-forming polymer, a curing agent (if present), and any additional water-dispersible non-pigmented resinous component(s) present in the electrodepositable coating composition. ) is included.

According to the present invention, the ionic salt group-containing film-forming polymer may comprise an anionic salt group-containing film-forming polymer. As used herein, the term "anionic salt group-containing film-forming polymer" refers to an anionic polymer comprising at least partially neutralized anionic functional groups such as carboxylic acid and phosphoric acid groups that impart a negative charge. The anionic salt group-containing film-forming polymer may comprise active hydrogen functional groups. An anionic salt group-containing film-forming polymer comprising active hydrogen functional groups may be referred to as an active hydrogen-containing, anionic salt group-containing film-forming polymer. Anionic salt group-containing film-forming polymers can be used in anionic electrodepositable coating compositions.

Anionic salt group-containing film-forming polymers include base-soluble carboxylic acid group-containing film-forming polymers, such as reaction products or adducts of a drying oil or semi-dry fatty acid ester with a dicarboxylic acid or anhydride; and reaction products of fatty acid esters, unsaturated acids or anhydrides, and any additional unsaturated modifiers further reacted with polyols. Also suitable are at least partially neutralized interpolymers of unsaturated carboxylic acids, hydroxy-alkyl esters of unsaturated carboxylic acids and at least one other ethylenically unsaturated monomer. Still other suitable anionic electrodepositable resins include alkyd-aminoplast vehicles, i.e., vehicles containing alkyd resins and amine-aldehyde resins. Another suitable anionic electrodepositable resin composition comprises a mixed ester of a resinous polyol. Other acid functional polymers may also be used, such as phosphated polyepoxides or phosphated acrylic polymers. Exemplary phosphated polyepoxides are disclosed in U.S. Patent Application Publication Nos. 2009-0045071 ([0004]-[0015]) and U.S. Patent Application Nos. 13/232,093 ([0014]-[0040]) (the portions cited are incorporated as if set forth in the specification). Also suitable are resins comprising one or more pendant carbamate functional groups, such as those described in US Pat. No. 6,165,338.

According to the present invention, the anionic salt group-containing film-forming polymer comprises in the anionic electrodepositable coating composition at least 50% by weight, for example at least 55% by weight, based on the total weight of resin solids of the electrodepositable coating composition; For example, it may be present in an amount of at least 60% by weight, and may be present in an amount of 90% by weight or less, such as 80% by weight or less, such as 75% by weight or less. The anionic salt group-containing film-forming polymer is present in the anionic electrodepositable coating composition from 50% to 90%, such as from 55% to 80%, for example, based on the total weight of the resin solids of the electrodepositable coating composition, for example, It may be present in an amount from 60% to 75%.

According to the present invention, the electrodepositable coating composition of the present invention may further comprise a curing agent. The curing agent may react with the ionic salt group-containing film-forming polymer. The curing agent comprises a functional group that reacts with a reactive functional group such as an active hydrogen group of an ionic salt group-containing film-forming polymer to cure the coating composition to form a coating. As used herein in reference to the electrodepositable coating composition described herein, the term "cured," "cured," or similar terms means that at least a portion of the components forming the electrodepositable coating composition are crosslinked to form a coating. means that Additionally, curing the electrodepositable coating composition means that the composition is subjected to curing conditions (eg, elevated temperature) to induce a reaction of reactive functional groups on the components of the electrodepositable coating composition such that the components of the composition are crosslinked and at least partially crosslinked. refers to the formation of a cured coating. Non-limiting examples of suitable curing agents are phenolformaldehyde condensates comprising at least partially blocked polyisocyanates, aminoplast resins and phenoplast resins, such as allyl ether derivatives thereof.

Suitable at least partially blocked polyisocyanates include aliphatic polyisocyanates, aromatic polyisocyanates, and mixtures thereof. The curing agent may include an at least partially blocked aliphatic polyisocyanate. Suitable at least partially blocked aliphatic polyisocyanates are those described, for example, in U.S. Pat. No. 3,984,299 (column 1, line 57 to column 3, line 15), the portions of which are incorporated herein by reference. fully blocked aliphatic polyisocyanates such as, or as described in U.S. Patent No. 3,947,338 (2 columns, lines 65 to 4 columns, line 30), which portions are also incorporated as described herein. partially blocked aliphatic polyisocyanates that react with the polymer backbone. "Blocked" means that an isocyanate group reacts with a compound and the resulting blocked isocyanate group is stable to active hydrogen at ambient temperature, but at elevated temperatures, such as 90°C to 200°C, of the film-forming polymer. It means that it is reactive with active hydrogen. The polyisocyanate curing agent may be a fully blocked polyisocyanate substantially free of free isocyanate groups.

로 상업적으로 입수 가능함)를 포함할 수 있다. 방향족 폴리아이소사이아네이트는 (i) 아릴렌 아이소사이아네이트, 예를 들어, m-페닐렌 다이아이소사이아네이트, p-페닐렌 다이아이소사이아네이트, 1,5-나프탈렌 다이아이소사이아네이트 및 1,4-나프탈렌 다이아이소사이아네이트, 및 (ii) 알카릴렌 아이소사이아네이트, 예를 들어, 4,4'-다이페닐렌 메탄("MDI"), 2,4-톨릴렌 또는 2,6-톨릴렌 다이아이소사이아네이트("TDI"), 또는 이들의 혼합물, 4,4-톨루이딘 다이아이소사이아네이트 및 자일릴렌 다이아이소사이아네이트를 포함할 수 있다. 또한 트라이페닐 메탄-4,4',4"-트라이아이소사이아네이트, 1,3,5-트라이아이소사이아네이토 벤젠 및 2,4,6-트라이아이소사이아네이토 톨루엔과 같은 트라이아이소사이아네이트, 4,4'-다이페닐다이메틸 메탄-2,2',5,5'-테트라아이소사이아네이트와 같은 테트라아이소사이아네이트, 및 톨릴렌 다이아이소사이아네이트 이량체 및 삼량체와 같은 중합된 폴리아이소사이아네이트 등이 사용될 수 있다. 경화제는 중합체성 HDI, 중합체성 MDI, 중합체성 아이소포론 다이아이소사이아네이트 등과 같은 중합체성 폴리아이소사이아네이트로부터 선택된 블록화된 폴리아이소사이아네이트를 포함할 수 있다. 또한 경화제는 Covestro AG사로부터 Desmodur N3300

로서 이용 가능한 헥사메틸렌 다이아이소사이아네이트의 블록화된 삼량체를 포함할 수 있다. 또한 폴리아이소사이아네이트 경화제의 혼합물이 사용될 수 있다.The polyisocyanate curing agent may include a diisocyanate, a high-functionality polyisocyanate, or a combination thereof. For example, the polyisocyanate curing agent may include an aliphatic and/or aromatic polyisocyanate. Aliphatic polyisocyanates include (i) alkylene isocyanates such as trimethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, hexamethylene diisocyanate. Anate (“HDI”), 1,2-propylene diisocyanate, 1,2-butylene diisocyanate, 2,3-butylene diisocyanate, 1,3-butylene diisocyanate isocyanates, ethylidene diisocyanate, and butylidene diisocyanate, and (ii) cycloalkylene isocyanates such as 1,3-cyclopentane diisocyanate , 1,4-cyclohexane diisocyanate, 1,2-cyclohexane diisocyanate, isophorone diisocyanate, methylene bis(4-cyclohexylisocyanate) ("HMDI") , cyclo-trimer of 1,6-hexamethylene diisocyanate (also known as isocyanurate trimer of HDI commercially available as Desmodur N3300 from Convestro AG), and meta-tetramethylxylylene diisocyanate Isocyanate (TMXDI from Allnex SA)

commercially available). Aromatic polyisocyanates include (i) arylene isocyanates such as m-phenylene diisocyanate, p-phenylene diisocyanate, 1,5-naphthalene diisocyanate. nate and 1,4-naphthalene diisocyanate, and (ii) an alkaryl isocyanate such as 4,4′-diphenylene methane (“MDI”), 2,4-tolylene or 2,6-tolylene diisocyanate (“TDI”), or mixtures thereof, 4,4-toluidine diisocyanate and xylylene diisocyanate. Also triisocyans such as triphenyl methane-4,4',4"-triisocyanate, 1,3,5-triisocyanatobenzene and 2,4,6-triisocyanatotoluene tetraisocyanate, such as 4,4'-diphenyldimethyl methane-2,2',5,5'-tetraisocyanate, and tolylene diisocyanate dimers and trimers with polymerized polyisocyanates such as can be used, etc. The curing agent is a blocked polyisocyanate selected from polymeric polyisocyanates such as polymeric HDI, polymeric MDI, polymeric isophorone diisocyanate, etc. The curing agent may also include Desmodur N3300 from Covestro AG.

