Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
  • B05D5/005—Repairing damaged coatings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
  • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
  • B05D3/065—After-treatment
  • B05D3/067—Curing or cross-linking the coating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
  • B05D7/50—Multilayers
  • B05D7/52—Two layers

Definitions

• Body filler compositions are used in the vehicle repair aftermarket industry to repair of deformities such as holes and dents in vehicle bodies.
• the filler composition cures following application to the deformity and upon reaching a level of hardness, the resulting coating overlying the defect is sanded and finished with suitable painting steps to affect the repair of the vehicle body.
• a primer is often used to adhere to a damaged vehicle surface and assure adhesion of subsequently applied layer such as paint layers that are needed to achieve the class A, high sheen surface finish common to exterior, new vehicle surfaces. The ability to control viscosity and cure to avoid pinhole formation would eliminate several remedial steps.
• a method for repairing surface imperfections on a vehicle body includes the application of an uncured layer to a thickness of up to 0.254 mm of a primer composition comprising: a polyester resin, an acrylated urethane resin, a crosslinking agent, a solvent, and a particulate filler to the vehicle body.
• a surface coating primer composition includes a polyester resin; an acrylate urethane oligomer or polymer; a crosslinking agent; a solvent; a photoinitiator; and [0009] A particulate filler.
• the uncured composition has a viscosity of between 100 and 800 centipoise.
• the present invention has utility as an ultraviolet (UV) light curable primer composition that is well suited for curing to form a coating directly on a vehicle exterior or a coated vehicle exterior.
• the resulting coating being amenable to overcoating with substances functioning as topcoats, primers, or paints.
• the present invention affords a user advantages in terms eliminating the need for pinhole revision after common to conventional coating compositions.
• the uncured inventive primer composition contains up to 45 total volume percent fillers thereby improving flow and sanding characteristics upon cure.
• UV curable primer composition mixing errors and unlimited working time are provided with a rapid cure once UV cure is initiated.
• An inventive primer composition achieves thicknesses of up to 0.254 millimeters (mm).
• a user has a visual cue as to when the primer composition has achieved sufficient hardness to sand so as eliminate yet another deficiency of prior art systems.
• sandable with reference to a cured inventive primer composition is defined as having limited clogging of sandpaper and able to form featheredge.
• Embodiments of the inventive primer compositions provide UV curing coatings utilizing photo polymerization reactions using a variety of light sources such as low energy consuming and environmentally-friendly ultraviolet light emitting diode (UV-LED), older mercury or xenon arc lights, or simply sunlight. Absent UV exposure, an inventive primer composition has a working time that is longer than conventional two-part, peroxide cured coating system and is effectively infinite, yet cures more rapidly upon UV exposure thereby offering a user a controlled working time and a rapid cure thereafter. As a result, the applied material can be corrected or reworked without the conventional problem of viscosity build. Also, the UV cure of the inventive primer composition reduces temperature dependency of cure rates compared to conventional surface defect repair systems.
• UV-LED ultraviolet light emitting diode
• An inventive polyester resin has a degree of ethylenic unsaturation that is between 20 and 100% of the non-alcoholic monomer in the polyester resin and denotes reactivity within the polyester resin backbone to free radical polymerization.
• the unsaturation in a polyester backbone is reactive with vinyl and allyl moieties of a styrenic or non-styrenic molecule through free-radical polymerization.
• an inventive unsaturated polyester resin is terminally functionalized with molecules illustratively including allyl glycidyl ether, glycidyl methacrylate, trimethylolpropane diallyl ether, allyl pentaerythritol or polymeric allyl glycidyl ether. Docket No.: 70652-WO-ITW-0258PCT [0017]
• An inventive unsaturated polyester is readily formed in a single reaction or in multi-stage reactions. Typical reaction temperatures range from 130-240 °C.
