WO2012002932A1 - Single-component coating having alkoxysilane-terminated n-substituted urea resins - Google Patents

Single-component coating having alkoxysilane-terminated n-substituted urea resins Download PDF

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WO2012002932A1
WO2012002932A1 PCT/US2010/040332 US2010040332W WO2012002932A1 WO 2012002932 A1 WO2012002932 A1 WO 2012002932A1 US 2010040332 W US2010040332 W US 2010040332W WO 2012002932 A1 WO2012002932 A1 WO 2012002932A1
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Prior art keywords
resin
polyisocyanate based
aminopropyltrimethoxysilane
butyl
aliphatic polyisocyanate
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PCT/US2010/040332
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French (fr)
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Erick B. Iezzi
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Science Applications International Corporation
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Priority to EP10854202.8A priority Critical patent/EP2588051A1/en
Priority to PCT/US2010/040332 priority patent/WO2012002932A1/en
Publication of WO2012002932A1 publication Critical patent/WO2012002932A1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/2805Compounds having only one group containing active hydrogen
    • C08G18/288Compounds containing at least one heteroatom other than oxygen or nitrogen
    • C08G18/289Compounds containing at least one heteroatom other than oxygen or nitrogen containing silicon
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72Polyisocyanates or polyisothiocyanates
    • C08G18/77Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78Nitrogen
    • C08G18/79Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
    • C08G18/791Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
    • C08G18/792Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D175/00Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/04Polyurethanes
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20Oxides; Hydroxides
    • C08K3/22Oxides; Hydroxides of metals
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds
    • C08K3/36Silica

Definitions

  • the present application relates generally to the synthesis of alkoxysilane- terminated N-substituted urea resins and their application in single-component coatings.
  • This coating which is a silicone alkyd, has been used by the Navy for over 50 years, even though the technology continues to provide poor exterior durability (color and gloss retention upon exposure to an oxidative environment with UV and visible light), poor chemical resistance, low hardness, slow cure times and limited cleanability.
  • the formulation of low volatile organic component (“VOC”) versions has also recently become difficult, as the utilization of lower viscosity raw materials are increased in effort to maintain sprayable and/or rollable formulations. Unfortunately, this continued decrease in viscosity is typically accompanied by a reduction in resin molecular weight and cross-linkable functionality, thereby reducing the cross-link density and hardness of the resulting cured coating.
  • a reduction in the molecular weight of resin components can also lead to sagging of the coating when applied.
  • the VOC of silicone alkyd formulations has also been lowered by using exempt solvents, such as Oxsol 100, which do not count against the VOC rule. Although these solvents do not contribute to ozone depletion, it remains beneficial for paint applicators to use coatings with the lowest solvent content possible.
  • Silicone alkyd coatings can be formulated as single-component (also known as
  • IK insky et al.
  • 2K two-component (2K) systems because they cross-linking mechanism occurs as a result of atmospheric oxygen reacting with residual alkenes contained within the resins of the coating.
  • the coating does not begin to cure until it is applied on a surface and the solvent evaporates, thereby giving it essentially a limitless pot-life, unlike two-component (2K) systems that begin to react once the components are mixed. Because it is a single-component system, no specialty mixing, equipment, or training is needed to apply the coating, as it can be easily spray-applied by individuals during depot level painting.
  • Acrylic siloxanes are conventionally used as both additives and base resins in commercial coatings. These resins are easily manufactured via polymerization of alkoxysilane- functional acrylate monomers with ethyl, butyl, or hexyl acrylate and/or meth(acrylate) monomers. Depending on the molecular weight, acrylic siloxane resins may contain moderate- to-high VOC levels, yet because the alkoxysilane groups are the only reactive functionality, these resins can be used to generate single-component (IK) coatings. Nevertheless, while these moisture curable resins are found in commercial IK coatings, they are not without their drawbacks. The biggest problem with acrylic siloxanes is that they are slow to cure when not exposed to high humidity environments.
  • the coating described herein attempts to provide this solution by synthesizing alkoxysilane-terminated N-substituted urea resins, then formulating them into moisture-curable single-component (IK) topside coatings. These coatings will provide greater external stability (color and gloss retention upon exposure to UV and visible light), cleanability, flexibility, cure times and lower VOC content than the currently qualified silicone alkyd topside coatings that are found on Navy ships.
  • a single-component coating comprises an alkoxysilane- terminated N-substituted urea resin, a reactive diluent, a pigment, a filler, and a catalyst.
  • a resin comprises an amino-functional silane substituted at the N-position and a non-aromatic isocyanate.
  • a method for producing a single component coating comprises synthesizing a resin from an amino-functional silane substituted at the N- position and a non-aromatic isocyanate; and mixing the synthesized resin with a catalyst, a pigment, a filler, and a reactive diluent.
  • a single-component coating is one that is pre-mixed and does not require any additional additives before being applied to a surface.
  • the coating may need to be shaken before use, but the entire product is contained within a single can.
  • By using a single-component coating less material is wasted and the product is easier to use.
  • the term "single-component" or "IK" is not intended to mean that the coating is made from a single chemical or substance, but rather that the end product does not need to be mixed with another component before application as a coating.