It may include a blocked trimer of hexamethylene diisocyanate available as Mixtures of polyisocyanate curing agents may also be used.

Polyisocyanate curing agents include 1,2-alkane diols such as 1,2-propanediol; 1,3-alkane diols such as 1,3-butanediol; benzyl alcohol such as benzyl alcohol; allylic alcohol such as allyl alcohol; caprolactam; dialkylamines such as dibutylamine; and at least one blocking agent selected from mixtures thereof. The polyisocyanate curing agent may be at least partially blocked with at least one 1,2-alkane diol having 3 or more carbon atoms, for example 1,2-butanediol.

Other suitable blocking agents include, for example, lower (eg, C ₁ -C ₆ ) aliphatic alcohols such as methanol, ethanol, and n-butanol; alicyclic alcohols such as cyclohexanol; aromatic-alkyl alcohols such as phenyl carbinol and methylphenyl carbinol; and phenolic compounds, such as aliphatic, cycloaliphatic or aromatic alkyl monoalcohols or phenolic compounds, including phenol itself and substituted phenols in which the substituents do not affect the coating operation, such as cresol and nitrophenol. include Also glycol ethers and glycol amines can be used as blocking agents. Suitable glycol ethers include ethylene glycol butyl ether, diethylene glycol butyl ether, ethylene glycol methyl ether and propylene glycol methyl ether. Other suitable blocking agents include oximes such as methyl ethyl ketoxime, acetone oxime and cyclohexanone oxime.

The curing agent may include an aminoplast resin. Aminoplast resins are the condensation products of aldehydes with amino or amido group carriers. Condensation products obtained by reaction of alcohols and aldehydes with melamine, urea or benzoguanamine can be used. However, condensation products of other amines and amides, such as triazines, diazines, triazoles, guanidines, guanamines, and alkyl- and aryl-substituted derivatives of these compounds, such as alkyl- and Aldehyde condensates of derivatives including aryl-substituted ureas and alkyl- and aryl-substituted melamines may be used. Some examples of such compounds include N,N'-dimethyl urea, benzourea, dicyandiamide, formaguanamine, acetoguanamine, ammeline, 2-chloro-4,6-diamino-1,3, 5-triazine, 6-methyl-2,4-diamino-1,3,5-triazine, 3,5-diaminotriazole, triaminopyrimidine, 2-mercapto-4,6-diamino pyrimidine, 3,4,6-tris(ethylamino)-1,3,5-triazine, and the like. Suitable aldehydes include formaldehyde, acetaldehyde, crotonaldehyde, acrolein, benzaldehyde, furfural, glyoxal, and the like.

The aminoplast resin may contain methylol or similar alkylol groups, and at least some of these alkylol groups may be etherified by reaction with an alcohol to provide an organic solvent soluble resin. Alcohols such as methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, etc. as well as benzyl alcohol and other aromatic alcohols, cyclic alcohols such as cyclohexanol, glycols such as Cellosolve and Carbitol Any monohydric alcohol may be used for this purpose, including monoethers of , and halogen-substituted or other substituted alcohols such as 3-chloropropanol and butoxyethanol.

;, 예를 들어, CYMEL 1130 및 1156, 및 INEOS Melamines사로부터의 RESIMENE

, 예를 들어, RESIMENE 750 및 753 하에서 이용 가능한 것이다. 또한 적합한 아미노플라스트 수지의 예로는 미국 특허 번호 3,937,679(16 칼럼, 3줄 내지 17 칼럼, 47줄)(이 부분은 본 명세서에 기재된 것처럼 병합됨)에 설명된 것을 포함한다. '679 특허의 전술된 부분에 개시된 바와 같이, 아미노플라스트는 메틸올 페놀 에테르와 조합하여 사용될 수 있다.Non-limiting examples of commercially available aminoplast resins include, but are not limited to, the trade name CYMEL from Allnex Belgium SA/NV.

;, for example CYMEL 1130 and 1156, and RESIMENE from the company INEOS Melamines

, for example those available under RESIMENE 750 and 753. Also examples of suitable aminoplast resins include those described in US Pat. No. 3,937,679 (column 16, lines 3 to 17, line 47), the portions of which are incorporated herein by reference. As disclosed in the aforementioned section of the '679 patent, aminoplasts can be used in combination with methylol phenol ethers.

Fenoplast resins are formed by the condensation of aldehydes and phenols. Suitable aldehydes include formaldehyde and acetaldehyde. Methylene-releasing agents and aldehyde-releasing agents such as paraformaldehyde and hexamethylene tetramine can also be used as aldehyde agents. Various phenols can be used, such as phenol itself, cresol, or substituted phenols, for example phenols in which a hydrocarbon radical having a straight-chain, branched-chain or cyclic structure is replaced with hydrogen in the aromatic ring. Also mixtures of phenols may be used. Some specific examples of suitable phenols are p-phenylphenol, p-tert-butylphenol, p-tert-amylphenol, cyclopentylphenol and unsaturated hydrocarbon-substituted phenols, e.g., at the ortho, meta or para position. It is a monobutenyl phenol containing a tenyl group, where the double bond occurs at various positions in the hydrocarbon chain.

The aforementioned aminoplast and phenoplast resins are further described in US Pat. No. 4,812,215 (column 6, lines 20 through 7, line 12), the portions of which are incorporated herein by reference.

The curing agent may be present in the cationic electrodepositable coating composition in an amount of at least 10% by weight, such as at least 20% by weight, such as at least 25% by weight, based on the total weight of resin solids in the electrodepositable coating composition. and may be present in an amount of 60% by weight or less, such as 50% by weight or less, such as 40% by weight or less. The curing agent may be added to the cationic electrodepositable coating composition in an amount of from 10% to 60% by weight, such as from 20% to 50% by weight, such as from 25% by weight, based on the total weight of the resin solids of the electrodepositable coating composition. 40% by weight.

The curing agent may be present in the anionic electrodepositable coating composition in an amount of at least 10% by weight, such as at least 20% by weight, such as at least 25% by weight, based on the total weight of resin solids of the electrodepositable coating composition. and may be present in an amount of 50 wt% or less, such as 45 wt% or less, such as 40 wt% or less. The curing agent is present in the anionic electrodepositable coating composition in an amount of from 10% to 50% by weight, such as from 20% to 45% by weight, such as from 25% by weight, based on the total weight of the resin solids of the electrodepositable coating composition. 40% by weight.

The electrodepositable coating composition according to the present invention may optionally include one or more additional components in addition to the aforementioned film-forming binder and curing agent.

