WO2019236503A1 - Compositions d'enveloppement, procédés, et applications pour substrats à faible frottement et durabilité élevée - Google Patents

Compositions d'enveloppement, procédés, et applications pour substrats à faible frottement et durabilité élevée Download PDF

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Publication number
WO2019236503A1
WO2019236503A1 PCT/US2019/035267 US2019035267W WO2019236503A1 WO 2019236503 A1 WO2019236503 A1 WO 2019236503A1 US 2019035267 W US2019035267 W US 2019035267W WO 2019236503 A1 WO2019236503 A1 WO 2019236503A1
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WO
WIPO (PCT)
Prior art keywords
coating composition
fluoropolymer
coating
ptfe
dopamine derivative
Prior art date
Application number
PCT/US2019/035267
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English (en)
Other versions
WO2019236503A8 (fr
Inventor
Samuel George BECKFORD
Cameron Crane
Randy ESPINAL
German PEREZ
Seyed Mohammad Reza RAZAVI
Giselle TOLEDO
Original Assignee
Inv. Namesurftec, Llc
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Application filed by Inv. Namesurftec, Llc filed Critical Inv. Namesurftec, Llc
Priority to CA3102120A priority Critical patent/CA3102120A1/fr
Publication of WO2019236503A1 publication Critical patent/WO2019236503A1/fr
Publication of WO2019236503A8 publication Critical patent/WO2019236503A8/fr

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/046—Forming abrasion-resistant coatings; Forming surface-hardening coatings
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
    • C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
    • C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • C09D127/18—Homopolymers or copolymers of tetrafluoroethene
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/08—Anti-corrosive paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/65—Additives macromolecular
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C08K2003/085—Copper
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C08K3/046—Carbon nanorods, nanowires, nanoplatelets or nanofibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C08K3/36—Silica

Definitions

  • the present invention relates to a coating composition
  • PTFE Polytetrafluoroethylene
  • binders such as polyimide are typically used in combination with PTFE and PTFE copolymers.
  • the surface of the fluoropolymer is typically etched to de-fluorinate the polymer surface.
  • Another way of attaching fluoropolymers to another material surface is to create a porous surface on the opposing material to allow the fluoropolymer to be diffused into these pores.
  • the latter is typically achieved by depositing metal particles on the opposing surface or utilizing a meshed structure that will allow the fluoropolymer to diffuse through and create a matrix of the fluoropolymer and porous surface.
  • the combination of polyimide and PTFE copolymers with PTFE creates a more wear resistant surface, but significantly increase the coefficient of friction and surface energy of PTFE. Further, etching processes can be very costly or involve the use of hazardous etchants that are problematic to store, use and dispose of. Mechanical keying
  • polyimide/polyamide and a blend of fluoropolymer copolymer coatings has created non-stick surfaces with sufficient bonding to prevent removal of the coating when used with low hardness cooking utensils.
  • the scratch resistance and overall durability can be improved.
  • US 4,049,863 discloses a method for applying a PTFE (polytetrafluoroethylene) coating to cookware through the use of polyimide and PTFE copolymers.
  • PTFE polytetrafluoroethylene
  • the present invention provides a coating composition comprising a dopamine derivative and a fluoropolymer that exhibits strong adhesion to fluoropolymer surfaces. Depositing the coating on a fluoropolymer surface allows subsequent bonding of that surface to various metal, non-metal, polymer, and ceramic surfaces.
  • the coating composition of the present invention allows the bonding of fluoropolymers through a process that eliminates the need for mechanical keying and hazardous or costly etching processes.
  • the coating composition of the present invention exhibits low friction, hydophobocity, icephobicity, and anticorrosive, properties.
  • a comparable and improved adhesion strength is achieved without negatively affecting the desirable properties of fluoropolymers, as is the case with most mechanical keying and etching processes.
  • Another attribute of the present coating composition allows for extruded and skived fluoropolymer films with excellent cohesive strength to be bonded directly onto various substrates.
  • the present coating composition can be used with various fluoropolymer products of different geometries that are currently only bonded by utilizing a hazardous etching process to break fluorine bonds at the surface of the fluoropolymer component.
  • Another attribute of the present invention provides the ability to modify the surface of a fluoropolymer to allow it to be directly bonded to various other materials.
  • the adhesion of fluoropolymer components to various rubbers, for example, has significant industrial applicability. These compositions can be used in various seals, gaskets, and diaphragm pumps.
  • Another attribute of the present invention is that the highly durable, protective coating technology withstands extreme environmental wear and resists corrosion while continuously maintaining anti-corrosion as well as anti-icing/ice-phobic physical attributes.
  • substrates coated with the present composition can avoid aircraft detection by RADAR because the present compositions reduce reflection of RADAR spectrum.
  • An embodiment of the present invention provides a coating composition comprising a fluoropolymer and a dopamine derivative.
  • An embodiment of the present invention provides a process for fabricating a coated a substrate, the process comprising the steps of:
  • An embodiment of the present invention provides the process, wherein the fluoropolymer to the dopamine derivative in the composition has a weight ratio of from 1.0 to 50.
  • An embodiment of the present invention provides the process, wherein the fluoropolymer to dopamine derivative in the composition has a weight ratio of from 5.0 to 40.0.