  • the single-component coating described herein can be applied to a primer or directly to a metal substrate.
  • An exemplary single-component coating has various components, including, but not limited to, a resin formed from an amino-functional silane substituted at the N-position and a non-aromatic isocyanate.
  • the resin should be alkoxysilane-terminated and be a urea resin.
  • the resin is formed of a combination of an isocyanate and a N- substituted amino-functional alkoxysilane in a ratio of about 1 : 1. In other examples, the ratio can range from about 1.05: 1 to about 1 : 1.05.
  • the amino-functional silane substituted at the N-position can be an alkoxysilane.
  • Examples include N-butyl-3-aminopropyltrimethoxysilane, commercially available as SIB1932.2 from Gelest or Dynasylan 1189 from Evonik; N-butyl-3-aminopropylmethyldimethoxysilane, commercially available as 3B3-073658 from 3B Scientific Corp.; N-butyl-3- aminopropyltriethoxysilane; N-ethyl-3 -aminopropyltriethoxysilane; N-phenyl-3 - aminopropyltrimethoxysilane, commercially available as SIP6724.0 from Gelest; N-cyclohexyl- 3-aminopropyltrimethoxysilane, commercially available as 3B3-072498 from 3B Scientific Corp.; N-hexyl-3-aminopropyltrimethoxysilane; N-pentyl-3-aminopropyltrimethoxysilane; N- isopropyl-3
  • the non-aromatic isocyanate can be an aliphatic or cycloaliphatic polyisocyanate, which is more durable to exterior elements than an aromatic isocyanate.
  • examples include aliphatic polyisocyanate based on HDI trimer, commercially available as Desmodur N 3600 from Bayer; aliphatic polyisocyanate based on HDI uretdione, commercially available as Desmodur XP 2730 from Bayer; aliphatic polyisocyanate based on HDI biuret, commercially available as Desmodur N 3200 from Bayer; aliphatic polyisocyanate based on HDI allophanate trimer, commercially available as Desmodur XP 2731 from Bayer; aliphatic polyisocyanate based on asymmetric HDI trimer, commercially available as Desmodur XP 2410 from Bayer; cycloaliphatic polyisocyanate based on IPDI trimer, commercially available as Desmodur Z 4700 from
  • the reaction was heated at 50 °C for 30 minutes. Drying agents, such as vinyltrimethoxysilane, can also be added to the reaction in amounts of about 1.5% by weight.
  • the resin was 76 wt.% solids (as determined by 110 °C for 1 hour).
  • the resin can be synthesized using aromatic solvents, ester-based solvents, or others known to one of ordinary skill in the art.
  • the resin is a trimethoxysilane-terminated N-butyl urea resin, which has the chemical name urea, N,N",N""-[( remind5-trioxo-l procur5-triazine-l, 3,(2H,4H,6H)-triyl)tri-6,l- hexanediyl]tris[N-butyl-N'-[3-(trimethoxysilyl)propyl]- or 1,1 ', l"-(6,6',6"-(2,4,6-trioxo-l ,3,5- triazinane-l,3,5-triyl)tris(hexane-6,l-diyl))tris(3-butyl-3-(trimethoxysilyl)propyl)urea).
  • the resin described herein allows terminal alkoxysilane groups to be moderate-to- fast reacting due to inclusion of a substituent on a nitrogen atom of the urea linkage.
  • Commercial acrylic siloxane resins are slow to react because they do not have nitrogen's electron density to aid with moisture hydrolysis.
  • the urea linkage would no longer remain planar as the substituted nitrogen fragment rotates to alleviate sterric interactions, and nitrogen's lone pair would now become available to aid with hydrolysis of the tethered alkoxysilane group.
  • Greater rotation within the urea linkages will also lead to less intermolecular hydrogen bonding, thereby yielding coatings with greater flexibility and lower viscosity.
  • Alternative versions of the resin can be synthesized using mixtures of N- substituted aminoalkoxysilanes and di-substituted amines, so that all portions of the resulting resin do not contain terminal alkoxysilane groups, yet the resin still remains an N-substituted urea.
  • Examples of commercially available di-substituted amines include, but are not limited to, ⁇ , ⁇ -dibutylamine, N,N-diethylamine, ⁇ , ⁇ -dimethylamine, N,N-diisopropylamine,
  • N,N-dicyclohexylamine, ⁇ , ⁇ -diphenylamine N-methylcyclohexylamine, N-tert- butylcyclohexylamine, N-ethylcyclohexylamine, N-butylcyclohexylamine, N-ethylaniline, N- butylaniline.
  • the resin can be used to form a single component coating.
  • About 105.26g of the resin from the figure of the first example above is mixed with 35g of various pigments (e.g., titanium dioxide or colorants), 5g of a matting agent (e.g., amorphous silica or micronized urea), 20g of an alkoxysilane-functional diluent (e.g., hexyltrimethoxysilane, oligomeric methyl silicates), and 0.5g of a catalyst (e.g., dibutyltin dilaurate).
