Powder spray coating composition, powder spray coating material, and powder spray method

Abstract

The invention relates to the field of powder spraying, in particular to a powder spraying coating composition, a powder spraying coating material and a powder spraying method. The powder spraying coating composition comprises the following components in parts by mass: 30-50 parts of polyether sulfone; 3 to 10 parts of polyaniline; 5 to 10 parts of polyaryletherketone; and 0.01 to 0.5 part of a surfactant. The powder spraying coating composition provided by the invention is simple in composition, low in preparation cost and strong in adhesive force. By using the powder spraying coating composition provided by the invention and according to the powder spraying method provided by the invention, a coating material obtained after spraying is excellent in impact resistance, heat resistance and corrosion resistance.

Description

Technical Field

[0001] This invention relates to the field of powder coating, and more specifically to a powder coating composition, a powder coating material, and a powder coating method. Background Technology

[0002] Polyethersulfone (PES) is a thermoplastic polymer with excellent comprehensive properties and is one of the few specialty engineering plastics that has been widely applied. It possesses excellent heat resistance, physical and mechanical properties, and insulation properties. In particular, it has outstanding advantages such as continuous use at high temperatures and maintaining stable performance in environments with rapid temperature changes, leading to its widespread application in many fields.

[0003] Polyethersulfone coatings are high-performance polymer materials with excellent heat resistance, physical and mechanical properties, impact resistance, creep resistance, dimensional stability, hydrolysis resistance, chemical resistance, insulation, and self-extinguishing properties. They are widely used in the manufacturing of electronics, electrical appliances, machinery, automobiles, instruments, medical devices, coatings, molds, ultrafiltration membranes, and other fields.

[0004] Powder coating involves spraying powder coating onto the surface of a workpiece using powder spraying equipment. Under electrostatic attraction, the powder adheres evenly to the workpiece surface, forming a powdery coating. This powdery coating is then baked at high temperature to achieve leveling and curing, resulting in a final coating with varying effects. Common powder coatings include polyethylene, polypropylene, polyester, polyvinyl chloride, chlorinated polyether, polyamide, cellulose, epoxy resin, epoxy-polyester, polyester, polyurethane, and acrylic resin. To date, there are few reports on polyethersulfone powder coatings in existing technologies. Summary of the Invention

[0005] The purpose of this invention is to provide a low-cost, simple-formulated powder coating composition, powder coating material, and powder spraying method that can meet the required adhesion, impact resistance, heat resistance, corrosion resistance, and other properties after spraying.

[0006] To achieve the above objectives, a first aspect of the present invention provides a powder coating composition comprising the following components in parts by weight:

[0007] 30-50 parts of polyethersulfone;

[0008] 3-10 parts of polyaniline;

[0009] 5-10 parts of polyaryletherketone;

[0010] Surfactant 0.01-0.5 parts.

[0011] A second aspect of the present invention provides a powder coating material comprising: a substrate and a coating layer attached to the substrate, wherein the coating layer comprises the following components in parts by weight:

[0012] 30-50 parts of polyethersulfone;

[0013] 3-10 parts of polyaniline;

[0014] 5-10 parts of polyaryletherketone;

[0015] Surfactant 0.01-0.5 parts.

[0016] A third aspect of the present invention provides a method for powder coating, wherein the method includes: mixing in proportion to obtain a powder coating composition, then grinding it until the particle size is ≤15μm before powder coating.

[0017] The fourth aspect of the present invention provides a powder coating material obtained by the method of the present invention.

[0018] The powder coating composition of the present invention is low-cost, simple in formulation, has strong adhesion, and the coating obtained after spraying can meet the required properties such as impact resistance, heat resistance, and corrosion resistance. Detailed Implementation

[0019] The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0020] This invention provides a powder coating composition comprising the following components in parts by weight:

[0021] 30-50 parts of polyethersulfone;

[0022] 3-10 parts of polyaniline;

[0023] 5-10 parts of polyaryletherketone;

[0024] Surfactant 0.01-0.5 parts.

[0025] The powder coating composition of the present invention is low in cost, simple in formulation, strong in adhesion, and the coating obtained after spraying can meet the required properties such as impact resistance, heat resistance, and corrosion resistance.