XC-7231), SbF₆의 t-아민염(예를 들어, NACURE

XC-9223), 트라이플산(triflic acid)의 Zn 염(예를 들어, NACURE

A202 및 A218), 트라이플산의 4원 염(예를 들어, NACURE

XC-A230), 및 트라이플산의 다이에틸아민염(예를 들어, NACURE

A233), King Industries사로부터 상업적으로 입수 가능한 모든 것, 및/또는 이들의 혼합물을 포함하지만 이들로 제한되지 않는다. 잠복성 산 촉매는 파라-톨루엔술폰산(para-toluenesulfonic acid)(pTSA) 또는 기타 술폰산과 같은 산 촉매의 유도체를 제조함으로써 형성할 수 있다. 예를 들어, 블록화된 산 촉매의 잘 알려진 기는 피리디늄 파라-톨루엔술폰산염과 같은 방향족 술폰산의 아민염이다. 이러한 설폰산염은 가교 촉진에 있어서 유리산보다 덜 활성이다. 경화 동안 촉매는 가열에 의해 활성화될 수 있다.According to the present invention, the electrodepositable coating composition may optionally include a catalyst that catalyzes the reaction between the curing agent and the polymer. Examples of suitable catalysts for cationic electrodepositable coating compositions include U.S. Pat. No. 7,842,762 (column 1, lines 53 to 4 columns, lines 18 and 16 columns, lines 62 to 19 columns, line 8), the cited portions of which are described herein. organotin compounds (eg, dibutyltin oxide and dioctyltin oxide) and salts thereof (eg, dibutyltin diacetate); other metal oxides (eg, oxides of cerium, zirconium and bismuth) and salts thereof (eg, bismuth sulfamate and bismuth lactate); or cyclic guanidine. Examples of suitable catalysts for anionic electrodepositable coating compositions include latent acid catalysts, specific examples of which are identified in WO 2007/118024 (paragraph [0031]), ammonium hexafluoroantimonate, SbF ₆ of 4 Raw salts (e.g., NACURE

XC-7231), the t-amine salt of _{SbF 6 (eg, NACURE}

XC-9223), the Zn salt of triflic acid (e.g. NACURE

A202 and A218), the quaternary salts of triflic acid (eg NACURE

XC-A230), and the diethylamine salt of triflic acid (eg, NACURE

A233), all commercially available from King Industries, and/or mixtures thereof. Latent acid catalysts can be formed by preparing derivatives of acid catalysts such as para-toluenesulfonic acid (pTSA) or other sulfonic acids. For example, a well-known group of blocked acid catalysts are the amine salts of aromatic sulfonic acids, such as pyridinium para-toluenesulfonate. These sulfonates are less active than free acids in promoting crosslinking. During curing, the catalyst can be activated by heating.

According to the invention, the electrodepositable coating composition comprises other optional components, for example pigment compositions and/or various additives, for example fillers, plasticizers, antioxidants, biocides, UV light absorbers and stabilizers, hindered amines. It may further include a light stabilizer, an antifoaming agent, a bactericide, a dispersion aid, a flow control agent, a surfactant, a wetting agent, a pH adjusting agent, a buffering agent, or a combination thereof. Alternatively, the electrodepositable coating composition may be completely free of any optional components, ie, the optional components may not be present in the electrodepositable coating composition. The pigment composition may include, for example, iron oxide, lead oxide, strontium chromate, coal dust, titanium dioxide, talc, barium sulfate as well as coloring pigments such as cadmium yellow, cadmium red, chromium yellow and the like. The pigment content of the pigment composition excluding the above-described electrically conductive particles may be expressed as a pigment-binder weight ratio, and may be in the range of 0.03 to 0.1 when a pigment is used. The other additives mentioned above may be present in the electrodepositable coating composition in an amount of 0.01% to 3% by weight based on the total weight of resin solids in the electrodepositable coating composition.

According to the present invention, the electrodepositable coating composition typically comprises an aqueous dispersion medium comprising water and/or one or more organic solvent(s). The water may be present, for example, in an amount of from 40% to 90% by weight, such as from 50% to 80% by weight, such as from 60% to 75% by weight, based on the total weight of the electrodepositable coating composition. can Examples of suitable organic solvents include ethylene glycol, diethylene glycol, propylene glycol, and monoalkyl ethers of dipropylene glycol containing 1 to 10 carbon atoms in the alkyl group, such as monoethyl and monobutyl of these glycols. oxygenated organic solvents such as ethers. Examples of other at least partially water-miscible solvents include alcohols such as ethanol, isopropanol, butanol and diacetone alcohol. When used, the organic solvent may typically be present in an amount of less than 10% by weight, such as less than 5% by weight, based on the total weight of the electrodepositable coating composition. The electrodepositable coating composition may be provided in particular in the form of a dispersion, such as an aqueous dispersion.

According to the present invention, the total solids content of the electrodepositable coating composition may be at least 1% by weight, for example at least 10% by weight, at least 20% by weight, and 60% by weight, based on the total weight of the electrodepositable coating composition. or less, for example, 40% by weight or less, for example, 20% by weight or less. The total solids content of the electrodepositable coating composition may be 1% to 60% by weight, such as 10% to 40% by weight, such as 20% to 30% by weight, based on the total weight of the electrodepositable coating composition. can be

Methods for coating substrates and coated substrates

The present invention also relates to a method of coating a substrate comprising electrophoretically applying an electrodepositable coating composition 900 to at least a portion of a substrate 1000 using the electrocoating system 10 described above. The method includes placing a substrate (1000) in a tank (100), wherein the surface of the substrate (1000) to be coated is at least partially immersed in an electrodepositable coating composition (900); positioning the movable electrode 200; electrically coupling the movable electrode 200 and the substrate 1000 to opposite poles of a power source; and then applying an electric current to the electrocoating system 10 from a power source to electrodeposit the electrodepositable coating composition 900 on the surface of the substrate 1000 . For example, the substrate 1000 may be electrically coupled to a positive or negative terminal such that, during electrocoating, the substrate 1000 functions as a cathode or an anode, respectively, the movable electrode 200 (and if present) The fixed electrode 800 is connected to the opposite pole to function as a counter electrode for the substrate 1000 . With the movable electrode 200 in place, the outer surface of the movable electrode 200 may be at a distance of no more than 4 feet from the surface of the substrate 1000 to be coated.

The substrate 1000 used in the method of the present invention may include cavities. As discussed above, the substrate 1000 may include an open polygonal, polygonal, or round cross-sectional shape having at least one open end and a cavity. For example, the substrate 1000 may be in the form of a container or pipe having at least one open end and an interior cavity. In the method of the present invention, the movable electrode 200 may be positioned or extended so that the movable electrode 200 enters the cavity of the substrate 1000 . As described above, the outer surface of the movable electrode 200 may be 4 feet or less, such as 3.5 feet or less, such as 3 feet or less, such as 2.5 feet or less, from the surface of the substrate 1000 to be coated. It may be at a distance of no more than a foot, such as no more than 2 feet, such as no more than 1.5 feet, such as no more than 1 foot, such as no more than 0.5 feet.

After immersing at least a portion of the substrate 1000 in the electrodepositable coating composition 900, the adhesive film of the electrodepositable coating composition 900 is applied to the electrodes (ie, the substrate 1000 and the movable electrode(s)) by a power source. It is deposited on the substrate when a sufficient voltage is applied between 200 and the fixed electrode(s) 800 if present). The applied voltage can vary and can range from as low as one volt to as high as several thousand volts, for example between 25 volts and 600 volts. The current density may be between 0.5 and 15 amps per square foot.

Electrodepositable coating compositions that may be used in the methods of the present invention may include any of those known in the art, including those described above. For example, the electrodepositable coating composition may comprise a cationic film-forming resin comprising sulfonium groups and/or ammonium groups, or the electrodepositable coating composition may comprise an anionic film-forming resin comprising carboxylic acid and/or phosphoric acid groups. It may include an anionic electrodepositable coating composition comprising a.

According to the present invention, the method may further comprise the step of at least partially curing the electrophoretically applied electrodepositable coating composition onto the substrate. As discussed above, at least partially curing the electrodepositable coating composition may include applying the substrate to an elevated temperature. With respect to the cationic electrodepositable coating composition, the coated substrate may be, for example, from 250°F to 450°F (121.1°C to 232.2°C), such as from 275°F to 400°F (135°C to 204.4°C), for example , 300°F to 360°F (149°C to 180°C). With respect to the anionic electrodepositable coating composition, the coated substrate may be, for example, 200°F to 450°F (93°C to 232.2°C), such as 275°F to 400°F (135°C to 204.4°C), for example , 300°F to 360°F (149°C to 180°C). The curing time may vary depending on the curing temperature as well as other variables such as the film thickness of the electrodeposited coating, the level and type of catalyst present in the composition, the type of curing agent used, and the like. For the purposes of the present invention, all that is required is sufficient time to effect the curing of the coating on the substrate. For example, the curing time may range from 10 minutes to 60 minutes, such as from 20 minutes to 40 minutes. For example, the thickness of the resulting cured electrodepositable coating may range from 1 to 50 microns, such as from 15 to 50 microns.