  • An embodiment of the present invention provides the process, wherein the fluoropolymer to dopamine derivative in the composition has a weight ratio of from 6.0 to 30.0.
  • An embodiment of the present invention provides the process, wherein the fluoropolymer to dopamine derivative in the composition has a weight ratio of from 7.0 to 20.0.
  • An embodiment of the present invention provides the process, wherein the solvent is an aqueous liquid.
  • An embodiment of the present invention provides the process, wherein the solvent is water.
  • An embodiment of the present invention provides the process, wherein the solvent is isopropanol, ethanol, or methanol.
  • An embodiment of the present invention provides the process, wherein the solvent is combined with one or more components selected from the group consisting of n-butyl acetate, n-heptane, ethylene glycol monoethyl ether, ethyl acetate, and methyl ethyl ketone.
  • An embodiment of the present invention provides the process, wherein the coating composition further comprises a filler.
  • An embodiment of the present invention provides the process, wherein the coating composition further comprises a nanoparticle filler.
  • An embodiment of the present invention provides the process, wherein the filler is selected from one or more members of the group consisting of alumina, graphite, silica, quartz, sepiolite, capstone, and copper nanoparticles.
  • An embodiment of the present invention provides the process, wherein the coating composition further comprises a surfactant.
  • An embodiment of the present invention provides the process, wherein the dopamine derivative has a concentration of between 1.0 weight % to 20.0 weight %.
  • An embodiment of the present invention provides the process, wherein the dopamine derivative has a concentration of between 2.0 weight % to 8.0 weight %.
  • An embodiment of the present invention provides the process, wherein the fluoropolymer in the coating composition has a
  • An embodiment of the present invention provides the process, wherein the fluoropolymer in the coating composition has a
  • An embodiment of the present invention provides the process, wherein locating the coating composition further comprises dipping, spraying, spinning, or roll coating, or any combination thereof.
  • An embodiment of the present invention provides the process, wherein heating is at a temperature of between 250°C to 400°C.
  • An embodiment of the present invention provides the process, wherein the process further comprises pressing the heated and coated substrate surface against another material surface to provide a lamination.
  • An embodiment of the present invention provides the process, wherein the coated substrate is anti-corrosive.
  • An embodiment of the present invention provides the process, wherein the coated substrate is anti-radar.
  • An embodiment of the present invention provides the process, wherein the coated substrate is ice-phobic.
  • An embodiment of the present invention provides a coating composition comprising a fluoropolymer, a dopamine derivative, and copper nanoparticles.
  • An embodiment of the present invention provides a coating composition comprising a fluoropolymer, a dopamine derivative, and graphite nanoparticles.
  • An embodiment of the present invention provides a coating composition comprising a fluoropolymer, a dopamine derivative, and silica nanoparticles.
  • composition comprising: a fluoropolymer, a dopamine derivative, and alumina nanoparticles.
  • An embodiment of the present invention provides, the process, wherein the filler is one or more nanoparticle components selected from the group consisting of alumina, graphite, silica, quartz, sepiolite, capstone, and copper.
  • An embodiment of the present invention provides, an anti-radar coating composition prepared by a process comprising the steps of:
  • An embodiment of the present invention provides, the process, wherein the filler is one or more nanoparticle components selected from the group consisting of alumina, graphite, silica, quartz, sepiolite, capstone, and copper.
  • An embodiment of the present invention provides, an anti-corrosive coating composition prepared by a process comprising the steps of:
  • An embodiment of the present invention provides, the process, wherein the filler is one or more nanoparticle components selected from the group consisting of alumina, graphite, silica, quartz, sepiolite, capstone, and copper.
  • An embodiment of the present invention provides a coated composition characterized by the XPS pattern shown in FIG. 47.
  • An embodiment of the present invention provides a coated composition characterized by the XPS pattern shown in FIG. 48.
  • An embodiment of the present invention further comprising pressing to densify and reduce porosity before, after, or during heating and curing the coating composition to remove the solvent.
  • FIG. 1a is a picture of a peel test equipment used to determine the adhesion strength of laminated samples.
  • FIG. 1b is a picture of a peel testing process of laminated PTFE composite films 1” x 2” 1006 carbon steel substrate samples (laminated sample before testing).
  • FIG. 1c is a picture of a peel testing process of laminated PTFE composite films 1” x 2” 1006 carbon steel substrate samples (laminated sample during testing).
  • FIG. 1d is a picture of 90° bending of laminated samples (laminated sample before bending).
  • FIG. 1e is a picture of 90° bending of laminated samples (laminated sample after bending).
  • FIG. 2 is a graph of a typical 90°peel test raw data and processing.
  • FIG. 3 is a raw graph obtained from 90°peel test using the
  • FIG. 4 is a graph of data from FIG. 3 processed using ORIGINPRO 2018.
  • FIG. 7 is a graph of coating thickness for the different amounts of coating composition sprayed on the PTFE composite film.
  • FIG. 8 is a graph of surface profile illustrating the thickness of the spray coated material (right) relative to the surface of uncoated PTFE composite film liners (left) corresponding to a coating of 0.006 g/in 2 on the surface.
  • FIG. 9 is a graph of surface profile illustrating the thickness of the spray coated material (right) relative to the surface of uncoated PTFE composite film liners (left) corresponding to a coating of 0.06 g/in 2 on the surface.