  • various pigments e.g., titanium dioxide or colorants
  • a matting agent e.g., amorphous silica or micronized urea
  • an alkoxysilane-functional diluent e.g., hexyltrimethoxysilane, oligomeric methyl silicates
  • a catalyst e.g., dibut
  • the formulas were coated on tinplate test panels and allowed to cure for 7 days at ambient conditions (75 °F, 50% R.H.) before being tested.
  • the coatings were tack-free after several hours. Once cured, the coatings demonstrated good hardness, flexibility, and solvent resistance.
  • the cured coatings also showed good color and gloss retention upon exposure to ultraviolet and visible radiation from QUV-B and weatherometer (WOM) instruments. For instance, the color change (delta E) of the coatings was ⁇ 0.4 after 1000 hours WOM exposure.
  • coatings of various gloss levels and colors have been made using a variety of pigments, reactive diluents, fillers, and other additives.
  • the coating can also include a silicone-based diluent, such as methoxy-functional silicone resin, commercially available as Silres SY 231 from Wacker; oligomeric methyl silicates, commercially available as Silres MSE 100 from Wacker; hexyltrimethoxysilane, commercially available as SIH6168.5 from Gelest; octylmethyldiethoxysilane, commercially available as SI06712.4 from Gelest; n-octyltrimethoxysilane, commercially available as SI06715.5 from Gelest; and methoxy functional silicone, commercially available as DC-3074 Intermediate from Dow Corning.
  • methoxy-functional silicone resin commercially available as Silres SY 231 from Wacker
  • oligomeric methyl silicates commercially available as Silres MSE 100 from Wacker
  • the single-component coating can also include a catalyst, which can be used to accelerate the rate of cure.
  • the catalyst can include dibutyltin dilaurate (“DBTDL").
  • DBTDL dibutyltin dilaurate
  • the single-component coating can also include one or more of various pigments, fillers, additives (e.g., adhesion promoters, wetting and dispersing agents, thickening agents), and solvents known to a person having ordinary skill in the art.
  • Silicone-containing coatings are becoming increasing popular within the global coatings market due to their outstanding external durability, chemical resistance, ability to cure with atmospheric moisture, and reduced VOC requirements.
  • Siloxane coatings have an inherent advantage over conventional organic coatings due to the presence of silicone-oxygen bonds. For instance, the Si-0 bond, which has an enthalpy of 110 kcal/mol, is much stronger than a carbon- hydrogen (99 kcal/mol) or carbon-carbon bond (83 kcal/mol), thereby leading to an increased ultraviolet (UV), oxidative and thermal stability.
  • siloxane-based materials are designed to react in the presence of moisture.
  • these siloxane materials contain hydrolyzable alcohol groups, such as methanol or ethanol, which are bound to the silicone atom.
  • alcohol groups When moisture is present, the alcohol groups are released and silanol (Si-OH) groups are formed.
  • Si-OH silanol
  • the silanols then condense with one another, both intra- and intermolecularly, to yield a cured siloxane network.
  • the number of alcohol groups on a silicone atom will determine the potential points of hydrolysis, and a greater number of condensed silanol groups will result in a higher cross-link density within the coating.
  • Example 1 Semi-gloss, light gray
  • N-substituted urea resin (as shown in the figure 63.50%
  • Titanium dioxide 18.20%
  • N-substituted urea resin (as shown in the figure 61.64% in the first example)
  • Titanium dioxide 16.40%
  • N-substituted urea resin (as shown in the figure 71.00% in the first example)
  • N-substituted urea resin (as shown in the figure 64.35%) in the first example)
  • Titanium dioxide 7.12%
  • Example 5 High gloss, white
  • Titanium dioxide 21.77%
  • Titanium dioxide 21.77%
  • the single-component, low VOC, moisture-curable silicone-containing coating described herein can solve many of the problems that are inherent with many commercial single component coatings, while also remaining applicable to both depot level and ship's force painters.
  • the developed coating should greatly outperform the Navy's qualified silicone alkyd coatings in terms of exterior durability (color stability and gloss retention), cleanability, flexibility and cure times, while also overcoming a limit of acrylic siloxane coatings, which is the inability to properly cure when not exposed to a high humidity environment.

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Abstract

The coating described herein attempts to provide this solution by synthesizing alkoxysilane- terminated N-substituted urea resins, then formulating them into moisture-curable single- component (IK) topside coatings. These coatings will provide greater external stability (to UV and visible radiation), cleanability, flexibility, cure times and lower VOC content than the currently qualified silicone alkyd topside coatings that are found on Navy ships. The single- component coating can include at least an alkoxysilane-terminated N-substituted urea resin, a reactive diluent, a pigment, a filler, and a catalyst. The resin can include an amino-functional silane substituted at the N-position and a non-aromatic isocyanate.

Description

SINGLE-COMPONENT COATING HAVING ALKOXYSILANE-TERMINATED
N-SUBSTITUTED UREA RESINS
TECHNICAL FIELD
[0001] The present application relates generally to the synthesis of alkoxysilane- terminated N-substituted urea resins and their application in single-component coatings.