According to the present invention, a method of coating a substrate comprises the steps of (a) electrophoretically depositing an electrodepositable coating composition (900) onto at least a portion of a substrate (1000) using an electrocoating system (10) of the present invention; and (b) heating the coated substrate for a temperature and time sufficient to at least partially cure the electrodeposited coating composition 900 on the substrate. According to the present invention, the method optionally comprises (c) directly applying one or more pigment-containing coating compositions and/or one or more pigment-free coating compositions directly to the at least partially cured electrodepositable coating to achieve at least partially cured electrodepositable properties. forming an additional coating layer over at least a portion of the coating, and (d) subjecting the additional coating layer to ambient temperature or sufficient energy from an external energy source for conditions and for a time sufficient to at least partially cure the additional coating layer ( It may further comprise the step of curing the additional coating layer by applying to the coated substrate of c). Non-limiting examples of external energy sources include thermal energy and radiation, such as ultraviolet, infrared or microwave, and the like.

Optional additional coating layers may include one or more primer layer(s) and suitable topcoat layer(s) (eg, a base coat, a clearcoat layer, a pigment containing monocoat, and a color plus clear composite composition). . It is understood that suitable additional coating layers include any of those known in the art, each independently being in the form of a water-based, solvent-based, solid particulate (ie, powder coating composition) or powder slurry. The additional coating composition may comprise a film-forming polymer, a crosslinking material, and, if present, a colored base coat or monocoat, one or more pigments. The primer layer(s) may optionally be disposed between the electrocoat layer and the topcoat layer(s). Alternatively, the topcoat layer(s) may be omitted such that the composite comprises an electrocoat layer and one or more primer layer(s).

Moreover, the topcoat layer(s) may be applied directly onto the electrodepositable coating layer. In other words, the substrate may be free of a primer layer such that the composite comprises an electrocoat layer and one or more topcoat layer(s). For example, the basecoat layer may be applied directly over at least a portion of the electrodepositable coating layer.

It is also understood that any of the topcoat layers may be applied over the underlying layer even if the underlying layer is not fully cured. For example, a clearcoat layer may be applied on the basecoat layer (wet over wet) even if the basecoat layer has not undergone a curing step. The two layers can then be cured during a subsequent curing step, eliminating the need to cure the basecoat layer and the clearcoat layer separately.

In accordance with the present invention, additional ingredients such as colorants and fillers may be present in the various coating compositions that produce the top coat layer. Any suitable colorants and fillers such as those described above may be used. For example, colorants may be added to the coating in any suitable form, such as discrete particles, dispersions, solutions and/or flakes. A single colorant or a mixture of two or more colorants may be used in the coatings of the present invention. It is generally understood that colorants may be present in the layers of the multilayer composite in any amount sufficient to impart desired properties, visual effects and/or color effects.

Exemplary colorants include pigments, dyes and tints, as well as special effect compositions, such as those used in the paint industry, and/or listed in the Dry Color Manufacturers Association (DCMA). Colorants may include, for example, finely divided solid powders that are insoluble but wettable under the conditions of use. The colorant may be organic or inorganic, and may or may not aggregate. Colorants may be incorporated into the coating by grinding or simple mixing. Colorants can be incorporated by grinding into the coating using a grind vehicle, for example, an acrylic grind vehicle, the use of which is familiar to those skilled in the art.

Exemplary pigments and/or pigment compositions include carbazole dioxazine crude pigments, azo, monoazo, disazo, naphthol AS, salt type (lake), benzimidazolone, condensate, metal complex, isoindolinone, isoin Doline and polycyclic phthalocyanine, quinacridone, perylene, perinone, diketopyrrolopyrrole, thioindigo, anthraquinone, indanthrone, anthrapyrimidine, flavanthrone, pyranthrone, ananthrone, dioxazine, triarylcar Bonium, quinophthalone pigments, diketopyrrolopyrrole red (“DPP red BO”), titanium dioxide, carbon black, zinc oxide, antimony oxide, etc., and organic or inorganic UV opaque pigments such as iron oxide, transparent red or yellow iron oxide, phthalocyanine blue, and mixtures thereof. The terms “pigment” and “colored filler” may be used interchangeably.

Exemplary dyes include acid dyes, azo dyes, basic dyes, direct dyes, disperse dyes, reactive dyes, solvent dyes, sulfur dyes, mordant dyes such as bismuth vanadate, anthraquinone, perylene, aluminum, quina solvents such as, but not limited to, cridone, thiazole, thiazine, azo, indigoid, nitro, nitroso, oxazine, phthalocyanine, quinoline, stilbene and triphenyl methane and/or aqueous based. .

Exemplary tints include, but are not limited to, AQUA-CHEM 896 commercially available from Degussa, Inc., CHARISMA colorant commercially available from the Accurate Dispersions division of Eastman Chemical, Inc., and dispersed in an aqueous or water-miscible carrier such as MAXITONER INDUSTRIAL COLORANTS. pigments, but are not limited thereto.

The colorant may be in the form of a dispersion including, but not limited to, nanoparticle dispersions. Nanoparticle dispersions may include one or more highly dispersed nanoparticle colorants and/or colorant particles that produce a desired visible color and/or opacity and/or visual effect. The nanoparticle dispersion may include a colorant, such as a pigment or dye, having a particle size of less than 150 nm, eg, less than 70 nm, or less than 30 nm. Nanoparticles can be produced by milling stock organic or inorganic pigments with grinding media having a particle size of less than 0.5 mm. Exemplary nanoparticle dispersions and methods of making them are identified in US Pat. No. 6,875,800 B2, incorporated herein in its entirety as if set forth in its entirety. Nanoparticle dispersions can also be produced by crystallization, precipitation, gas phase condensation, and chemical attrition (ie, partial dissolution). To minimize re-agglomeration of nanoparticles within the coating, dispersions of resin coated nanoparticles can be used. As used herein, "dispersion of resin coated nanoparticles" refers to a continuous phase in which individual "composite microparticles" comprising nanoparticles and a resin coating on the nanoparticles are dispersed. Examples of dispersions of resin coated nanoparticles and methods of making the same include, but are not limited to, U.S. Patent Application No. 10/876,031, filed June 24, 2004, the entire contents of which are incorporated herein by reference, and U.S. Provisional Patent No. 60/ 482,167, filed on Jun. 24, 2003, the entire contents of which are incorporated herein by reference.

According to the present invention, the special effect composition that can be used in one or more layers of the multilayer coating composite can be one such as reflectance, pearlescent, metallic, phosphorescent, fluorescent, photochromic, photosensitive, thermochromic, chromatic and/or color changing. pigments and/or compositions that produce the above appearance effect. Additional special effect compositions may provide other recognizable properties such as reflectivity, opacity or texture. For example, the special effect composition can create a color shift such that the color of the coating changes when the coating is viewed from different angles. Exemplary color effect compositions are identified in US Pat. No. 6,894,086, the entire contents of which are incorporated herein by reference. The additional color effect composition comprises clear coated mica and/or synthetic mica, coated silica, coated alumina, clear liquid crystal pigment, liquid crystal coating, and/or a difference in refractive index within the material that is not due to a difference in refractive index between the surface and air of the material. It may include any composition in which interference occurs.

In accordance with the present invention, photosensitive and/or photochromic compositions that reversibly change color when exposed to one or more light sources may be used in multiple layers of a multilayer composite. The photochromic and/or photosensitive composition may be activated by exposure to radiation of a particular wavelength. When the composition is excited, the molecular structure changes, and the altered structure exhibits a new color different from the original color of the composition. When exposure to radiation is removed, the photochromic and/or photosensitive composition may return to a resting state, in which the original color of the composition is restored. For example, a photochromic and/or photosensitive composition may be colorless in an unexcited state and exhibit a color in an excited state. The overall color change may appear within milliseconds to minutes, for example within 20 seconds to 60 seconds. Exemplary photochromic and/or photosensitive compositions include photochromic dyes.

The photosensitive and/or photochromic composition may be associated and/or at least partially associated with the polymer and/or the polymeric material of the polymerizable component, for example by covalent bonding. Unlike some coatings, in which the photosensitive composition may migrate out of the coating and crystallize into a substrate, the photosensitive composition and/or photochromic composition associated with and/or at least partially associated with the polymer and/or polymerizable component according to the present invention is a coating. has the least movement in Exemplary photosensitive compositions and/or photochromic compositions and methods of making them are identified in US Patent Application Serial No. 10/892,919, filed July 16, 2004, the entire contents of which are incorporated herein by reference.