  • FIG. 10 is a graph of surface profile illustrating the thickness of the spray coated material (right) relative to the surface of uncoated PTFE composite film liners (left) corresponding to a coating of 0.02 g/in 2 on the surface.
  • FIG. 15 is a depiction of Salt Spray results (0.1 M NaCI at 35 C) illustrating difference in corrosion for coated and uncoated substrates.
  • FIG. 16 is a graph of Tribo-corrosion results (0.1 M NaCI at 25 C) demonstrating corrosion with regards to wear for coated and uncoated steel substrates.
  • FIG. 17 represents contact angle measurements with respect to time illustrating the effect of immersion in acidic and basic conditions have on the coated substrates.
  • FIG. 18 is a schematic of the anti-radar mechanism.
  • FIG. 19 is a 2D and 3D image of coated aluminum substrates.
  • FIG. 20 is the 3D laser Microscope Surface Profile.
  • FIG. 21 is an image of system arrangement for bistatic
  • FIG. 22 is an image of the coated anti-radar sample.
  • FIG. 23 depicts images of four samples of uncoated embossed aluminum sheets.
  • FIG. 24 depicts images of four samples of coated embossed aluminum sheets.
  • FIG. 25 depicts glaze ice on uncoated sample sheets after 5 days.
  • FIG. 26 depicts coated sample sheets after 5 days.
  • FIG. 27 depicts uncoated sample sheets after 9 days.
  • FIG. 28 depicts Cassie-Baxter ice on coated sample after 9 days. depicts ice formation on coated beams before and after centrifuge.
  • FIG. 29 depicts coated samples with spherical shaped ice formed on the surface after 14 days.
  • FIG. 30 depicts uncoated sample sheets had flat glaze ice form on the surface at 14 days.
  • FIG. 31 depicts the ice formation on coated beams before and after centrifuge ice adhesion test.
  • FIG. 32 depicts the effect of withdraw speed on film thickness.
  • FIG. 33 depicts the effect of withdraw angle on film thickness.
  • FIG. 34 depicts the film thickness of multilayer dip coatings.
  • FIG. 35 depicts the effect of withdraw speed on top to bottom film thickness uniformity in large and curved substrates.
  • FIG. 36 depicts multilayer PTFE dip coating illustrating the coating’s thickness and roughness relative to mirror polished stainless-steel substrate.
  • FIG. 37 depicts PTFE‘dry’ spray coating illustrating the coating’s thickness and roughness relative to mirror polished stainless-steel substrate.
  • FIG. 38 depicts PTFE‘wet’ spray coating illustrating the coating’s thickness and roughness relative to mirror polished stainless-steel substrate.
  • FIG. 39 depicts different spray coated fluorocarbon composite materials.
  • FIG. 40 depicts Spray coated PTFE and PDA/PTFE/Graphite coatings on curved substrates.
  • FIG. 41 depicts a graph of surface roughness of PTFE dip and spray coatings on stainless steel substrates.
  • FIG. 42 depicts durability of‘dry’ sprayed virgin PTFE and PDA sub coat + PTFE top coat on stainless steel substrates
  • FIG. 43 depicts durability of‘wet’ sprayed virgin PTFE and PDA sub coat + PTFE top coat on stainless steel substrates
  • FIG. 44 depicts coefficients of friction for different spray coated fluorocarbon composite materials
  • FIG. 45 depicts a graph of the durability of composite
  • FIG. 46 depicts a graph of the durability of PTFE
  • FIG. 47 depicts high-resolution XPS spectra of a) PDA dip coating tris.HCI method b) dip coating PDA formed with oxidizer c) spray coating without curing d) spray coating with curing at 315 °C.
  • FIG. 48 depicts nitrogen high-resolution XPS spectra of a) PDA dip coating tris.HCI method b) dip coating fast PDA c) spray coating without curing d) spray coating curing at 315 °C. DETAILED DESCRIPTION OF THE INVENTION
  • aqueous and“aqueous liquid” is understood to mean a solution in which the solvent is water.
  • aqueous is defined as pertaining to, related to, similar to, or dissolved in water.
  • a “filler” will be in a quantity or concentration less than PDA or PFTE.
  • surfactant is understood to mean compounds that lower the surface tension (or interfacial tension) between two liquids, between a gas and a liquid, or between a liquid and a solid.
  • Surfactants may act as detergents, wetting agents, emulsifiers, foaming agents, and dispersants.
  • solvent is understood to mean the component of a solution that is present in the greatest amount. It is the substance in which the solute is dissolved.
  • to“mix” or“mixture” is understood to mean a material made up of two or more different substances which are physically combined.
  • locating a coating composition is understood to mean coating a substrate by dipping, spraying, spinning, or rolling coating, or any combination thereof.
  • the term“substrate” is understood to mean the medium in which a chemical reaction takes place or the reagent in a reaction that provides a surface for absorption.
  • a “substrate” is a base on which a process occurs.
  • anti-corrosion is understood to mean the protection of metal surfaces from corroding in high-risk (corrosive) environments such as where high humidity, mist, and salt are factors.
  • ice-phobic or“anti-ice” is understood to mean properties of a substance that can de-ice, delay the reformation of ice for a certain period of time, or prevent adhesion of ice to make mechanical removal easier.
  • the term“anti-radar” is understood to mean applications, components, or compositions used to prevent or minimize RADAR (Radio Detection and Ranging) or LIDAR detection.