• a conventional esterification catalyst is present and illustratively includes acids, transition metal catalysts and organo-tin compounds.
• Typical catalyst loadings range from 0.01 to 1 total weight percent of the reactants.
• Reactive polyester resins used in a primer composition for repairing imperfections on surfaces of auto-body repair coatings have a weight average molecular average weight ranging from 5,000 to 600,000, as determined by gas permeation chromatography (GPC). For purposes of calculating monomer percent, reactive diluents are omitted. Based polyester resin compositions operative herein are detailed in Table 1. [0019] To form a primer composition for repairing imperfections on surfaces of auto-body repair coatings, the resulting reactive polyester resin is dissolved in a multifunctional reactive diluent.
• Reactive diluents operative herein include acrylics, acrylates, and methacrylates such as methyl methacrylate, butyl acrylate, ethyl-hexyl acrylate, hydroxpropyl methacrylate, hydroxethyl methacrylate, lauryl acrylate, stearyl methacrylate, lauryl methacrylate, butanediol diacrylate, ethyleneglycol dimethacrylate, ethyleneglycol-DCPD methacrylate, ethyl(meth)acrylate and n- and isobutyl(meth)acrylate, cyclohexyl(meth)acrylate, isobornyl(meth)acrylate, benzyl(meth)acrylate, butyleneglycol dimethacrylate, diethyleneglycol dimethacrylate, triethyleneglycol dimethacrylate, propyleneglycol dimethacrylate, dipropyleneglycol dim
• a phenyl ring having two moieties in the aforementioned list is intended to include ortho isomers, para isomers, meta isomers, and isomeric mixtures of each.
• Typical loadings of polyester resin in an inventive primer composition are from 20 to 50 total weight percent of a fully formulated primer composition.
• An actinic radiation curable resin is also present in some embodiments of an inventive primer composition in the form of an acrylated urethane oligomer or polymeric resin.
• Such resins are readily formed from polyether polyol, a diisocyanate and hydroxyethyl acrylate.
• the resin typically has a number average molecular weight of 1,000 to 20,000 Daltons as measure by GPC.
• Diisocyanates operative herein illustratively include dicyclohexyl methane diisocyanate, isophorone diisocyanate. It is appreciated that aliphatic urethane acrylate resins are typically sold commercially as a 60 to 85% by weight in a diluent such as trimethylolpropane triethoxy triacrylate, pentaerythritol tri/tetracrylate, or the like. Still other actinic radiation curable resins operative herein are detailed in U.S. Patent 5,908,873. Typical loadings of acrylated urethane in an inventive primer composition are from 3 to 20 total weight percent of a fully formulated primer composition.
• a crosslinking agent that is multifunctional is also present in an inventive primer composition.
• multifunctional is defined as a compound that has a polymerizable functionality of at least 2.
• Difunctional crosslinking agents are particularly well suited for use in the present invention.
• Crosslinking agents operative in the present invention illustratively include diallyl fumarate, diallyl diglycol carbonate, allyl methacrylate, isobornyl acrylate, diallyl phthalate, diallyl suberate, diallyl tetrabromophthalate, diethylene glycol diacrylate, diethylene glycol dimethacrylate, diethylene glycol divinyl-ether, N,N′- dimethacryloylpiperazine, 2,2-dimethylpropanediol dimethacrylate, dipentaerythritol pentaacrylate, dipropylene glycol dimethacrylate, di-trimethylolpropane tetraacrylate, divinyl Docket No.: 70652-WO-ITW-0258PCT glycol, divinyl sebacate, glycerol trimethacrylate, 1,5-hexadiene, 1,6-hexanediol diacrylate, 1,6-hexaned
• a reactive diluent, the crosslinking agent, or the combination thereof are operative in curing and also serves to reduce the viscosity of the under ambient temperature and pressure application conditions of Standard Temperature and Pressure (STP) and without appreciable degassing as the reactive diluents and crosslinking agents are cured into the final solid, cured coating.
• STP Standard Temperature and Pressure
• Typical loadings of crosslinking agent in an inventive Docket No.: 70652-WO-ITW-0258PCT primer composition are from 0.1 to 10 total weight percent of a fully formulated primer composition.
• a photoinitiator is present from 0.1 to 5 total weight percent.
• Bisacylphosphine oxides are exemplary of a photoinitiator operative in the present invention.
• bisacylphosphine oxides operative herein illustratively in phenyl bis(2, 4, 6-trimethylbenzoyl)-phosphine oxide, diphenyl(2,4,6- trimethylbenzoyl)phosphine oxide, bis-(2,6-dichlorobenzoyl)phenylphosphine oxide, bis-(2,6- dichlorobenzoyl)-2,5-dimethylphenylphosphine oxide, bis-(2,6-dichlorobenzoyl)-4- ethoxyphenylphosphine oxide, bis-(2,6-dichlorobenzoyl)-4-biphenylylphosphine oxide, bis- (2,6-dichlorobenzoyl)-4-propylphenylphosphine oxide, bis-(2,6-dichlorobenzoyl)-2- naphthylphosphine oxide, bis-(2,6-dichlorobenzoyl)-1-napth