Additional coating layers may be applied by means of a topcoat system. The topcoat system may include any equipment and/or method known in the art for applying the topcoat coating composition. For example, the topcoat system may include equipment for applying a powder coating composition or a liquid coating composition. For example, the topcoat system may include a spray gun, brush, roller, tank for dipping the coating, or a combination thereof. The topcoat system may optionally further include a spray booth, and the spray booth may optionally include a ventilation system.

As mentioned above, the coating composition may be a powder coating composition. As used herein, “powder coating composition” refers to a coating composition that is completely free of water and/or solvent. Accordingly, the powder coating compositions disclosed herein are not synonymous with water-based and/or solvent-based coating compositions known in the art.

According to the present invention, the powder coating composition comprises (a) a film-forming polymer having reactive functional groups; and (b) a curing agent that reacts with the functional group. Examples of powder coating compositions that can be used in the present invention include the polyester-based ENVIROCRON line of powder coating compositions (commercially available from PPG Industries, Inc.) or epoxy-polyester hybrid powder coating compositions. Alternative examples of powder coating compositions that can be used in the present invention include (a) at least one tertiary aminourea compound, at least one tertiary aminourethane compound, or mixtures thereof, and (b) at least one film-forming compound. Epoxy-containing resins and/or at least one siloxane-containing resin as described, for example, in U.S. Pat. No. 7,470,752 assigned to PPG Industries Ohio, Inc., the entire contents of which are incorporated herein by reference. ) low temperature curing thermosetting powder coating composition comprising; generally (a) at least one tertiary aminourea compound, at least one tertiary aminourethane compound, or mixtures thereof, and (b) at least one film-forming epoxy-containing resin and/or at least one siloxane- a curable powder coating composition comprising an oleoresin (eg, as described in US Pat. No. 7,432,333 assigned to PPG Industries Ohio, Inc., incorporated herein in its entirety as if set forth in its entirety); _{and a solid particulate mixture of a reactive group-containing polymer having a T g} of at least 30° C. (eg, US Pat. No. 6,797,387 assigned to PPG Industries Ohio Inc., incorporated herein in its entirety as described herein) those described).

Suitable film-forming polymers that may be used in the powder coating compositions of the present invention are (poly)esters (eg, polyester triglycidyl isocyanurate), (poly)urethane, isocyanurate, (poly) Urea, (poly) epoxy, anhydride, acrylic, (poly) ether, (poly) sulfide, (poly) amine, (poly) amide, (poly) vinyl chloride, (poly) olefin, (poly) vinylidene fluoride, or combinations thereof.

According to the present invention, the reactive functional groups of the film-forming polymer of the powder coating composition are hydroxyl, carboxyl, isocyanate (including blocked (poly)isocyanate), primary amine, secondary amine, amide , carbamates, ureas, urethanes, vinyls, unsaturated esters, maleimides, fumarates, anhydrides, hydroxyl alkylamides, epoxies, or combinations thereof.

Suitable curing agents (crosslinking agents) that may be used in the powder coating compositions of the present invention include aminoplast resins, polyisocyanates, blocked polyisocyanates, polyepoxides, polyacids, polyols, or combinations thereof. include

After deposition of the powder coating composition, the coating is often heated to cure the deposited composition. The heating or curing operation is often carried out at a temperature in the range of 150° C. to 200° C., for example in the range of 170° C. to 190° C., for a time period in the range of 10 minutes to 20 minutes. According to the present invention, the thickness of the resulting film is between 50 microns and 125 microns.

As mentioned above, the coating composition may be a liquid coating composition. As used herein, “liquid coating composition” refers to a coating composition containing a portion of water and/or solvent. Accordingly, the liquid coating compositions disclosed herein are synonymous with water-based and/or solvent-based coating compositions known in the art.

라인의 용매계 코팅 조성물, AQUACRON

라인의 수계 코팅 조성물, 및 RAYCRON

라인의 UV 경화 코팅(모두 PPG Industries, Inc.사로부터 상업적으로 입수 가능함)을 포함한다.According to the present invention, the liquid coating composition comprises, for example, (a) a film-forming polymer having reactive functional groups; and (b) a curing agent that reacts with the functional group. In another example, the liquid coating may contain a film-forming polymer that can react with oxygen in the air or incorporate into the film by evaporation of water and/or solvent. This film-forming mechanism may require or be accelerated by the application of heat or some type of radiation, such as ultraviolet or infrared radiation. Examples of liquid coating compositions that can be used in the present invention include SPECTRACRON

Solvent-based coating compositions from the line, AQUACRON

A line of water-based coating compositions, and RAYCRON

a line of UV-curable coatings (all commercially available from PPG Industries, Inc.).

Suitable film-forming polymers that can be used in the liquid coating compositions of the present invention are (poly)esters, alkyds, (poly)urethanes, isocyanurates, (poly)ureas, (poly)epoxy, anhydrides, acrylics, (poly) ethers, (poly)sulfides, (poly)amines, (poly)amides, (poly)vinyl chloride, (poly)olefins, (poly)vinylidene fluoride, (poly)siloxanes, or combinations thereof.

According to the present invention, the reactive functional groups of the film-forming polymer of the liquid coating composition are hydroxyl, carboxyl, isocyanate (including blocked (poly)isocyanate), primary amine, secondary amine, amide , carbamate, urea, urethane, vinyl, unsaturated ester, maleimide, fumarate, anhydride, hydroxyl alkylamide, epoxy, or combinations thereof.

Suitable curing agents (crosslinking agents) that may be used in the liquid coating compositions of the present invention include aminoplast resins, polyisocyanates, blocked polyisocyanates, polyepoxides, polyacids, polyols, or combinations thereof. may include

In addition, colorants and, if desired, various additives, such as surfactants, wetting agents or catalysts, may be included in the coating composition (electrodepositable, powder or liquid). As used herein, the term "colorant" means any substance that imparts color and/or other opacity and/or other visual effect to a composition. The colorant may be added to the composition in any suitable form, such as discrete particles, dispersions, solutions and/or flakes. A single colorant or a mixture of two or more colorants may be used.

Exemplary colorants include pigments, dyes and tints, as well as special effect compositions, such as those used in the paint industry and/or listed in the Dry Color Manufacturers Association (DCMA). Colorants may include, for example, finely divided solid powders that are insoluble but wettable under the conditions of use. The colorant may be organic or inorganic and may or may not aggregate. Colorants can be incorporated by use of a grind vehicle, such as an acrylic grind vehicle, the use of which will be familiar to one of ordinary skill in the art.

Exemplary pigments and/or pigment compositions include carbazole dioxazine crude pigments, azo, monoazo, disazo, naphthol AS, salt type (lake), benzimidazolone, condensate, metal complex, isoindolinone, isoin Doline and polycyclic phthalocyanine, quinacridone, perylene, perinone, diketopyrrolopyrrole, thioindigo, anthraquinone, indanthrone, anthrapyrimidine, flavanthrone, pyranthrone, ananthrone, dioxazine, triarylcar Bonium, quinophthalone pigments, diketo pyrrolo pyrrole red (“DPPBO red”), titanium dioxide, carbon black, and mixtures thereof. The terms “pigment” and “colored filler” may be used interchangeably.

Exemplary dyes include, but are not limited to, solvents and/or aqueous based such as phthalo green or blue, iron oxide, bismuth vanadate, anthraquinone, perylene, aluminum and quinacridone.

Exemplary tints include pigments dispersed in an aqueous or water-miscible carrier, such as AQUA-CHEM 896 commercially available from Degussa, Inc., CHARISMA COLORANTS and MAXITONER INDUSTRIAL COLORANTS commercially available from the Accurate Dispersions division of Eastman Chemical, Inc. including, but not limited to.