[0026] According to a preferred embodiment of the present invention, the composition comprises the following components in parts by weight:

[0027] Polyethersulfone 32.5-45 parts;

[0028] 6-9 parts of polyaniline;

[0029] 5.7-8.3 parts of polyaryletherketone;

[0030] Surfactant 0.05-0.3 parts.

[0031] The aforementioned technical solution has the advantages of stronger adhesion of powder coating compositions and better impact resistance, heat resistance and corrosion resistance of the coating material after spraying.

[0032] In this invention, the properties of the polyethersulfone, such as the number-average molecular weight, can be selected over a wide range. The following is an illustrative description, but it is not intended to be considered within the scope of this invention. According to a preferred embodiment of this invention, the number-average molecular weight of the polyethersulfone is 3000-5000.

[0033] In this invention, the properties of the polyaniline, such as the range of selectable number-average molecular weight, are quite wide. The following is an illustrative description, but it is not intended to be within the scope of this invention. According to a preferred embodiment of the invention, the number-average molecular weight of the polyaniline is 8000-10000.

[0034] In this invention, the properties of the polyaryletherketone, such as the number-average molecular weight, can be selected over a wide range. The following is an illustrative description, but it is not intended to be considered within the scope of this invention. According to a preferred embodiment of the invention, the number-average molecular weight of the polyaryletherketone is 600-900.

[0035] In this invention, there are no special requirements for the type of surfactant. The following is an illustrative description, but it does not limit the scope of the invention. According to a preferred embodiment of the invention, the surfactant is a nonionic surfactant, preferably a polyol ester surfactant, and more preferably a stearate.

[0036] In this invention, there are no special requirements for the type of polyol ester surfactant. Any suitable type can be selected as long as it can achieve the purpose of this invention. The following is an illustrative description, but it does not limit the scope of this invention. For example, the polyol ester surfactant can be stearate, propylene glycol alginate, sorbitan monolaurate, sorbitan monopalmitate, sorbitan monooleate, or sorbitan trioleate.

[0037] In this invention, there are no special requirements for the type of stearate ester. Any suitable type can be selected as long as it achieves the purpose of this invention. The following is an illustrative description, but it does not limit the scope of this invention. For example, the stearate ester can be ethylene glycol monostearate, ethylene glycol distearate, polyethylene glycol distearate, propylene glycol monostearate, glycerol monostearate, glycerol distearate, sorbitan monostearate, sucrose monostearate, polyethylene oxide stearate, polyethylene oxide propylene stearate, polyethylene oxide sorbitan monostearate, or polyethylene oxide sorbitan tristearate.

[0038] The aforementioned technical solution has the advantages of stronger adhesion of powder coating compositions and better impact resistance, heat resistance and corrosion resistance of the coating material after spraying.

[0039] This invention provides a powder coating material, comprising: a substrate and a coating layer adhered to the substrate, wherein the coating layer contains the following components in parts by weight:

[0040] 30-50 parts of polyethersulfone;

[0041] 3-10 parts of polyaniline;

[0042] 5-10 parts of polyaryletherketone;

[0043] Surfactant 0.01-0.5 parts.

[0044] The powder coating material provided by this invention has excellent impact resistance, heat resistance, and corrosion resistance.

[0045] According to a preferred embodiment of the present invention, the coating contains the following components in parts by weight:

[0046] Polyethersulfone 32.5-45 parts;

[0047] 6-9 parts of polyaniline;

[0048] 5.7-8.3 parts of polyaryletherketone;

[0049] Surfactant 0.05-0.3 parts.

[0050] The coating material obtained by adopting the aforementioned preferred embodiments has better impact resistance, heat resistance, and corrosion resistance.

[0051] In this invention, the polyethersulfone, polyaniline, polyaryletherketone, and surfactant have been described in detail above and will not be repeated here.

[0052] In this invention, there are no special requirements for the thickness of the coating material. The following is an illustrative description, but it does not limit the scope of the invention. According to a preferred embodiment of the invention, the thickness of the coating is 60-200 μm. The aforementioned technical solution has the advantages of good impact resistance, heat resistance, and corrosion resistance, as well as a strong bond between the substrate and the coating.

[0053] The coating material of the present invention has excellent impact resistance, heat resistance, and corrosion resistance. According to a preferred embodiment of the present invention, the impact strength of the coating is 50-80 kg·cm. The aforementioned technical solution has the advantage of good impact resistance.