BACKGROUND
[0002] The Navy currently has only one topside coating that is qualified for use under
MIL-PRF-24635. This coating, which is a silicone alkyd, has been used by the Navy for over 50 years, even though the technology continues to provide poor exterior durability (color and gloss retention upon exposure to an oxidative environment with UV and visible light), poor chemical resistance, low hardness, slow cure times and limited cleanability. The formulation of low volatile organic component ("VOC") versions has also recently become difficult, as the utilization of lower viscosity raw materials are increased in effort to maintain sprayable and/or rollable formulations. Unfortunately, this continued decrease in viscosity is typically accompanied by a reduction in resin molecular weight and cross-linkable functionality, thereby reducing the cross-link density and hardness of the resulting cured coating. A reduction in the molecular weight of resin components can also lead to sagging of the coating when applied. The VOC of silicone alkyd formulations has also been lowered by using exempt solvents, such as Oxsol 100, which do not count against the VOC rule. Although these solvents do not contribute to ozone depletion, it remains beneficial for paint applicators to use coatings with the lowest solvent content possible.
[0003] Silicone alkyd coatings can be formulated as single-component (also known as
"IK") systems because their cross-linking mechanism occurs as a result of atmospheric oxygen reacting with residual alkenes contained within the resins of the coating. The coating does not begin to cure until it is applied on a surface and the solvent evaporates, thereby giving it essentially a limitless pot-life, unlike two-component (2K) systems that begin to react once the components are mixed. Because it is a single-component system, no specialty mixing, equipment, or training is needed to apply the coating, as it can be easily spray-applied by individuals during depot level painting. Navy sailors are routinely found applying (via roller or brush) silicone alkyd coatings to a ship for the sake of touch-up and/or beauty coating, yet this mundane and non war-related task would not be required if the silicone alkyd coatings already on the ship did not fade, chalk, discolor or stain within only a few months after application.
[0004] Acrylic siloxanes are conventionally used as both additives and base resins in commercial coatings. These resins are easily manufactured via polymerization of alkoxysilane- functional acrylate monomers with ethyl, butyl, or hexyl acrylate and/or meth(acrylate) monomers. Depending on the molecular weight, acrylic siloxane resins may contain moderate- to-high VOC levels, yet because the alkoxysilane groups are the only reactive functionality, these resins can be used to generate single-component (IK) coatings. Nevertheless, while these moisture curable resins are found in commercial IK coatings, they are not without their drawbacks. The biggest problem with acrylic siloxanes is that they are slow to cure when not exposed to high humidity environments.
SUMMARY OF THE INVENTION
[0005] It is desirable have a single component topside coating. The coating described herein attempts to provide this solution by synthesizing alkoxysilane-terminated N-substituted urea resins, then formulating them into moisture-curable single-component (IK) topside coatings. These coatings will provide greater external stability (color and gloss retention upon exposure to UV and visible light), cleanability, flexibility, cure times and lower VOC content than the currently qualified silicone alkyd topside coatings that are found on Navy ships.
[0006] In one embodiment, a single-component coating comprises an alkoxysilane- terminated N-substituted urea resin, a reactive diluent, a pigment, a filler, and a catalyst.
[0007] In another embodiment, a resin comprises an amino-functional silane substituted at the N-position and a non-aromatic isocyanate.
[0008] In yet another embodiment, a method for producing a single component coating, the method comprises synthesizing a resin from an amino-functional silane substituted at the N- position and a non-aromatic isocyanate; and mixing the synthesized resin with a catalyst, a pigment, a filler, and a reactive diluent.
[0009] Additional features and advantages of an embodiment will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the exemplary embodiments in the written description and claims hereof as well as the appended drawings.
[0010] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
DETAILED DESCRIPTION
[0011] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0012] A single-component coating is one that is pre-mixed and does not require any additional additives before being applied to a surface. The coating may need to be shaken before use, but the entire product is contained within a single can. By using a single-component coating, less material is wasted and the product is easier to use. The term "single-component" or "IK" is not intended to mean that the coating is made from a single chemical or substance, but rather that the end product does not need to be mixed with another component before application as a coating. The single-component coating described herein can be applied to a primer or directly to a metal substrate.
[0013] An exemplary single-component coating has various components, including, but not limited to, a resin formed from an amino-functional silane substituted at the N-position and a non-aromatic isocyanate. The resin should be alkoxysilane-terminated and be a urea resin. In an exemplary embodiment, the resin is formed of a combination of an isocyanate and a N- substituted amino-functional alkoxysilane in a ratio of about 1 : 1. In other examples, the ratio can range from about 1.05: 1 to about 1 : 1.05.
[0014] The amino-functional silane substituted at the N-position can be an alkoxysilane.
Examples include N-butyl-3-aminopropyltrimethoxysilane, commercially available as SIB1932.2 from Gelest or Dynasylan 1189 from Evonik; N-butyl-3-aminopropylmethyldimethoxysilane, commercially available as 3B3-073658 from 3B Scientific Corp.; N-butyl-3- aminopropyltriethoxysilane; N-ethyl-3 -aminopropyltriethoxysilane; N-phenyl-3 - aminopropyltrimethoxysilane, commercially available as SIP6724.0 from Gelest; N-cyclohexyl- 3-aminopropyltrimethoxysilane, commercially available as 3B3-072498 from 3B Scientific Corp.; N-hexyl-3-aminopropyltrimethoxysilane; N-pentyl-3-aminopropyltrimethoxysilane; N- isopropyl-3 -aminopropyltrimethoxysilane; or N-isobutyl-3 -aminopropyltrimethoxysilane .