  • RADAR is a detection system that uses radio waves to determine and map the location, direction, and/or speed of both moving and fixed objects such as aircraft, ships, motor vehicles, weather formations and terrain.
  • LIDAR is Light Detection and Ranging.
  • a lidar system uses laser pulses to measure atmospheric constituents such as aerosol particles, ice crystals, water vapor, or trace gases (e.g. ozone).
  • a lidar transmits short pulses of laser light into the atmosphere to reveal the corresponding distance between the atmospheric scatter and the lidar.
  • One embodiment of the present invention relates to a coating composition comprising a fluoropolymer and a dopamine derivative.
  • fluoropolymer refers to any polymer including the fluoro group.
  • the fluoropolymer may be PTFE (polytetrafluoroethylene).
  • PTFE polytetrafluoroethylene
  • PTFE refers to polytetrafluoroethylene and all its derivatives, composites, and copolymers in which polytetrafluoroethylene is the main component.
  • dopamine derivative refers to any catecheolamine-based substance rich in 3,4-dihydroxy-L-phenylalanine (DOPA) that will form macromolecules or polymerize upon oxidation.
  • DOPA 3,4-dihydroxy-L-phenylalanine
  • the term“dopamine derivative” as used herein may also refer to any dopamine based substance which can be polymerized to produce PDA.
  • PDA polydopamine
  • PDA polydopamine
  • the term “PDA” as used herein may also refer to polydopamine, noncovalent aggregates of dopamine and 5,6-dihydroxyindole, and any polydopamine composite in which polydopamine is the main component.
  • the dopamine derivative can include a dopamine monomer, or a combination of the dopamine monomer and polydopamine. This is because, when the dopamine derivative is mixed with PTFE, the dopamine derivative can begin to form macro molecules such as some degree of polymerization.
  • the dopamine derivative may include, but is not limited to, one or more derivatives selected from the group consisting of dopamine hydrochloride, norepinephrine, epinephrine, isoproterenol, unpolymerized dopamine, L-3,4-dihydroxyphenylalanine, and melanin.
  • the ratio by weight the fluoropolymer to the dopamine derivative in the coating composition can be controlled depending on the desired physical properties such as friction and durability. In one embodiment, the ratio by weight the fluoropolymer to the dopamine derivative may range from 1.0 to 50.0, preferably 5.0 to 40.0, preferably 6.0 to 30.0, or preferably 7.0 to 20.0.
  • the coating is applied to the substrate.
  • composition comprises a solvent.
  • the solvent may include, but is not limited to, an aqueous liquid.
  • the solvent is water.
  • the solvent is isopropanol, ethanol, or methanol.
  • solvents may be combined with additional components in small concentrations, such as for example, n- butyl acetate, n-heptane, ethylene glycol monoethyl ether, ethyl acetate, and methyl ethyl ketone to give a particular characteristic, like fast-drying.
  • the coating composition may further comprise fillers to improve adhesion to specific substrates.
  • the filler comprises one or more of alumina, graphite, silica, quartz, sepiolite, capstone, or copper nanoparticles.
  • nanoparticle fillers to polymers leads to an enhancement of the material’s mechanical and physical properties.
  • the key to this phenomenon is the miscibility of the nanoparticles within a polymeric matrix.
  • the hydrophilic filler particles disperse better in a hydrophilic polymer than in a hydrophobic polymer. Copper nanoparticles, for example, are widely used in different research applications.
  • Fluoropolymers have appealing properties such as low surface energy and hydrophobicity. However, because fluoropolymers are susceptible to creep, deformation, and wear, the incorporation of nanoparticle fillers, inter alia, can increase the modulus of elasticity and hardness of a polymer matrix. In order to evenly disperse nanoparticles in a fluoropolymer matrix the surface of the nanoparticles must be modified. One method of modification is through the oxidation of dopamine hydrochloride in a basic solution to yield a PDA coating of a certain thickness. The resulting PDA coating can then be used to modify the surface of nanoparticles fillers to promote chemical or physical bonding within the polymer chains.
  • the coating composition may further comprise various surfactants.
  • the various suitable surfactants are well known to one of reasonable skill in the relevant art.
  • One embodiment of the present invention relates to a process for coating a substrate, comprising the steps of (a) providing a coating composition comprising a fluoropolymer, a dopamine derivative and a solvent; (b) locating the coating composition on a substrate; (c) heating the coated substrate to remove the solvent; and optionally (d) pressing the heated coated substrate against another material surface to bond these to each other.
  • the substrate may vary depending on the desired target.
  • the substrate may comprise a metal, a polymer, or ceramic.
  • the substrate may be bearings.
  • the step (a) comprises providing a coating composition comprising a fluoropolymer, a dopamine derivative and a solvent.
  • the ratio by weight of the fluoropolymer to the dopamine derivative in the coating composition can vary depending on the desired physical properties.
  • the dopamine derivative solution and the fluoropolymer solution can be mixed with each other to make the coating composition.
  • concentration of the dopamine derivative and the fluoropolymer may vary depending on the ratio by weight of the
  • the concentration of the dopamine derivative in the dopamine derivative solution may range from 1.0 to 20.0 weight %, preferably 1.0 to 15.0 weight %, preferably 1.0 to 10.0 weight %, or preferably 2.0 to 8.0 weight %.