• Still other photoinitiators operative herein include mono-aryl ketones, and trimethylbenzoyldiphenyl phosphinates, with specific examples thereof illustratively including 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenyl- propan-1-one, ethyl-2,4,6-trimethylbenzoylphenyl phosphinate
• liquid blends of photoinitiators are provided by dissolving solid bisacylphosphine oxide photoinitiator in another liquid photoinitiator or a photoinitiator blend which is of liquid form.
• an anti-oxidant is present in a UV curable coating primer composition and without intending to be bound to a particular theory is believed to function as a cure inhibitor to mitigate premature cure.
• An antioxidant operative herein illustratively includes butylated hydroxyanisole, 2,6-di-ter-butyl cresol, 2,2′-methylene bis(6- t-butyl-4-methyl phenol), 2,2′-thio bis(6-t-butyl-4-methyl phenol), tert-butyl hydroquinone, di- tert-butyl hydroquinone, di-tert-amyl hydroquinone, methyl hydroquinone, p-methoxy phenol, tetrakis[methylene-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl)propionate]methane, N-(2- aminoethyl)-3-[3,5-bis(tert-butyl)-4-
• Typical loadings of an anti-oxidant in an inventive primer composition are from 0 to 6 total weight percent of a fully formulated primer composition.
• solvents can be effective as a dispersive vehicle for the fillers and resins in an inventive primer composition prior to curing, yet without inducing pinholes upon cure.
• solvents aid in achieving an appropriate viscosity of the primer composition.
• it can be expected that there is less than 0.1% of the solvent to no detectable residual solvent.
• Solvents operative herein Docket No.: 70652-WO-ITW-0258PCT illustratively include hydrocarbons, alcohols, polyols, ketones, ethers, and pyrrolidinones, subject to the proviso that the solvent has a molecular weight of less than 300 Daltons.
• Examples of hydrocarbons operative herein illustratively include Stoddard solvent, toluene, xylene, naphtha, petroleum distillates, ethyl benzene, trimethyl benzenes, and fractions of hydrocarbon mixtures obtained from petroleum refineries.
• Alcohols operative herein illustratively include ethanol, n-propanol, iso-propanol, n-butanol, iso-butanol, benzyl alcohol, 2-(n-propoxy)ethanol, 2-(n-butoxy)ethanol, 3-(n-propoxy)ethanol, and 2-phenoxyethanol.
• Ketones operative herein illustratively include acetone, methyl ethyl ketone, methyl n-propyl ketone, methyl n-butyl ketone, methyl amyl ketone, and methyl isoamyl ketone.
• Esters operative herein illustratively include ethyl propanoate, ethyl butanoate, ethyl glycolate, propyl glycolate, butyl glycolate, and isoamyl glycolate, methyl acetate, ethyl acetate, n-butyl acetate, isoamyl acetate, and t-butyl acetate.
• Glycols operative herein illustratively include ethylene glycol and polypropylene glycol.
• Glycol ethers operative herein illustratively include propylene glycol monomethyl ether and ethylene glycol monobutyl ether.
• Pyrrolidinones operative herein illustratively include 1-methyl-2-pyrrolidinone and 1-ethylpyrrolidin-2- one.Mixtures of any two or more of these solvents may also be utilized. Mixtures of miscible combinations of any of the aforementioned are also appreciated to be operative herein.
• Solvent is typically present in an inventive primer composition from 5 to 30 weight percent.
• additives are readily included in an inventive primer composition that illustratively include corrosion inhibitors, flow control additives, a color changing dye indicative of extent of cure, pigments and dyes and combinations thereof. A color changing dye indicative of the extent of cure is detailed in US2020/0239710A1.
• each of the aforementioned additives is independently present from 0 to 12 total weight percent.
• Filler particulates or fibers operative in the present invention illustratively include talc, alumina trihydrate, calcium sulfate, calcium carbonate, magnesium sulfate, magnesium Docket No.: 70652-WO-ITW-0258PCT carbonate, barium sulfate, microspheroids and the like.
• a filler is present as the remainder total weight percent of a complete primer composition for application to a substrate, with a typical upper limit being 45 volume percent of the uncured primer composition. It is appreciated that a pigment and filler can have the same function and in those instances where both are present in a primer composition, the amounts of both are cumulative.