[0015] The non-aromatic isocyanate can be an aliphatic or cycloaliphatic polyisocyanate, which is more durable to exterior elements than an aromatic isocyanate. Examples include aliphatic polyisocyanate based on HDI trimer, commercially available as Desmodur N 3600 from Bayer; aliphatic polyisocyanate based on HDI uretdione, commercially available as Desmodur XP 2730 from Bayer; aliphatic polyisocyanate based on HDI biuret, commercially available as Desmodur N 3200 from Bayer; aliphatic polyisocyanate based on HDI allophanate trimer, commercially available as Desmodur XP 2731 from Bayer; aliphatic polyisocyanate based on asymmetric HDI trimer, commercially available as Desmodur XP 2410 from Bayer; cycloaliphatic polyisocyanate based on IPDI trimer, commercially available as Desmodur Z 4700 from Bayer; cycloaliphatic polyisocyanate based on IPDI allophanate, commericallly available as Desmodur XP 2565 from Bayer; aliphatic polyisocyanate based on HMDI biuret, commercially available as Basonat HB 100 from BASF; and aliphatic polyisocyanate based on HDI trimer, commercially available as Basonat HI 100 from BASF.
[0016] An exemplary process for producing the single-component coating follows. To synthesize the resin depicted below, 81.6g (0.446 mol) of Desmodur N 3600 (an aliphatic polyisocyanate resin from Bayer Material Science) was dissolved in 60g butyl propionate (commercially available from Aldrich) in a 500 ml 3 -neck round bottom flask equipped with an Argon inlet and thermometer. The temperature of the solution was heated to 50 °C, then 104.9g (0.446 mol) of N-butyl-3 -aminopropyltrimethoxysilane (commercially available as Dynasylan 1189 from Evonik Corporation) was added dropwise to the solution while keeping the temperature between 50-60 °C. After the addition was complete, the reaction was heated at 50 °C for 30 minutes. Drying agents, such as vinyltrimethoxysilane, can also be added to the reaction in amounts of about 1.5% by weight. The resin was 76 wt.% solids (as determined by 110 °C for 1 hour). The resin can be synthesized using aromatic solvents, ester-based solvents, or others known to one of ordinary skill in the art.
[0017] Referring to the figure below, in a first example, the synthesis of trimethoxysilane-terminated N-butyl urea resin is shown. Infrared (IR) spectroscopy showed that no more free or reactive isocyanate (NCO) (2260 cm"1) remained in solution.
Figure imgf000006_0001
[0018] The resin is a trimethoxysilane-terminated N-butyl urea resin, which has the chemical name urea, N,N",N""-[(„5-trioxo-l„5-triazine-l, 3,(2H,4H,6H)-triyl)tri-6,l- hexanediyl]tris[N-butyl-N'-[3-(trimethoxysilyl)propyl]- or 1,1 ', l"-(6,6',6"-(2,4,6-trioxo-l ,3,5- triazinane-l,3,5-triyl)tris(hexane-6,l-diyl))tris(3-butyl-3-(trimethoxysilyl)propyl)urea).
[0019] The resin described herein allows terminal alkoxysilane groups to be moderate-to- fast reacting due to inclusion of a substituent on a nitrogen atom of the urea linkage. Commercial acrylic siloxane resins are slow to react because they do not have nitrogen's electron density to aid with moisture hydrolysis. However, if a urea linkage has a substituent on a nitrogen atom, as is the case with the herein described resins, then the urea linkage would no longer remain planar as the substituted nitrogen fragment rotates to alleviate sterric interactions, and nitrogen's lone pair would now become available to aid with hydrolysis of the tethered alkoxysilane group. Greater rotation within the urea linkages will also lead to less intermolecular hydrogen bonding, thereby yielding coatings with greater flexibility and lower viscosity.
[0020] Alternative versions of the resin can be synthesized using mixtures of N- substituted aminoalkoxysilanes and di-substituted amines, so that all portions of the resulting resin do not contain terminal alkoxysilane groups, yet the resin still remains an N-substituted urea.
Figure imgf000007_0001
[0021] As shown in the figure directly above, in a second example, two-thirds of the isocyanate groups were reacted with N-butyl-3-aminopropyltrimethoxysilane, whereas one-third of the isocyanate groups were reacted with a di-substituted amine. This di-substituted amine can contain aliphatic, cycloaliphatic, or aromatic groups, and Ri and R2 can be the same group or different.
Figure imgf000007_0002
[0022] As shown directly above, in a third example, one-third of the isocyanate groups were reacted with N-butyl-3-aminopropyltrimethoxysilane, whereas two-thirds of the isocyanate groups were reacted with a di-substituted amine. This di-substituted amine can contain aliphatic, cycloaliphatic, or aromatic groups, and Ri and R2 can be the same group or different.