  • the concentration of the fluoropolymer in the fluoropolymer solution may range from 5.0 to 60.0 weight %, preferably from 5.0 to 50.0 weight %, or preferably from 10.0 to 60.0 weight %.
  • the step (b) comprises locating the coating composition on a substrate.
  • the method of locating the coating composition on the substrate may vary depending on the desired properties or various shapes of the target for coating.
  • the coating method may include, but not be limited to, a dip coating, spray coating, spin coating, or roll coating process, or any combination thereof.
  • the coating method may include the spray coating.
  • the thickness of the coating may vary. In one embodiment, the thickness of the coating may range from 1 pm to 300 pm; preferably 1 pm to 120 pm; preferably 1 pm to 100 pm; preferably 3 pm to 40 pm; or preferably 4 pm to 6 pm.
  • the step (c) comprises heating the coated substrate to remove the solvent.
  • the dopamine derivative is polymerized to produce PDA (polydopamine).
  • the dopamine derivative can be polymerized and carbonized to a certain extent. This may produce the final bonding to the substrate.
  • polymer particles of the fluoropolymer and PDA are sintered.
  • the coated substrate is heated at a temperature of 250°C to 400°C; preferably 250°C to 350°C; preferably 280 °C to 340°C; preferably 300°C to 330°C; or preferably 310°C to 320°C. Further, in some embodiments, the coated substrate may be heated for 20 seconds to 11 min; preferably 3 min to 20 min; preferably 5 min to 15 min; or preferably 9 min to 11 min.
  • the optional step (d) comprises pressing the heated coated substrate against another material surface to bond these to each other.
  • the pressure, time and temperature at the step (d) can vary.
  • the pressing may be carried out under a pressure of 100 to 1 ,700 lb/in 2 ; preferably 500 to 1 ,500 lb/in 2 ; preferably 800 to 1 ,200 lb/in 2 ; and preferably 950 to 1 ,050 lb/in 2 depending on the desired physical properties.
  • the pressing may be carried out for 3 min to 20 min; preferably 5 min to 15 min; or preferably 9 min to 11 min.
  • the pressing may be carried out at a
  • the present invention has been successfully used in the deposition of PTFE films on larger 2”x4” 316 stainless-steel substrates via dip coating.
  • Dip coated PTFE samples demonstrate comparable performance all in terms of surface coverage, coating thickness, surface immobilization, and time of deposition as compared to smaller 1”x1” substrates used in preliminary studies.
  • the PTFE solution used was 60 w/w PTFE aqueous dispersion. The solution was used as-is to deposit the PTFE coatings. Diluting the solution further resulted in the formation of thinner films, while attempting to incorporate different solvents in order to aid with the drying time affected the dispersion of the PTFE particles in solution, yielding non- uniform films. Dip coatings offer outstanding surface coverage upon scale-up. Trends in film properties with regards to withdraw speeds FIG. 32 and withdraw angles FIG. 33, as well as reproducibility in film thickness FIG.
  • film thickness can be tailored upon increasing the withdraw speed at which a substrate is withdrawn from the solution.
  • FIG. 32 illustrates, while this trend rises sharply up to 200 mm/min, it then tends to flatten at higher withdraw speeds.
  • liquid drag on the surface also hinders the formation of thicker films, as excess film simply drags down the surface of the substrate. This can result in the formation of uneven coating which exhibit thicker film towards the bottom.
  • the withdraw angle at which a substrate is removed from the solution can be used to tailor the thickness of the film.
  • the effect of withdraw angle on film thickness as FIG. 33 demonstrates is much smaller than that of withdraw speed. Additionally, while easy to demonstrate and utilize on flat substrates, it is much more complicated to employ in one’s favor with more complex geometries.
  • the duration of the process is predominately determined by the desired film thickness, and thus depends more on the number of layers required in order to reach a certain thickness FIG. 34 than the size of the substrate. It is well known that in general, performance is proportional to the thickness of the coating. In essence, thicker coatings take longer to wear, and thus lead to an increase in performance. In addition, thicker coats allow for the formation of a transfer film on the counterface that in essence results as if the coating was sliding against itself, thus in such balance allowing for the formation of interface of outstanding low friction/low wear practical properties. To ensure reproducible results, the durability tests were repeated three times on different replicate samples for each coating condition, error bars in the data plots represent the standard deviation among replicates.
  • Durability tests on the samples were performed using a rotary ball-on-disk configuration, with a 6.5 mm diameter chromium steel balls, 15 N load, 500 RPM sliding speed, and 4 mm stroke diameter on a Tribometer. It is important to note that tests performed on these surfaces are rather aggressive. We employ this high speed/high force tests to assess the surfaces wear life and coefficient of friction keeping in mind the demanding requirements of the bearings application for which these surfaces are being developed.
  • Spray coatings offer the practical benefit of being more versatile, in particular when there exists the need of attaining thicker coatings. While traditional dip coating methods require multiple layers (fourteen or more) in order to reach thickness greater than 100 microns, consequently requiring hours (ten or more), spray coated substrates can reach single film of comparable thickness in minutes. A surface stylus profilometer was used to measure the surface roughness and coating thickness of the samples. Dip coatings yield dense films of outstanding uniformity FIG. 36. PTFE spray yields less dense, much more uneven coverages. More aerosolized (dry) sprays FIG. 37 further amplify such disparity. Less aerosolized‘wet’ sprays FIG.