[0054] The coating material of the present invention has excellent impact resistance, heat resistance, and corrosion resistance. According to a preferred embodiment of the present invention, the coating adhesion of the coating material is grade 0-3. The aforementioned technical solution has the advantage of a strong bond between the substrate and the coating material.

[0055] The coating material of the present invention has excellent impact resistance, heat resistance, and corrosion resistance. According to a preferred embodiment of the present invention, the coating material has a salt spray resistance of 2000-3000 hours. The aforementioned technical solution offers the advantage of good corrosion resistance.

[0056] In this invention, a wide range of substrate types can be selected. The following is an illustrative description, but it does not limit the scope of the invention. For example, the substrate can be selected from one or more of metal, wood, stone, and plastic. The aforementioned technical solution offers advantages such as good impact resistance, heat resistance, and corrosion resistance, as well as a strong bond between the substrate and the coating.

[0057] The present invention provides a method for powder coating using the powder coating composition provided by the present invention. The method includes: mixing the powder coating composition according to a certain ratio to obtain the powder coating composition of the present invention, then grinding it until the particle size is ≤15μm, and then performing powder coating.

[0058] In this invention, there are no special requirements for the spraying operation conditions. The following is an illustrative description, but it does not limit the scope of the invention. The spraying operation conditions include: performing a first spray and a second spray in sequence, the temperature of the first spray being lower than the temperature of the second spray, and the time of the first spray being longer than the time of the second spray.

[0059] The aforementioned technical solution has the advantages of producing a coating material with good impact resistance, heat resistance, and corrosion resistance, and a strong bond between the substrate and the coating.

[0060] According to a preferred embodiment of the present invention, the temperature of the first spraying is 90-100°C lower than the temperature of the second spraying; the time of the first spraying is 4-7 minutes longer than the time of the second spraying. Using the aforementioned technical solution, the resulting coating material has the advantages of better impact resistance, heat resistance, and corrosion resistance, and a stronger bond between the substrate and the coating layer.

[0061] According to a preferred embodiment of the present invention, the temperature of the first spraying is 285-289°C, and the spraying time is 11-13 minutes. Using the aforementioned technical solution, the resulting coating material has the advantages of better impact resistance, heat resistance, and corrosion resistance, and a stronger bond between the substrate and the coating layer.

[0062] According to a preferred embodiment of the present invention, the temperature of the second spraying is 383-385°C, and the spraying time is 6-7 minutes. Using the aforementioned technical solution, the resulting coating material has better impact resistance, heat resistance, and corrosion resistance, and the substrate and coating layer have a stronger bond.

[0063] According to a particularly preferred embodiment of the present invention, the spraying operation conditions are as follows: a first spray at 285-289°C for 11-13 minutes, followed by a second spray at 383-385°C for 6-7 minutes. Using the aforementioned technical solution, the resulting coating material has the advantages of better impact resistance, heat resistance, and corrosion resistance, and a stronger bond between the substrate and the coating layer.

[0064] The present invention provides a powder coating material obtained by spraying using the spraying method provided by the present invention, wherein the coating thickness of the powder coating material is 60-200μm.

[0065] The present invention provides a powder coating material obtained by spraying using the spraying method provided by the present invention, wherein the impact strength of the powder coating material is 50-80 kg·cm.

[0066] The present invention provides a powder coating material obtained by spraying using the spraying method provided by the present invention, wherein the coating adhesion of the powder coating material is grade 0-3.

[0067] The present invention provides a powder coating material obtained by spraying using the spraying method provided by the present invention, wherein the coating of the powder coating material has a salt spray resistance of 2000-3000h.

[0068] The present invention will be described in detail below through embodiments. It should be noted that the following embodiments are only used to further illustrate the present invention and should not be construed as limiting the scope of protection of the present invention. Those skilled in the art can make some non-essential improvements and adjustments to the present invention based on the above description.

[0069] For any experimental steps or conditions not specified in the examples and comparative examples, the procedures or conditions described in the literature in this field can be followed. Reagents or instruments whose manufacturers are not specified are all commercially available conventional reagent products.

[0070] In the following examples and comparative examples:

[0071] The impact strength of the paint film was tested according to the test method of GB / T 1732-2020;

[0072] Adhesion was tested according to the test method of GB / T 9286-2021;

[0073] Salt spray resistance was tested according to the test method of GB / T 1771-2007.