[0023] Examples of commercially available di-substituted amines include, but are not limited to, Ν,Ν-dibutylamine, N,N-diethylamine, Ν,Ν-dimethylamine, N,N-diisopropylamine,
N,N-dicyclohexylamine, Ν,Ν-diphenylamine, N-methylcyclohexylamine, N-tert- butylcyclohexylamine, N-ethylcyclohexylamine, N-butylcyclohexylamine, N-ethylaniline, N- butylaniline.
[0024] The resin can be used to form a single component coating. About 105.26g of the resin from the figure of the first example above is mixed with 35g of various pigments (e.g., titanium dioxide or colorants), 5g of a matting agent (e.g., amorphous silica or micronized urea), 20g of an alkoxysilane-functional diluent (e.g., hexyltrimethoxysilane, oligomeric methyl silicates), and 0.5g of a catalyst (e.g., dibutyltin dilaurate). In testing, the formulas were coated on tinplate test panels and allowed to cure for 7 days at ambient conditions (75 °F, 50% R.H.) before being tested. The coatings were tack-free after several hours. Once cured, the coatings demonstrated good hardness, flexibility, and solvent resistance. The cured coatings also showed good color and gloss retention upon exposure to ultraviolet and visible radiation from QUV-B and weatherometer (WOM) instruments. For instance, the color change (delta E) of the coatings was <0.4 after 1000 hours WOM exposure.
[0025] In other embodiments, coatings of various gloss levels and colors have been made using a variety of pigments, reactive diluents, fillers, and other additives. For example, the coating can also include a silicone-based diluent, such as methoxy-functional silicone resin, commercially available as Silres SY 231 from Wacker; oligomeric methyl silicates, commercially available as Silres MSE 100 from Wacker; hexyltrimethoxysilane, commercially available as SIH6168.5 from Gelest; octylmethyldiethoxysilane, commercially available as SI06712.4 from Gelest; n-octyltrimethoxysilane, commercially available as SI06715.5 from Gelest; and methoxy functional silicone, commercially available as DC-3074 Intermediate from Dow Corning.
[0026] The single-component coating can also include a catalyst, which can be used to accelerate the rate of cure. In one example, the catalyst can include dibutyltin dilaurate ("DBTDL"). The single-component coating can also include one or more of various pigments, fillers, additives (e.g., adhesion promoters, wetting and dispersing agents, thickening agents), and solvents known to a person having ordinary skill in the art.
[0027] Silicone-containing coatings are becoming increasing popular within the global coatings market due to their outstanding external durability, chemical resistance, ability to cure with atmospheric moisture, and reduced VOC requirements. Siloxane coatings have an inherent advantage over conventional organic coatings due to the presence of silicone-oxygen bonds. For instance, the Si-0 bond, which has an enthalpy of 110 kcal/mol, is much stronger than a carbon- hydrogen (99 kcal/mol) or carbon-carbon bond (83 kcal/mol), thereby leading to an increased ultraviolet (UV), oxidative and thermal stability.
[0028] A large majority of commercially available siloxane-based materials are designed to react in the presence of moisture. Typically, these siloxane materials contain hydrolyzable alcohol groups, such as methanol or ethanol, which are bound to the silicone atom. When moisture is present, the alcohol groups are released and silanol (Si-OH) groups are formed. The silanols then condense with one another, both intra- and intermolecularly, to yield a cured siloxane network. The number of alcohol groups on a silicone atom will determine the potential points of hydrolysis, and a greater number of condensed silanol groups will result in a higher cross-link density within the coating.
[0029] Examples of the single component coating are provided below. The percentages of each material in the single-component coatings are merely exemplary and are not intended to be limited to those particular percentages or ratios.
[0030] Example 1 - Semi-gloss, light gray
Trade/Chemical Name Wt.% of Formula
DBTDL 0.30%
N-substituted urea resin (as shown in the figure 63.50%
in the first example)
Titanium dioxide 18.20%
Shepherd black 10C909A 3.00%
Amorphous silica 3.00%
Silres MSE 100 12.00% [0031] Example 2 - Semi-gloss, light gray
Trade/Chemical Name Wt.% of Formula
DBTDL 0.30%
N-substituted urea resin (as shown in the figure 61.64% in the first example)
Titanium dioxide 16.40%
Shepherd black 10C909A 7.03%
Amorphous silica 2.93%
Hexyltrimethoxysilane 11.70%
[0032] Example 3 - Flat, haze gray
Trade/Chemical Name Wt.% of Formula
DBTDL 0.48%
N-substituted urea resin (as shown in the figure 71.00% in the first example)
Titanium dioxide 7.00%
Shepherd Black 30C940 1.74%
Shepherd Green 410 1.17%
Shepherd Yellow 30C119 0.60%
Amorphous silica 12.00%
Hexyltrimethoxysilane 6.00%
[0033] Example 4 - Flat, haze gray
Trade/Chemical Name Wt.% of Formula
DBTDL 0.49%
N-substituted urea resin (as shown in the figure 64.35%) in the first example)
Titanium dioxide 7.12%
Shephard Black 30C940 1.77%
Shephard Green 410 1.19%
Shephard Yellow 30C119 0.61% Amorphous silica 12.22%
Silres SY 231 12.22%
[0034] Example 5 - High gloss, white
Trade/Chemical Name Wt.% of Formula
DBTDL 0.30%
N-substituted urea resin (as shown in the figure 65.47%)
in the first example)
Titanium dioxide 21.77%
Silres SY 231 12.44%
[0035] Example 6 - High gloss, white
Trade/Chemical Name Wt.% of Formula
DBTDL 0.30%
N-substituted urea resin (as shown in the figure 65.47%)
in the first example)
Titanium dioxide 21.77%
Hexyltrimethoxysilane 12.44%
[0036] The single-component, low VOC, moisture-curable silicone-containing coating described herein can solve many of the problems that are inherent with many commercial single component coatings, while also remaining applicable to both depot level and ship's force painters. The developed coating should greatly outperform the Navy's qualified silicone alkyd coatings in terms of exterior durability (color stability and gloss retention), cleanability, flexibility and cure times, while also overcoming a limit of acrylic siloxane coatings, which is the inability to properly cure when not exposed to a high humidity environment.