  • Spraying thick‘wet’ films (over 50 microns) thus need greater care upon spraying and can require in some cases drying steps between sprays. Applying pressure and heat, aids in densifying the coating, reducing porosity, and reducing the surface roughness.
  • FIG. 39 shows the different PTFE based coatings successfully deposited onto stainless-steel substrates via spray coating.
  • Various particle filler PDA/PTFE coatings have been developed to improve the load bearing capability of PTFE, thermal conductivity, transfer film formation, as well as reduce crack propagation and debris formation.
  • Substrates having curved geometries FIG. 40 have also been coated using the present invention.
  • PTFE exhibits a characteristic color change in appearance from white to clear as it cures past crystalline melting point of the resin particles.
  • the PDA based coatings of the present invention exhibit its own unique color change as dopamine polymerizes upon exposure to similar curing temperatures. Such changes were clearly observed for both PTFE and the PDA/PTE/Graphite coating.
  • spray coating atomizes the solution, and thus deposits drier coatings with PTFE particles arranged in agglomerates that produce a more porous surface compared to dip coating in which a thin wet film is added which allows the PTFE particles to arrange themselves in a more ordered fashion and produce denser and smoother coatings.
  • the added surface roughness resulting from spray coating yields a final micro texture that enables spray coating to exhibit ultra-hydrophobic properties, much higher than those of the properties of the bulk material.
  • Adhering virgin PTFE onto substrates can be a challenge. Poor surface adhesion often results in poor tribological performance, so do imperfections such as cracks in the material.
  • PTFE coatings can suffer from both. While the PTFE coatings exhibit strong polymer cohesion upon curing, they often demonstrate very poor adhesion to the surface.
  • Spray and dip coated pure PTFE coatings exhibit the low coefficient of friction expected of PTFE, however wear at a rapid rate, regardless of the spraying or dipping condition. It is important to once again to note, that durability tests performed on these surfaces are by design aggressive (ball-on-flat tribological set up, 15 N Load, 500 RPM, 8mm diameter ball counterface) in order to reduce testing duration. As FIG. 42 demonstrates, and data in FIG.
  • PDA/PTFE composite materials demonstrate a similar trend with regards to durability as it relates to coating thickness.
  • the incorporation of PDA as a bulk composite PTFE material also enables for the spraying of coatings of 500 microns without the adverse effects of cracking upon drying and curing that limit the formation of thicker pure PTFE spray coatings.
  • PDA/PTFE composite spray coatings not only offer lower coefficient of friction (0.107 for PDA/PTFE vs 0.128 for pure PTFE) FIG.
  • thicker coatings will take longer to wear through, thicker coatings also enable for the formation of a transfer film on the counterface which allows for the formation of sliding interfaces of much lower wear rates.
  • Composite materials not only change the mechanical properties of the material but can speed up and affect the formation of a more tenacious transfer film. While the addition of different fillers can adversely affect the tribological properties of the material, a filler that has great potential is graphite. Graphite may precisely ensure the formation of a tenacious transfer film. PDA/PTFE/Graphite composite coatings illustrate this trend. As FIG. 45 demonstrates, the addition of graphite increased the
  • PDA/PTFE/Graphite coatings can first wear more rapidly, these surfaces offer an outstanding combination of coefficients frictions and durability upon formation of transfer films, as demonstrated by its outstanding performance at higher thickness.
  • the performance of a coating is dependent both on the adhesion to the surface as well as cohesion within the polymer. For this reason, it is not just the composition of the coating, but the treatment of the substrate, as well as post spraying treatments, such as the densification upon pressing for example, that dictate the final properties of the coating.
  • PDA/PTFE/Graphite incorporates those improvements to yield a product of outstanding tribological performance.
  • the PDA/PTFE/Graphite coating offers a 15978 fold increase in wear-life as compared to virgin PTFE spray coatings on stainless-steel substrates and a 154 fold increased in wear-life as compared PTFE coating with similar substrate and coating treatments (spray PDA coating on a sanded substrates and pressing at 300 °C at 1000 PSI for 5 minutes before final curing at 372 °C) FIG. 46.
  • the PDA/PTFE composite material of the present invention offers an outstanding platform to assess different fillers for the creation of more specialized next generation surface coatings.
  • the incorporation of different fillers can aid in the improvement of the coatings load carrying capacity, thermal conductivity, transfer film formation, as well as reduce crack propagation and debris formation.
  • PDA/PTFE/Quartz composition outperformed that of 10% by more than double. It is also important to note that this 5% PDA/PTFE/Quartz composition outperforms pure PTFE 670 times over.
  • the addition of different fillers can similarly allow us to modify the composition of the composite material, as well as the interfacial properties.
  • the addition of different filler materials offers differing opportunities to tune the interfacial properties of fluorocarbon coatings for the development of more robust next generation surface coatings.
  • compositions were prepared.
  • the first set was comprised of 5
  • PDA dopamine hydrochloride
  • Coated/cured PTFE composite film liners were laminated on 1” x 2” 1006 carbon steel substrates using a Carver hydraulic press with both platens at 371 °C, under an applied lamination force of 2,000 pounds, and lamination time of 10 min. Three samples per condition (10) were laminated. To evaluate the adhesion performance of the laminated samples, peel test experiments were conducted.