• a microspheroid is defined to include a hollow microsphere or a solid bead having an aspect ratio of between two normal maximal linear dimensions of between 1 and 1.6.
• a spheroid particle is formed of glass or a thermoplastic material.
• the microspheroid is within 10 linear dimension percent of spherical and formed of glass.
• a microspheroid typically has a longest linear dimension of between 20 and 100 microns to improve sandability and reduce density.
• the primer composition is readily be reapplied as many times as necessary, either before or after initiation of cure to fill surface imperfections. Each application being by applied by brushing, spraying, wiping, or blade spreading.
• Typical viscosities of an inventive primer composition fully formulated range from 100 to 800 Centipoise, as measured by tube viscosity measurement.
• the UV radiation necessary for curing can be provided from several sources, including mercury arc lamps, xenon arc lamps, and UV-light emitting diodes (UV-LED). Because of the lower consumption of energy, and reduced heating of the substrate, UV-LED curing is often a preferred actinic radiation source for curing relative to a mercury arc lamp. The UV-LED bulbs do not generate ozone, in contrast to the typical UV-bulbs, require less energy, and exhibit a longer lifetime. The absence of mercury also promotes ease of disposal.
• UV LEDs emissions a 365 nm, 385 nm, 395 nm, and 405 nm, are each alone or in combination suitable for inducing cure of an inventive primer composition.
• Typical rates of cure for an inventive primer composition is 0.3 to 2 minutes for 1 mm thick composition.
• Docket No.: 70652-WO-ITW-0258PCT [0030] The present invention is further detailed with respect to the following non limiting examples. These examples are not intended to limit the scope of the invention but rather highlight properties of specific inventive embodiments and the superior performance thereof relative to comparative examples.
• An inventive primer composition is provided based on a polyester resin (29 total weight percent), acrylated urethane resin (7.5 total weight percent), a crosslinking agent of dipropylene glycol diacrylate (2.5 total weight percent), a TPOL photoinitiator (CAS: 84434- 11-7, 1.3 total weight percent), solvent (14 total weight percent), a corrosion inhibitor mixture of zinc oxide 18 percent and trizinc bis(orthophosphate) 40 weight percent in a water suspension (10 total weight percent), and the remainder being 24 micron talc particulate filler.
• the inventive primer composition flowed onto an automotive vehicle exterior defect to a thickness of 0.254 mm.
• Example 2 [0032] The process of Example 1 is repeated with the acrylated urethane resin present at 15 total weight percent instead of 7.5 total weight percent of Example 1. A similar cure profile results. Docket No.: 70652-WO-ITW-0258PCT Example 3 [0033] The process of Example 1 is repeated with the polyester resin present at 18 total weight percent instead of 29 total weight percent of Example 1. A similar cure profile results.
• Example 4 [0034] The process of Example 1 is repeated with color changing Red Dye FR-1 per US2020/0239710A1 present at 0.1 total weight with a like amount reduction in the amount of solvent of Example 1. A similar cure profile results and a color change occurs within 5 minutes of hardness to sand of the resulting coating. Comparative Examples [0035] The process of Example 1 is repeated without acrylated urethane and dipropylene glycol diacrylate and the amount of the polyester resin increased by a like amount. The resulting layer is tacky at surface and the cure was incomplete. [0036] The process of Example 1 is repeated without TPOL photoinitiator. The coated layer did not cure.
• Example 1 The process of Example 1 is repeated without dipropylene glycol diacrylate and styrene was added at 8.2 total weight percent. The coated layer did not fully cure and the surface was tacky.
• Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and Docket No.: 70652-WO-ITW-0258PCT publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

Landscapes

• Physics & Mathematics (AREA)
• Engineering & Computer Science (AREA)
• Plasma & Fusion (AREA)
• Paints Or Removers (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=88146944

Family Applications (1)

Country Status (3)

Family Cites Families (5)

• 2023
  • 2023-08-29 EP EP23776162.2A patent/EP4580818A1/de active Pending
  • 2023-08-29 CA CA3265926A patent/CA3265926A1/en active Pending
  • 2023-08-29 WO PCT/US2023/031344 patent/WO2024049789A1/en not_active Ceased

Also Published As

Similar Documents

Legal Events