[0037] The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention.

Claims

CLAIMS What is claimed is:
1. A single-component coating comprising: an alkoxysilane-terminated N-substituted urea resin; a reactive diluent; a pigment; a filler; and a catalyst.
2. The single-component coating according to claim 1, wherein the alkoxysilane-terminated N-substituted urea resin comprises an amino-functional silane substituted at the N-position and a non-aromatic isocyanate.
3. The single-component coating according to claim 2, wherein the alkoxysilane-terminated N-substituted urea resin comprises an amino-functional silane substituted at one isocyanate group.
4. The single-component coating according to claim 2, wherein the alkoxysilane-terminated N-substituted urea resin comprises an amino-functional silane substituted at two isocyanate groups.
5. The single-component coating according to claim 2, wherein the silane is an
alkoxysilane.
6. The single-component coating according to claim 1 , wherein the resin is a urea resin.
7. The single-component coating according to claim 1, wherein the resin comprises subtanstially equal parts of an amino-functional silane and an isocyanate.
8. The single-component coating according to claim 2, wherein the amino-functional silane is selected from the group of: N-butyl-3-aminopropyltrimethoxysilane, N-butyl-3- aminopropylmethyldimethoxysilane, N-butyl-3 -aminopropyltriethoxysilane, N-ethyl-3 - aminopropyltriethoxysilane, N-cyclohexyl-3 -aminopropyltrimethoxysilane, N-phenyl-3 - aminopropyltrimethoxysilane, N-hexyl-3 -aminopropyltrimethoxysilane, N-pentyl-3 - aminopropyltrimethoxysilane, N-isopropyl-3 -aminopropyltrimethoxysilane, and N-isobutyl-3 - aminopropyltrimethoxysilane .
9. The single-component coating according to claim 1, wherein the resin is N,N",N""-[(„5- trioxo-l„5-triazine-l, 3,(2H,4H,6H)-triyl)tri-6,l-hexanediyl]tris[N-butyl-N'-[3- (trimethoxysilyl)propyl]- or 1,1 ',l"-(6,6',6"-(2,4,6-trioxo-l,3,5-triazinane-l,3,5- triyl)tris(hexane-6,l-diyl))tris(3-butyl-3-(trimethoxysilyl)propyl)urea).
10. The single-component coating according to claim 2, wherein the non-aromatic isocyanate comprises an aliphatic or cycloaliphatic polyisocyanate.
11. The single-component coating according to claim 2, wherein the non-aromatic isocyanate is selected from the group of: aliphatic polyisocyanate based on HDI trimer, aliphatic polyisocyanate based on HDI uretdione, aliphatic polyisocyanate based on HDI biuret, aliphatic polyisocyanate based on HDI allophanate trimer, aliphatic polyisocyanate based on asymmetric HDI trimer, cycloaliphatic polyisocyanate based on IPDI trimer, cycloaliphatic polyisocyanate based on IPDI allophanate, aliphatic polyisocyanate based on HMDI biuret, and aliphatic polyisocyanate based on HDI trimer.
12. The single-component coating according to claim 1, wherein the diluent is a silicone- based diluent.
13. The single-component coating according to claim 12, wherein the reactive diluent is selected from the group of: methoxy-functional silicone resin, oligomeric methyl silicates, hexyltrimethoxysilane, octylmethyldiethoxysilane, n-octyltrimethoxysilane, and methoxy functional silicone.
14. The single-component coating according to claim 1, wherein the alkoxysilane-terminated N-substituted urea resin comprises about 50 to 100 percent of the formula by weight.
15. The single-component coating according to claim 14, wherein the alkoxysilane- terminated N-substituted urea resin comprises about 61 to 71 percent of the formula by weight.
16. A resin comprising: an amino-functional silane substituted at the N-position; and a non-aromatic isocyanate.
17. The resin according to claim 16, wherein the silane is an alkoxysilane.
18. The resin according to claim 16, wherein the resin is a urea resin.
19. The resin according to claim 16, wherein the resin comprises substantially equal parts of the amino-functional silane and the isocyanate.