  • a surface stylus profilometer was used to measure the coating thickness of the samples. While the bulk of the examples was performed coating the liners to reach a surface coverage that corresponded to a mass of 0.006 g/in 2 on the surface, thicker coatings were also applied.
  • FIG. 5 shows the results of the first set of conditions evaluated using the maximum peel force or load of each sample.
  • the comparative example was 40%(w/w) PTFE (sample 15).
  • the comparative example was 4%(w/w) PDA (sample 25).
  • the concentration of PTFE was varied five times keeping the PDA concentration constant.
  • sample 25 As compared to the comparative example (4%(w/w) PDA) (sample 25), this condition was about 89% higher.
  • the maximum load for sample 25 was 1.7 lb ⁇ 0.2 lb.
  • Sample 23 was used for the rest of the
  • PTFE composite film liners were spray coated using the coating composition (sample 23). These liners were spray coated at three different thicknesses (5, 30, and 100pm). The curing temperature and time used for the samples was 315 °C and 10 min. The coating thicknesses of each sample were measured using a profilometer. As surface profiles in FIG. 8, FIG. 9, and FIG. 10 illustrate, and FIG. 7 summarizes for all samples, the target coating mass of 0.006 g/in 2 of the coating composition on the surface yielded a coating thickness of 5.2 ⁇ 0.6pm, while the higher masses of 0.06 and 0.2 g/in 2 correspond to coating thickness of 37.2 ⁇ 8.4 pm and 122.2 ⁇ 9.6 respectively. As it can be observed on the surface scans, the PTFE composite film liners on the left of the surface profiles have a much smoother overall surface texture, while the coatings on the right have a much rougher profile which is a characteristic of the spray deposition process.
  • the coated/cured liners were laminated at a temperature of 371 °C, under a lamination force of 2,000 pounds, and a lamination time of 10 min on 1” x 2” 1006 carbon steel substrates. All the samples tested for this report were laminated on 1” x 2” 1006 carbon steel substrates. After lamination, the maximum peel strength for each sample was measured using the 90° peel test. Three samples were peel tested for each thickness. FIG. 11 shows the results of the peel tests conducted on those samples.
  • the maximum load for that coating thickness was 16.1 lb ⁇ 1 .0 lb.
  • the adhesion strength of the coating decreases with increasing coating thickness.
  • the curing (heating) temperatures tested were 300 °C, 315 °C, and 330 °C. For these experiments, sample 23 having 5pm of thickness were used. Peel test measurements were conducted on the laminated samples.
  • FIG. 12 shows maximum load maximum load as a function of curing temperature. The maximum peel strength for the samples using 315 °C as curing temperate was 16.1 lb ⁇ 1 .0 lb.
  • the lamination time for PTFE composite film liner was studied using sample prepared using 315°C of heating temperature. Three different lamination times were tested using the sample prepared using 315°C of heating temperature (coating composition ratio, coating thickness, and curing temperature). Samples were laminated at 371 °C and under 2,000 pounds of force using Carver hydraulic press.
  • the lamination times used for this set of experiments were 5, 10, and 15 min.
  • the peel test results of the laminated samples are shown in FIG. 13. There was no significant difference between the lamination time of 10 and 15 min. Overall, the impact of the lamination time was not as pronounced as the coating thickness (FIG. 11).
  • the maximum load values for the lamination times of 5, 10, and 15 min were lamination times were 14.8 lb ⁇ 0.5 lb, 16.1 lb ⁇ 1.0 lb, and 16.0 lb ⁇ 0.5 lb respectively. The last
  • a coating composition having PTFE, PDA, and copper nanoparticles of 70 nm was prepared. These chemicals were mixed at a ratio by weight of 2:1 :1 PTFE:PDA:copper.
  • the coating composition was sprayed on PTFE composite film liners at a thickness of about 5pm.
  • the coated liner was cured at 315 °C for 10 min and laminated on 1” x 2” 1006 carbon steel substrates under the lamination conditions of 2,000 pound and 10 min. The laminated samples were tested using a 90 ° peel tester.
  • the present invention provides a corrosion resistant coating that can be readily applied to a wide array of metallic substrates (aluminum, magnesium, carbon-steel, stainless-steel, as well as anodized/alanine metals).
  • the coating offers a thin light weight permanent coating that requires no replenishing and is designed to allow sufficient corrosion protection necessary to last numerous overhaul cycles.
  • the present invention’s coating is also chemically inert, and thus can withstand exposure to harsh chemical conditions (highly acidic and basic conditions) and aggressive chemical cleaning procedures.
  • the coating yields a robust protective coating that can extend the lifecycle of highly complex and costly parts.
  • the salt spray results (0.1 M NaCI at 35 C) illustrate the difference in corrosion for coated and uncoated substrates FIG. 15.
  • the coating of the present invention offers a wear life greater than any other state of the art fluorocarbon coating FIG. 15.
  • Tribo-corrosion tests demonstrate will corrode at a fast rate as the surface is abraded.
  • the coating of the present invention provides wear resistance and resistance to chemical attack, which makes it an excellent candidate for an application where the anticorrosion protective coating is exposed to high load/high velocity dynamic contact. See for example Tribo-corrosion results (0.1 M NaCI at 25 C) demonstrating corrosion with regards to wear for coated and uncoated steel substrates FIG. 16.