As noted above, the colorant may be in the form of a dispersion including, but not limited to, nanoparticle dispersions. Nanoparticle dispersions may include one or more highly dispersed nanoparticle colorants and/or colorant particles that produce a desired visible color and/or opacity and/or visual effect. The nanoparticle dispersion may include a colorant, such as a pigment or dye, having a particle size of less than 150 nm, eg, less than 70 nm, or less than 30 nm. Nanoparticles can be produced by milling stock organic or inorganic pigments with grinding media having a particle size of less than 0.5 mm. Exemplary nanoparticle dispersions and methods of making them are identified in US Pat. No. 6,875,800 B2, incorporated herein in its entirety as if set forth in its entirety. Nanoparticle dispersions can also be produced by crystallization, precipitation, gas phase condensation, and chemical attrition (ie, partial dissolution). A dispersion of resin coated nanoparticles can be used to minimize reagglomeration of nanoparticles within the coating. As used herein, "dispersion of resin coated nanoparticles" refers to a continuous phase in which individual "composite microparticles" comprising nanoparticles and a resin coating on the nanoparticles are dispersed. Examples of dispersions of resin-coated nanoparticles and methods for preparing the same include U.S. Patent Application Publication No. 2005-0287348 A1 (filed on June 24, 2004), U.S. Provisional Patent Application No. 60/482,167 (filed with: June 2003) 24), and U.S. Patent Application No. 11/337,062, filed January 20, 2006, the entire contents of which are incorporated herein by reference.

Exemplary special effect compositions that may be used include pigments and/or compositions that produce one or more appearance effects such as reflectance, pearlescent, metallic luster, phosphorescence, fluorescence, photochromism, photosensitivity, thermochromism, color vision change, and/or color change. includes Additional special effect compositions may provide other recognizable properties such as opacity or texture. According to the present invention, the special effect composition can create a color shift such that the color of the coating changes when viewed from different angles. Exemplary color effect compositions are identified in US Pat. No. 6,894,086, the entire contents of which are incorporated herein by reference. The additional color effect composition comprises clear coated mica and/or synthetic mica, coated silica, coated alumina, clear liquid crystal pigments, liquid crystal coatings, and/or the refractive index within the material not due to a difference in refractive index between the surface and air of the material. It may include any composition in which interference occurs due to a difference in

In accordance with the present invention, photosensitive and/or photochromic compositions that reversibly change color when exposed to one or more light sources may be used. The photochromic and/or photosensitive composition may be activated by exposure to radiation of a particular wavelength. When the composition is excited, the molecular structure changes and the altered structure exhibits a new color different from the original color of the composition. When the exposure to radiation is removed, the photochromic and/or photosensitive composition can return to a resting state, in which the original color of the composition is restored. According to the present invention, the photochromic and/or photosensitive composition may be colorless in the unexcited state and may exhibit a color in the excited state. The overall color change may appear within milliseconds to minutes, for example within 20 seconds to 60 seconds. Exemplary photochromic and/or photosensitive compositions include photochromic dyes.

The photosensitive composition and/or the photochromic composition may be associated and/or at least partially associated with the polymer and/or the polymeric material of the polymerizable component, for example by covalent bonding. Unlike some coatings where the photosensitive composition may migrate in the coating and crystallize into the substrate, the photosensitive composition and/or photochromic composition associated with and/or at least partially associated with the polymer and/or polymerizable component exhibits minimal migration in the coating. have Exemplary photosensitive compositions and/or photochromic compositions and methods of making the same are identified in US Patent Application No. 10/892,919, filed July 16, 2004, the entire contents of which are incorporated herein by reference.

In general, the colorant may be present in any amount sufficient to impart the desired visual and/or color effect to the desired coating composition. The colorant may comprise from 1% to 65% by weight, for example from 3% to 40% or from 5% to 35% by weight, based on the total weight of the composition.

According to the present invention, the method may optionally further comprise the step of pretreating the substrate with a pretreatment composition prior to application of the electrodepositable coating composition using the electrocoating system. As used herein, the term “pretreatment composition” refers to a composition capable of reacting with a substrate surface to chemically change the substrate surface to form a film that bonds with the substrate surface to provide corrosion protection. Non-limiting examples of pretreatment compositions include, for example, zinc phosphate pretreatment compositions such as those described in U.S. Pat. Nos. 4,793,867 and 5,588,989, zirconium containing pretreatment compositions, such as those described in U.S. Pat. Nos. 7,749,368 and 8,673,091, and the like. . The pretreatment composition may be contacted with the substrate by any of a variety of known techniques, such as immersion or dipping, spraying, intermittent spraying, submerging spraying, spraying soaking, brushing or roll coating. According to the present invention, the pretreatment composition when applied to a substrate is, for example, in the range of 40°F to 160°F (4.4°C to 71.1°C), such as 60°F to 110°F (15.6°C to 43.3°C), such as For example, it may be at a temperature in the range of 70°F to 90°F (21.1°C to 32.2°C). For example, the pretreatment process may be performed at ambient temperature or room temperature. The contact time is often 1 second to 15 minutes, such as 4 seconds to 10 minutes, such as 5 seconds to 4 minutes.

After contacting with the pretreatment composition, the substrate may be exposed to high temperature briefly by flashing off the water using, for example, an air knife, for example, from 15°C to 100°C, e.g. optionally by drying the substrate in a heater assembly using infrared heat in an oven at 20° C. to 90° C. or, for example, at 70° C. for 10 minutes, or by passing the substrate between squeegee rolls. can be dried, for example, can be dried with air at room temperature or can be dried with hot air. The substrate surface may be partially or in some cases completely dried before subsequent contact of the substrate surface with any water, solution, composition, etc. According to the present invention, after contacting with the pretreatment composition, the substrate (wet or dried) may optionally be rinsed with tap water, deionized water and/or an aqueous solution of rinsing agent to remove any residue, then Optionally, it may be dried as described in the preceding sentence, for example air dried or hot air dried. According to the present invention, this water rinse can be removed and the substrate (wet in place or dried) can be contacted with the subsequent treatment composition.

The pretreatment composition may be applied to the substrate by the pretreatment system. The pretreatment system may include an immersion tank, a brush, a roller, a spray gun, or a combination thereof to apply the pretreatment composition to the substrate. The pretreatment system may further include a tank, brush, roller, spray gun, or combination thereof for applying a rinse composition, such as water, to the substrate after the substrate is contacted with the pretreatment composition.

According to the present invention, the method may optionally further comprise the step of priming the substrate with a priming composition prior to applying the electrodepositable coating composition using the electrocoating system. The priming composition may be used alone or in combination with a pretreatment composition or other treatment agent prior to application of the electrodepositable coating composition. The priming composition may include a metal-rich coating composition. As used herein, the term “metal-rich coating composition” refers to a film-forming composition comprising at least 65% by weight of metal particles and an organic or inorganic binder, based on the total solids weight of the coating composition. As used herein, the term “metal particle” refers to elemental (ie, zero-valent) metal and metal alloy particles. As used herein, the term "particle" refers to a powder or dust as well as a material in particulate form, such as flakes, in any shape, e.g., spherical, oval, cubic, rod-shaped, disc-shaped, prismatic, etc. may be in the form of The metal may include zinc, aluminum, or alloys thereof. The priming composition may be contacted with the substrate by any of a variety of known techniques, such as immersion or dipping, spraying, electrostatic spraying, intermittent spraying, submerging spraying, spraying and submerging, brushing or roll coating. It is understood that the metal-rich primer coating may also be applied in dry form, such as a powder or film. The metal-rich primer coating formed from the priming composition can be applied to a dry film thickness of, for example, 2.5 to 500 microns.

After application of the priming composition to the substrate, the film formed on the surface of the substrate may be dried by removing the solvent from the film by heating or a period of air drying. Suitable drying conditions will vary depending on the particular priming composition and/or application, but range from about 1 minute to about 60 to 250° F. An exemplary drying time of 5 minutes may be sufficient. More than one primer coating layer may be applied if desired. A previously applied coating may flash between coatings; That is, it is exposed to ambient conditions for a desired period of time.

After application of the priming composition to the substrate, the applied priming composition may be cured by any means known in the art. For example, the coating may be subjected to curing conditions sufficient to cure the priming composition. For example, the coating composition may be subjected to curing conditions, such as the ambient conditions discussed above, for hours or days. Alternatively, the substrate may be subjected to curing conditions such as radiation (eg, UV radiation) or heated for a temperature and time sufficient to cure the priming coating.

The priming composition may be applied to a substrate by a priming system. The priming system may include an immersion tank, a brush, a roller, a spray gun, or a combination thereof to apply the priming composition to the substrate. The priming system may further include a tank, brush, roller, spray gun, or combination thereof for applying a rinsing composition, such as water, to the substrate.