20. The resin according to claim 16, wherein the amino-functional silane is selected from the group of: N-butyl-3-aminopropyltrimethoxysilane, N-butyl-3- aminopropylmethyldimethoxysilane, N-butyl-3-aminopropyltriethoxysilane, N-ethyl-3- aminopropyltriethoxy silane, N-cyclohexyl-3-aminopropyltrimethoxysilane, N-phenyl-3- aminopropyltrimethoxysilane, N-hexyl-3 -ammopropyltrimethoxysilane, N-pentyl-3 - ammopropyltrimethoxysilane, N-isopropyl-3 -ammopropyltrimethoxysilane, and N-isobutyl-3 - ammopropyltrimethoxysilane .
21. The resin according to claim 16, wherein the resin is N,N",N""-[(„5-trioxo-l„5-triazine- 1, 3,(2H,4H,6H)-triyl)tri-6,l-hexanediyl]tris[N-butyl-N'-[3-(trimethoxysilyl)propyl]- or Ι,Γ,Γ'- (6,6 6''-(2,4,6-trioxo-l,3,5-triazinane-l,3,5-triyl)tris(hexane-6,l-diyl))tris(3-butyl-3- (trimethoxy sily l)propy l)urea) .
22. The resin according to claim 16, wherein the non-aromatic isocyanate comprises an aliphatic or cycloaliphatic polyisocyanate.
23. The resin according to claim 16, wherein the non-aromatic isocyanate is selected from the group of: aliphatic polyisocyanate based on HDI trimer, aliphatic polyisocyanate based on HDI uretdione, aliphatic polyisocyanate based on HDI biuret, aliphatic polyisocyanate based on HDI allophanate trimer, aliphatic polyisocyanate based on asymmetric HDI trimer, cycloaliphatic polyisocyanate based on IPDI trimer, cycloaliphatic polyisocyanate based on IPDI allophanate, aliphatic polyisocyanate based on HMDI biuret, and aliphatic polyisocyanate based on HDI trimer.
24. A method for producing a single component coating, the method comprising: synthesizing a resin from an amino-functional silane substituted at the N-position and a non-aromatic isocyanate; and mixing the synthesized resin with a reactive diluent, a pigment, a filler, and a catalyst.
25. The method according to claim 24, wherein the synthesized resin is an alkoxysilane- terminated N-substituted urea resin.
26. The method according to claim 24, wherein the silane is an alkoxysilane.
27. The method according to claim 24, wherein the synthesized resin is a urea resin.
28. The method according to claim 24, wherein synthesizing the resin comprises mixing substantially equal parts of the amino-functional silane and the isocyanate.
29. The method according to claim 24, wherein the amino-functional silane is selected from the group of: N-butyl-3-aminopropyltrimethoxysilane, N-butyl-3- aminopropylmethyldimethoxysilane, N-butyl-3 -aminopropyltriethoxysilane, N-ethyl-3 - aminopropyltriethoxysilane, N-cyclohexyl-3 -aminopropyltrimethoxysilane, N-phenyl-3 - aminopropyltrimethoxysilane, N-hexyl-3 -aminopropyltrimethoxysilane, N-pentyl-3 - aminopropyltrimethoxysilane, N-isopropyl-3 -aminopropyltrimethoxysilane, and N-isobutyl-3- aminopropy ltrimethoxy silane .
30. The method according to claim 24, wherein the synthesized resin is N,N",N""-[(„5- trioxo-l„5-triazine-l, 3,(2H,4H,6H)-triyl)tri-6,l-hexanediyl]tris[N-butyl-N'-[3- (trimethoxysilyl)propyl]- or 1,1 ',l"-(6,6',6"-(2,4,6-trioxo-l,3,5-triazinane-l,3,5- triyl)tris(hexane-6,l-diyl))tris(3-butyl-3-(trimethoxysilyl)propyl)urea).
31. The method according to claim 24, wherein the non-aromatic isocyanate comprises an aliphatic or cycloaliphatic polyisocyanate.
32. The method according to claim 24, wherein the non-aromatic isocyanate is selected from the group of: aliphatic polyisocyanate based on HDI trimer, aliphatic polyisocyanate based on HDI uretdione, aliphatic polyisocyanate based on HDI biuret, aliphatic polyisocyanate based on HDI allophanate trimer, aliphatic polyisocyanate based on asymmetric HDI trimer,
cycloaliphatic polyisocyanate based on IPDI trimer, cycloaliphatic polyisocyanate based on IPDI allophanate, aliphatic polyisocyanate based on HMDI biuret, and aliphatic polyisocyanate based on HDI trimer.
33. The method according to claim 24, wherein the diluent is a silicone-based reactive diluent.
34. The method according to claim 24, wherein the diluent is selected from the group of: methoxy-functional silicone resin, oligomeric methyl silicates, hexyltrimethoxysilane, octylmethyldiethoxysilane, n-octyltrimethoxysilane, and methoxy functional silicone.
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