[0074] Example 1

[0075] By weight, 48 parts of polyethersulfone, 3.9 parts of polyaniline, 5.6 parts of polyaryletherketone, and 0.3 parts of ethylene glycol monostearate were mixed and ground until the particle size of the mixture was ≤15μm. The number average molecular weight of polyethersulfone was 4000, that of polyaniline was 9000, and that of polyaryletherketone was 800.

[0076] The obtained coating was sprayed: first spray: 285℃, 13min; then second spray: 385℃, 7min, with a coating thickness of 100μm.

[0077] Tests showed that the paint film has an impact strength of 62 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2300 h.

[0078] Example 2

[0079] By weight, 30 parts of polyethersulfone, 4.2 parts of polyaniline, 7.8 parts of polyaryletherketone, and 0.09 parts of ethylene glycol monostearate were mixed and ground until the particle size of the mixture was ≤15μm. The number average molecular weight of polyethersulfone was 4000, that of polyaniline was 9000, and that of polyaryletherketone was 800.

[0080] The obtained coating was sprayed: first spray: 286℃, 13min; then second spray: 385℃, 7min, with a coating thickness of 100μm.

[0081] The paint film was tested and found to have an impact strength of 59 kg·cm, an adhesion grade of 2, and a salt spray resistance of 2200 h.

[0082] Example 3

[0083] By weight, 37 parts of polyethersulfone, 5.4 parts of polyaniline, 5.5 parts of polyaryletherketone, and 0.35 parts of dehydrated sorbitan monostearate were mixed and ground until the particle size of the mixture was ≤15μm. The number average molecular weight of polyethersulfone was 4000, that of polyaniline was 9000, and that of polyaryletherketone was 800.

[0084] The obtained coating was sprayed: first spray: 286℃, 12min; then second spray: 383℃, 6min, with a coating thickness of 100μm.

[0085] The paint film was tested and found to have an impact strength of 61 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2300 h.

[0086] Example 4

[0087] By weight, 40 parts of polyethersulfone, 6.3 parts of polyaniline, 6.7 parts of polyaryletherketone, and 0.03 parts of glycerol distearate were mixed and ground until the particle size of the mixture was ≤15μm. The number average molecular weight of polyethersulfone was 4000, that of polyaniline was 9000, and that of polyaryletherketone was 800.

[0088] The obtained coating was sprayed: first spray: 289℃, 11min; then second spray: 383℃, 6min, with a coating thickness of 100μm.

[0089] Tests showed that the paint film has an impact strength of 60 kg·cm, an adhesion grade of 2, and a salt spray resistance of 2100 h.

[0090] Example 5

[0091] By weight, 43 parts of polyethersulfone, 7.9 parts of polyaniline, 6.6 parts of polyaryletherketone, and 0.2 parts of ethylene glycol monostearate were mixed and ground until the particle size of the mixture was ≤15μm. The number average molecular weight of polyethersulfone was 4000, that of polyaniline was 9000, and that of polyaryletherketone was 800.

[0092] The obtained coating was sprayed: First spray: 287℃, 12min; Second spray: then 384℃, 7min, with a coating thickness of 100μm.

[0093] Tests showed that the paint film had an impact strength of 74 kg·cm, an adhesion grade of 0, and a salt spray resistance of 2700 h.

[0094] Example 6

[0095] The method is the same as in Example 5, except that the number average molecular weight of polyethersulfone is 2000, the number average molecular weight of polyaniline is 7000, and the number average molecular weight of polyaryletherketone is 500.

[0096] Tests showed that the paint film has an impact strength of 64 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2400 h.

[0097] Example 7

[0098] The method is the same as in Example 5, except that the first spraying is carried out at 275°C for 12 minutes, and the second spraying is carried out at 372°C for 7 minutes.

[0099] Tests showed that the paint film has an impact strength of 67 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2500 h.

[0100] Example 8

[0101] The method is the same as in Example 5, except that the first spraying is carried out at 275°C for 12 minutes, and the second spraying is carried out at 384°C for 7 minutes.

[0102] Tests showed that the paint film has an impact strength of 68 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2500 h.

[0103] Example 9

[0104] The method is the same as in Example 5, except that the first spraying is carried out at 287°C for 9 minutes, and the second spraying is carried out at 384°C for 4 minutes.

[0105] Tests showed that the paint film has an impact strength of 66 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2400 h.