According to the present invention, the substrate may optionally be subjected to another treatment prior to electrocoating. For example, the substrate may be rinsed, cleaned, deoxidized, cleaned and deoxidized, anodized, pickled, plasma treated, laser treated, or ion vapor deposition (IVD) treated. At least a portion of the surface of the substrate may be treated by physical and/or chemical means such as mechanically polishing the surface and/or cleaning/degreasing the surface with commercially available alkaline or acidic cleaners well known to those skilled in the art. can be cleaned by These optional treatments may be used alone or in combination with pretreatment compositions and/or priming compositions.

The present invention also relates to substrates coated using the electrocoating system described above. The substrate may optionally be further coated using a topcoat system. Accordingly, the substrate includes an electrocoat layer and an optional topcoat layer.

The present invention also relates to substrates coated using the pretreatment system and electrocoating system described above. The substrate may optionally be coated using a topcoat system. Accordingly, the substrate may include a pretreatment layer, an electrocoat layer and an optional topcoat layer.

The present invention also relates to substrates coated using the priming system and electrocoating system described above. The substrate may optionally be coated using a topcoat system. Accordingly, the substrate may include a priming layer, an electrocoating layer and an optional topcoat layer.

The present invention also relates to substrates coated using the pretreatment system, priming system and electrocoating system described above, respectively. The substrate may optionally be coated using a topcoat system. Accordingly, the substrate includes a pretreatment layer, a priming layer, an electrocoat layer and an optional topcoat layer.

The invention also relates to a substrate coated according to the method of the invention.

Systems for coating substrates

The present invention also relates to a system for coating a substrate comprising the electrocoating system described above. The system for coating the substrate may optionally further comprise a pretreatment system, a priming system, a topcoat system, or any combination thereof. For example, a system for coating a substrate may include a pretreatment system for pretreating the substrate; a priming system for priming the substrate; an electrocoating system for electrocoating a substrate; and a topcoat system for applying the topcoat coating to the substrate. A system for coating a substrate may comprise any combination of the systems discussed above applied sequentially. For example, a system for coating a substrate may include a pretreatment system followed by an electrocoating system; A system for coating a substrate may comprise a pretreatment system followed by an electrocoating system followed by a topcoat system; A system for coating a substrate may include a priming system followed by an electrocoating system; A system for coating a substrate may comprise a priming system followed by an electrocoating system followed by a topcoat system; A system for coating a substrate may include a pretreatment system followed by a priming system followed by an electrocoating system; A system for coating a substrate may comprise a pretreatment system followed by a priming system followed by an electrocoating system followed by a topcoat system; Alternatively, the system for coating the substrate may comprise an electrocoating system followed by a topcoat system.

Accordingly, in view of the foregoing, the present invention particularly relates to, but is not limited to, the following aspects: A first aspect is an electrocoating system comprising at least one sidewall, the electrodepositionable for receiving a substrate to be coated An electrocoating system comprising: a tank configured to hold a coating composition; and a movable electrode positioned within the tank, wherein the movable electrode does not extend through the sidewall. A second aspect relates to the electrocoating system of the first aspect, further comprising at least one means for positioning the movable electrode within the tank. A second aspect is an electrocoating system according to the second aspect, wherein the means for positioning the movable electrode within the tank comprises a device positioned above the tank, the device having an arm configured to position the expandable electrode within the tank. it's about A fourth aspect relates to the electrocoating system of the third aspect, wherein the apparatus comprises a cart positioned on at least one rail and is laterally movable on the rail relative to the tank. A fifth aspect relates to the electrocoating system according to any one of the first to fourth aspects, wherein the movable electrode comprises an expandable electrode. A sixth aspect relates to the electrocoating system of the fifth aspect, wherein the expandable electrode is positioned on the sidewall and configured to extend away from the sidewall. A seventh aspect is the electricity of aspect 5, wherein the tank further comprises a bottom, wherein the expandable electrode is located on the bottom, the expandable electrode is configured to extend away from the bottom and does not extend through the bottom of the tank. It relates to a coating system. An eighth aspect is the electrocoating system according to any one of the fifth to seventh aspects, further comprising at least one of means for positioning the expandable electrode within the tank, means for expanding and/or means for retracting. is about A ninth aspect comprises the apparatus according to any one of the fifth to eighth aspects, wherein the means for positioning the expandable electrode within the tank, the means for expanding and/or the means for retracting are located above the tank, The apparatus relates to an electrocoating system having an arm configured to position an expandable electrode within a tank. A tenth aspect relates to the electrocoating system of the ninth aspect, wherein the apparatus comprises a cart, the cart positioned on at least one rail and laterally movable on the rail relative to the tank. An eleventh aspect further comprises the electrocoating of the tenth aspect, further comprising a second cart comprising an arm coupled to the expandable electrode, wherein the first cart and the second cart are configured to at least partially expand the expandable electrode It's about the system. A twelfth aspect relates to the electrocoating system of the eleventh aspect, wherein the system further comprises means for further expanding the expandable electrode. A thirteenth aspect is any one of the ninth to twelfth aspects, wherein the means for expanding or means for further expanding the expandable electrode comprises drive means, the drive means comprising a rack and pinion, a pneumatic press, a hydraulic press , or a combination thereof. A fourteenth aspect relates to the electrocoating system of any one of the first to thirteenth aspects, wherein the expandable electrode comprises a telescoping electrode. A fifteenth aspect is the aspect of the fourteenth aspect, wherein at least a portion of the telescoping electrode is formed of telescoping sections that can be fitted together, wherein the telescoping electrode comprises n telescoping sections each of length X, the telescoping The compartment may extend the length of the telescoping electrode up to a length of nX−X, wherein n is an integer greater than one. A sixteenth aspect relates to the electrocoating system of any one of the fifth to eighth aspects, wherein the expandable electrode comprises a flexible material comprising a rope or hose-like configuration. A seventeenth aspect relates to the electrocoating system according to any one of the first to sixteenth aspects, further comprising means for balancing the expandable electrode in the expanded state. An eighteenth aspect relates to the electrocoating system according to any one of the first to seventeenth aspects, further comprising at least one fixed electrode and/or free of an ion exchange membrane. A nineteenth aspect relates to the electrocoating system of any one of the fifth to eighteenth aspects, wherein the expandable electrode further comprises a spacer. A twentieth aspect is any one of aspects 1 to 19, wherein the movable electrode is (1) completely positioned within the tank, (2) configured to have no points of contact with the substrate to be coated, (3) at least one of having a surface free of electrocatalyst, (4) comprising a non-porous material, and/or (5) completely immersed in the electrodepositable coating composition. A twenty-first aspect relates to the electrocoating system according to any one of the first to twentieth aspects, wherein the movable electrode is connected to a terminal of a power source and the substrate to be coated is connected to a terminal of opposite polarity of the power source. A twenty-second aspect relates to the electrocoating system according to any one of the first to twenty-first aspects, further comprising means for rotating and/or rotating the substrate to be coated. A twenty-third aspect relates to the electrocoating system of any one of aspects 1 to 22, wherein the movable electrode further comprises at least one protrusion. A twenty-fourth aspect is a method of coating a substrate using the electrocoating system of any one of aspects 1 to 23, comprising the steps of positioning the substrate in a tank, wherein the surface of the substrate to be coated is retained in the tank. positioning a substrate to be immersed in the composition; positioning the movable electrode; electrically coupling the movable electrode and the substrate to opposite poles of the power source; and then applying an electric current from a power source to electrodeposit the coating deposited from the electrodepositable coating composition onto the surface of the substrate. A twenty-fifth aspect relates to the method of the twenty-fourth aspect, wherein the substrate comprises a container having a cavity, and wherein the movable electrode is positioned within the cavity. A twenty-sixth aspect relates to any one of aspects 24 or 25, wherein the movable electrode has an outer surface, the outer surface being at a distance of no more than 4 feet from the surface of the substrate to be coated after positioning the movable electrode; It relates to a method for coating a substrate. A twenty-seventh aspect comprises the steps of any one of aspects 5 to 23, comprising: placing the substrate in a tank, wherein the surface of the substrate to be coated is immersed in the electrodepositable coating composition held in the tank; expanding the expandable electrode; electrically coupling the expandable electrode and the substrate to opposite poles of the power source; and then applying an electric current from a power source to electrodeposit the coating deposited from the electrodepositable coating composition onto the surface of the substrate. A twenty-eighth aspect relates to the method of the twenty-seventh aspect, wherein the substrate comprises a container having a cavity, and wherein the expandable electrode extends into the cavity. A twenty-ninth aspect relates to a substrate coated by the method according to any one of the twenty-fourth to twenty-eighth aspects. A thirtieth aspect provides a method according to any one of aspects 1 to 23, further comprising: (1) a pretreatment system for pretreating the substrate prior to treating the substrate in the electrocoating system; (2) a priming system for priming the substrate prior to treating the substrate in the electrocoating system; and/or (3) a topcoat system for applying a topcoat coating to the substrate after treating the substrate in the electrocoating system. .