  • Water contact angle measurements reveal that the coating of the present invention has a low surface energy that makes it unreactive and resistant to chemical attack.
  • the surface energy is maintained in acidic and basic environments allowing the coating to remain unreactive and maintain its anticorrosion properties in both extremes. See for example FIG. 17, providing the contact angle measurements with respect to time illustrating the effect of immersion in acidic and basic conditions have on coated substrates of the present invention.
  • the examples were performed regarding the PTFE: PDA ratio, coating thickness, and curing temperature of the coating composition.
  • a coating composed of PTFE and PDA was deposited on carbon steel and aluminum.
  • Aluminum substrate with the surface area of 6x6 in 2 or 12x12 in 2 was cut.
  • the substrates were ultrasonically cleaned for 5 minutes in 1 % liquidnox, deionized water, acetone, deionized water, isopropanol and deionized water, respectively. Afterward ultrasonically cleaned substrates were air dried.
  • Anti-radar surfaces were fabricated using a facile one-step process through spraying the polymer/particle mixture onto substrates.
  • the prepared solution was fed into the pressure vessel immediately after preparation (to avoid polymerization of dopamine).
  • the deposition conditions employed are summarized in Table 1.
  • the coating solution was sprayed onto the aluminum substrates using high-volume low-pressure air atomization automatic spray gun (HVLP). After spraying multi layers of coating material the coated surface was dried using a blower.
  • HVLP high-volume low-pressure air atomization automatic spray gun
  • FIG. 22 shows the images of the coated sample.
  • the schematic of anti-radar mechanism is illustrated in FIG. 18.
  • bistatic measurements at different angles for coated and uncoated samples was done.
  • the system arrangement for bistatic measurements is shown in FIG. 21.
  • the bistatic measurement is 55 degrees for two different anti- radar coatings of the present invention versus the uncoated substrate.
  • the examples were performed regarding the PTFE: PDA ratio, coating thickness, and curing temperature of the coating composition.
  • a coating composed of PTFE and PDA was deposited on aluminum substrates.
  • the dopamine polymerization mechanism involves the oxidation of catechol in dopamine to quinone.
  • 4 different methods were used to coat stainless-steel by polydopamine.
  • the N/C molar ratio for PDA layers ranged from 0.05 to 0.07 (Table 2) which are below the theoretical value of pure dopamine.
  • XPS X-ray Photoelectron Spectroscopy
  • the N1s high resolution spectrum indicated two peaks for the polydopamine layer, R-NH2 and R-NH-R, and R-NH2 for dopamine molecules.
  • the proposed polydopamine structure show that both NH2 and NH groups are present in polydopamine, whereas dopamine alone has NH2 groups.
  • Dopamine Polydopamine proposed Therefore, the results show that for all three deposition methods: a) dip coating tris.HCL, b) polymerization of dopamine + oxidizer, and c) spray coating dopamine with subsequent curing at 315 °C, dopamine successfully polymerized to polydopamine.
  • PTFE/dopamine with different fillers was sprayed onto the stainless-steel substrate and cured at 315 °C FIG. 48.
  • the XPS result illustrated in Table 3 shows dopamine and fillers cannot be distinguished using XPS and it can be attributed to low concentration ⁇ 3% (w/w dopamine/PTFE) of dopamine.
  • Table 3 - PTFE/dopamine with different fillers was sprayed onto the stainless-steel substrate and was cured at 315 °C

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Abstract

La présente invention concerne une composition d'enveloppement comprenant un polymère fluoré et un dérivé de dopamine. En outre, la présente invention concerne un procédé d'enveloppement d'un substrat, comprenant les étapes de (a) fourniture d'une composition d'enveloppement comprenant un polymère fluoré, un dérivé de dopamine, et un solvant ; (b) localisation de la composition d'enveloppement sur un substrat ; (c) chauffage du substrat enveloppé pour retirer le solvant ; et (d) éventuellement de pressage du substrat enveloppé chauffé contre une autre surface de matériau pour lier ces derniers l'un à l'autre. La présente composition d'enveloppement permet la liaison de polymères fluorés à travers un procédé qui élimine le besoin de manipulation mécanique et de procédés de gravure dangereux ou coûteux.
PCT/US2019/035267 2018-06-03 2019-06-03 Compositions d'enveloppement, procédés, et applications pour substrats à faible frottement et durabilité élevée WO2019236503A1 (fr)

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CN111732864A (zh) * 2020-07-07 2020-10-02 安徽新大陆特种涂料有限责任公司 一种易清洁擦拭的外墙涂料生产工艺
CN114277377A (zh) * 2021-03-03 2022-04-05 吕承洋 一种采用化学腐蚀处理铝/铝合金制基材表面并成膜使之能够被涂层附着的方法
CN114277377B (zh) * 2021-03-03 2024-03-26 吕承洋 一种采用化学腐蚀处理铝/铝合金制基材表面并成膜使之能够被涂层附着的方法
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CN114854311A (zh) * 2022-06-17 2022-08-05 南京信息职业技术学院 一种抗紫外超疏水氟硅涂层及其制备方法与应用
CN114854311B (zh) * 2022-06-17 2023-03-21 南京信息职业技术学院 一种抗紫外超疏水氟硅涂层及其制备方法与应用

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