[0106] Example 10

[0107] The method is the same as in Example 5, except that 0.2 parts of ethylene glycol monostearate are replaced with 0.2 parts of dehydrated sorbitan monooleate.

[0108] Tests showed that the paint film has an impact strength of 67 kg·cm, an adhesion grade of 1, and a salt spray resistance of 2400 h.

[0109] Comparative Example 1

[0110] The method of Example 5 is followed, except that the coating composition comprises: 60 parts polyethersulfone, 2 parts polyaniline, 12 parts polyaryletherketone, and 0.7 parts ethylene glycol monostearate.

[0111] Tests showed that the paint film has an impact strength of 45 kg·cm, an adhesion grade of 3, and a salt spray resistance of 1800 h.

[0112] Comparative Example 2

[0113] The method is the same as in Example 5, except that the coating contains only polyethersulfone.

[0114] Tests showed that the paint film had an impact strength of 42 kg·cm, an adhesion grade of 3, and a salt spray resistance of 1600 h.

[0115] Comparative Example 3

[0116] The method of Example 5 is followed, except that the coating composition is not ground after mixing, and the content of the component with a particle size ≤15μm is 30wt%.

[0117] Tests showed that the paint film had an impact strength of 44 kg·cm, an adhesion rating of 3, and a salt spray resistance of 1700 h.

[0118] The preferred embodiments of the present invention have been described in detail above; however, the present invention is not limited thereto. Within the scope of the inventive concept, various simple modifications can be made to the technical solutions of the present invention, including combinations of various technical features in any other suitable manner. These simple modifications and combinations should also be considered as the content disclosed in the present invention and are all within the protection scope of the present invention.

Claims

1. A powder coating composition, characterized in that, The composition comprises the following components in parts by weight:

2. The powder coating composition according to claim 1, wherein, The composition comprises the following components in parts by weight:

3. The powder coating composition according to claim 1 or 2, wherein, The molecular weight of polyethersulfone is 3000-5000; and / or Polyaniline has a number-average molecular weight of 8000-10000; and / or The number average molecular weight of polyaryletherketones is 600-900; and / or The surfactant is a nonionic surfactant, preferably a polyol ester surfactant, and more preferably a stearate.

4. A powder coating material, characterized in that, The coating material includes: a substrate and a coating layer attached to the substrate, wherein the coating layer contains the following components in parts by weight:

5. The coating material according to claim 4, wherein, The coating contains the following components in parts by weight:

6. The coating material according to claim 4 or 5, wherein, The number average molecular weight of polyethersulfone is 3000-5000; and / or Polyaniline has a number-average molecular weight of 8000-10000; and / or The number average molecular weight of polyaryletherketones is 600-900; and / or The surfactant is a nonionic surfactant, preferably a polyol ester surfactant, and more preferably a stearate.

7. The coating material according to claim 4 or 5, wherein, The coating thickness is 60-200 μm; and / or The coating has an impact strength of 50-80 kg·cm; and / or The coating adhesion is grade 0-3; and / or The coating has a salt spray resistance of 2000-3000 hours; and / or The matrix is ​​selected from one or more of metal, wood, stone, and plastic.

8. A method for powder coating using any one of the powder coating compositions of claims 1-3, wherein, The method includes: The powder coating composition is prepared by mixing according to the specified ratio, and then ground until the particle size is ≤15μm before powder spraying.

9. The method according to claim 8, wherein, The spraying operation conditions include: performing the first spray and the second spray in sequence, the temperature of the first spray being lower than that of the second spray, and the time of the first spray being longer than that of the second spray. Preferably, the temperature of the first spray is 90-100°C lower than the temperature of the second spray, and the time of the first spray is 4-7 minutes longer than the time of the second spray. More preferably, the temperature of the first spraying is 285-289℃, and the time of the first spraying is 11-13 minutes; More preferably, the temperature of the second spraying is 383-385℃, and the time of the second spraying is 6-7 minutes; More preferably, a first spraying is performed at 285-289°C for 11-13 minutes, followed by a second spraying at 383-385°C for 6-7 minutes.

10. The powder coating obtained by the method of claim 8 or 9, wherein, The coating thickness is 60-200 μm; and / or The coating material has an impact strength of 50-80 kg·cm; and / or The coating adhesion of the coating material is grade 0-3; and / or The coating material has a salt spray resistance of 2000-3000h.

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