For the purposes of this detailed description, it is to be understood that the invention is capable of various alternative modifications and sequence of steps except as expressly set forth otherwise. Further, except in any operational example or where otherwise indicated, all numbers, such as those expressing values, amounts, percentages, ranges, subranges, and fractions, are denoted by the word "about" even if the term about is not explicitly shown. It can be read as before. Accordingly, unless otherwise indicated, the numerical parameters set forth in the following specification and appended claims are approximations which may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter should at least be construed in light of the reported significant digits and by applying ordinary rounding techniques. Where closed or open numerical ranges are described herein, all numbers, values, amounts, percentages, subranges and fractions within or subsumed within the numerical range are such numbers, values, amounts, percentages, subranges and fractions. is considered to be specifically included and pertaining to the original invention of this application as if fully expressly set forth herein.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in each test measurement.

As used herein, plural terms, unless otherwise indicated, may include singular elements and vice versa. For example, a movable electrode, a telescoping compartment, a means for positioning the movable electrode within a tank, an arm, a cart, a rail, a leg, a means for extending the expandable electrode, a means for retracting the expandable electrode, a movement Although possible means for balancing electrodes, and fixed electrodes, are mentioned herein, combinations (ie, multiple) of these components may also be used. Also, the use of "or" in this application means "and/or" unless specifically indicated otherwise, but "and/or" may be used explicitly in certain instances.

As used herein, "comprising", "comprising" and similar terms are understood to be synonymous with "comprising" in the context of the present application, and are therefore open-ended and include additional elements, materials, and materials not described or mentioned; The presence of components or method steps is not excluded. As used herein, “consisting of” is understood to exclude the presence of any unrepresented element, component or method step in the context of the present application. As used herein, "consisting essentially of" means in the context of the present application that an element, material, ingredient or method step presented, and "does not materially affect the basic and novel property(s)" of the one described. It is understood to include

As used herein, the terms "on", "on", "applied on", "applied on", "formed on", "deposited on", "deposited on" means to be formed, superimposed, deposited or provided without need of contact. For example, an electrodepositable coating composition “deposited” on a substrate does not exclude the presence of one or more other intervening coating layers of the same or different composition positioned between the electrodepositable coating composition and the substrate.

Although specific embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that various modifications and alternatives to these details may be made in light of the overall disclosure of the present invention. Accordingly, the specific arrangements disclosed are for illustrative purposes only and are not intended to limit the scope of the invention, which is to be given the full scope of the appended claims and any and all equivalents thereof.

It will be appreciated by those skilled in the art that numerous modifications and variations are possible in light of the above disclosure without departing from the broad inventive concept described and illustrated herein. Accordingly, the foregoing disclosure is merely illustrative of various exemplary aspects of the present application, and those skilled in the art will recognize numerous modifications and variations that fall within the spirit and scope of this application and the appended claims. It is understood that it can be easily implemented.

Claims (27)

An electrocoating system comprising:
a tank comprising one or more sidewalls and configured to hold an electrodepositable coating composition for receiving a substrate to be coated, and
A movable electrode positioned within the tank, wherein the movable electrode does not extend through the sidewall.
comprising, an electrocoating system. The electrocoating system of claim 1 , further comprising at least one means for positioning the movable electrode within the tank. The electrocoating system of claim 1 , wherein the movable electrode comprises an expandable electrode. 4. The electrocoating system of claim 3, wherein the expandable electrode is positioned on the sidewall and configured to extend away from the sidewall. 4. The tank of claim 3, wherein the tank further comprises a bottom, the expandable electrode positioned on the bottom, the expandable electrode configured to extend away from the bottom, and wherein the expandable electrode does not extend through the bottom of the tank. Do not use, electro-coating system. 4. The electrocoating system of claim 3, further comprising at least one means for expanding and/or retracting the expandable electrode within the tank. 7. The device of claim 6, wherein the means for expanding and/or retracting the expandable electrode within the tank comprises a device positioned above the tank, the device configured to position the expandable electrode within the tank. An electrocoating system having an arm configured to 8. The system of claim 7, wherein the apparatus comprises a cart, the cart positioned on at least one rail and laterally movable on the rail with respect to the tank. 9. The electrocoating system of claim 8, wherein the electrocoating system further comprises a second cart comprising an arm coupled to the expandable electrode, the first cart and the second cart configured to at least partially expand the expandable electrode. Constructed, electro-coating system. 10. The system of claim 9, wherein the system further comprises means for further expanding the expandable electrode. 7. The method of claim 6, wherein the means for expanding and/or retracting the expandable electrode comprises a drive means, the drive means comprising a rack and pinion, a pneumatic press, a hydraulic press, or a combination thereof. comprising, an electrocoating system. 4. The electrocoating system of claim 3, wherein the expandable electrode comprises a telescoping electrode. 13. The method of claim 12, wherein at least a portion of the telescoping electrode is formed of a telescoping section that can be fitted with each other, the telescoping electrode each comprising n telescoping sections of length X, the telescoping section comprising: wherein the length of the stretchable electrode can be extended by a maximum of nX - X, n being an integer greater than one. 4. The system of claim 3, wherein the expandable electrode comprises a flexible material comprising a rope or hose-like configuration. The electrocoating system of claim 1 further comprising means for balancing the movable electrode. The electrocoating system of claim 1 , further comprising at least one fixed electrode. 4. The electrocoating system of claim 3, wherein the expandable electrode further comprises a spacer. The electrocoating system of claim 1 , wherein the movable electrode is positioned entirely within the tank. The electrocoating system of claim 1 , wherein the movable electrode is completely immersed in the electrodepositable coating composition. The electrocoating system of claim 1 , wherein the movable electrode has a cross-sectional shape of a triangle, a square, a rectangle, a pentagon, a hexagon, a heptagon, an octagon, a flat plate, a C-shape, a sector shape, or an annular shape. The electrocoating system of claim 1 , wherein the movable electrode is connected to a terminal of a power source and the substrate to be coated is connected to a terminal of opposite polarity of the power source. A method of coating a substrate using the electrocoating system of claim 1, comprising:
placing a substrate in the tank, wherein the surface of the substrate to be coated is immersed in an electrodepositable coating composition held in the tank;
positioning the movable electrode;
electrically coupling the movable electrode and the substrate to opposite poles of a power source; and then
electrodepositing the electrodepositable coating composition on the surface of the substrate by applying an electric current from the power source.
A method of coating a substrate comprising a. 23. The method of claim 22, wherein the substrate comprises a container having a cavity, and wherein the movable electrode is positioned within the cavity. 23. The method of claim 22, wherein the movable electrode has an exterior surface, the exterior surface being at a distance of no more than 4 feet from the surface of the substrate to be coated after positioning the movable electrode. 23. The method of claim 22,
pretreating the substrate prior to treating the substrate in the electrocoating system;
priming the substrate prior to treating the substrate in the electrocoating system; and/or
applying a topcoat coating to the substrate after treating the substrate in the electrocoating system;
A method of coating a substrate further comprising at least one of. A substrate coated by the method of claim 22 . A system for coating a substrate comprising:
The electrocoating system of claim 1, comprising:
a pretreatment system for pretreating the substrate prior to treating the substrate in the electrocoating system;
a priming system for priming the substrate prior to treating the substrate in the electrocoating system; and/or
A topcoat system for applying a topcoat coating to the substrate after treating the substrate in the electrocoating system
A system for coating a substrate, further comprising at least one of

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