METHOD FOR THE USE AND PREPARATION OF BASECOATS

Abstract

Method for producing a basecoat, comprising: Forming a chlorinated polyolefin (CPO) intermediate comprising a CPO solvent and a chlorinated polyolefin, wherein the CPO intermediate comprises 5 to 20 percent by weight of the chlorinated polyolefin, based on the total weight of the CPO intermediate; wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds having 6 to 10 carbon atoms and combinations thereof; Forming a color intermediate comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent; wherein the color solvent is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons and combinations thereof; Combining the CPO intermediate with the color intermediate to form the basecoat, wherein the basecoat comprises 1 to 3 percent by weight of the chlorinated polyolefin, based on the total weight of the basecoat, and wherein the basecoat comprises solids in an amount of 5 to 30 percent by weight, based on the total weight of the basecoat.

Description

TECHNICAL AREA

[0001] The present disclosure relates in general to processes for the use and production of basecoats and in particular to processes for the use and production of basecoats that can be applied directly to polymeric substrates without a primer layer. BACKGROUND

[0002] Manufacturers typically paint motor vehicles during the manufacturing process, with some vehicle components primarily consisting of thermoplastic polyolefins, polypropylene, or other polymers. For example, many bumper components of modern vehicles are made of materials containing thermoplastic polyolefins, and other components may be made of polypropylene. Multiple layers of different coatings are typically used to coat these substrates. A primer layer (sometimes called an adhesion layer) is deposited directly onto the polymer surface, and one or more basecoats are deposited over the primer layer. The primer layer improves the adhesion of the basecoat, and the basecoat provides the desired color and a protective polymer matrix.Often, a clear coat is applied over the base coat to provide additional protection and improve the overall appearance.

[0003] Painting is a time-consuming and energy-intensive process with many steps, each requiring time and incurring material and labor costs. Naturally, the more coats applied, the more time and expense are required.

[0004] Accordingly, it is desirable to develop basecoats that do not require a primer or adhesion promoter, methods for coating objects without a primer or adhesion promoter, and methods for producing such basecoats. Furthermore, it is desirable to develop basecoats that can be applied directly to thermoplastic polyolefin substrates, methods for producing such coatings, and methods for coating such substrates. Further desirable features and properties of the present embodiment will become apparent from the following detailed description and the accompanying claims in conjunction with the accompanying drawing and this background information.

[0005] DE 42 29 938 A1 describes a process for the finishing (coating, painting) of plastic substrates made of up to 100 wt.% polypropylene with solid or metallic effect paints using basecoats containing colored pigments and / or metallic effect pigments. The primers ensure good adhesion to the plastics. The basecoats used contain 5.0–35 wt.% water-dilutable binders based on physically drying synthetic resin dispersions, 0.5–15 wt.% of a chlorinated polyolefin with a chlorine content of 5–70 wt.%, 0.2–20 wt.% of one or more pigments, 30–89 wt.% water, and 5.0–40 wt.% organic solvents.

[0006] WO 2016 / 180 768 A1 describes binders with which a wide variety of coating products can be manufactured that adhere directly to plastics without any chemical or physical pretreatment. It is possible to produce primers, high-gloss lacquers, metallic lacquers, clear lacquers, and effect lacquers that can be applied directly to plastics without pretreatment. The described binder can also be used to formulate adhesives that ensure excellent bonding between plastics themselves and between plastics and cardboard packaging.

[0007] US 2008 / 152927 A1 describes a colored primer composition comprising a chlorinated polyolefin resin grafted with an acrylic component, wherein the acrylic component has a glass transition temperature (Tg) of 60 °C or higher, and an OH-group-containing acrylic resin. The chlorinated polyolefin resin grafted with the acrylic component and the OH-group-containing acrylic resin have a mass ratio of non-volatile components in the range of 70 / 30 to 50 / 50. SUMMARY

[0008] This is resolved by the subject matter of the independent claims. Further embodiments are provided in the dependent claims.

[0009] Methods for using basecoats and methods for producing basecoats are provided. In one embodiment, a method for producing a basecoat includes the formation of a CPO intermediate and a color intermediate. The CPO intermediate comprises a chlorinated polyolefin in an amount of 5 to 20 percent by weight, based on the total weight of the CPO intermediate, and a CPO solvent, wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds with 6 to 10 carbon atoms, and combinations thereof. The color intermediate comprises a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent and is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons, and combinations thereof.The CPO intermediate and the color intermediate are combined to form the basecoat, the basecoat containing 1 to 3 percent by weight of chlorinated polyolefin and 5 to 30 percent by weight of solids, based on the total weight of the basecoat.

[0010] In yet another embodiment, the use of a basecoat in a process for coating a substrate is provided. The process involves forming a CPO intermediate comprising a chlorinated polyolefin in an amount of 5 to 20 percent by weight, based on the total weight of the CPO intermediate, and a CPO solvent, wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds with 6 to 10 carbon atoms, and combinations thereof. A color intermediate is formed comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent and is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons, and combinations thereof.The CPO intermediate and the color intermediate are combined to form a basecoat, which contains 1 to 3% by weight of chlorinated polyolefin and 5 to 30% by weight of solids, based on the total weight of the basecoat. The basecoat is applied to the substrate so that it is in direct contact with the substrate, which is primarily composed of polyolefin. The basecoat is then cured in direct contact with the substrate to form a hardened coating layer.

[0011] Further examples of the present invention, which are numbered for ease of reference, are described below: Example [1] Method for producing a basecoat, comprising: Forming a CPO intermediate comprising a CPO solvent and a chlorinated polyolefin, wherein the CPO intermediate contains 5 to 20 percent by weight of the chlorinated polyolefin, based on the total weight of the CPO intermediate, comprising; wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds with 6 to 10 carbon atoms and combinations thereof; Forming a color intermediate comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent; wherein the color solvent is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons and combinations thereof; Combining the CPO intermediate with the color intermediate to form the basecoat, wherein the basecoat comprises 1 to 3 percent by weight of the chlorinated polyolefin, based on the total weight of the basecoat, and wherein the basecoat comprises solids in an amount of 5 to 30 percent by weight, based on the total weight of the basecoat. Example [2] Process according to Example [1], wherein the formation of the CPO intermediate comprises the formation of the CPO intermediate in an amount of 5 to 10 percent by weight of the chlorinated polyolefin. Example [3] Method according to Example [1] or [2], further comprising: Adding a coating resin to the basecoat. Example [4] The procedure according to Example [3], wherein: This includes adding the coating resin to the basecoat and adding the coating resin to the color intermediate before combining the color intermediate and the CPO intermediate. Example [5] Procedure according to Example [3] or [4], wherein: the addition of the coating resin to the base coat includes the addition of the coating resin, wherein the coating resin includes a crosslinkable component. Example [6] Procedure according to Example [5], furthermore comprehensive: Forming a crosslinking catalyst part, wherein the crosslinking catalyst part comprises a crosslinking component configured to crosslink the crosslinkable component of the coating resin; and Applying the base coat to the crosslinking catalyst section. Example [7] Method according to Example [3] or one of Examples [4] to [6], wherein: the addition of the coating resin to the basecoat comprises the addition of the coating resin, wherein the coating resin is selected from a urethane resin, an acrylic resin, a polyester resin and combinations thereof. Example [8] Process according to Example [1] or one of Examples [2] to [7], wherein the combination of the CPO intermediate and the color intermediate to form the basecoat comprises combining the CPO intermediate and the color intermediate such that the basecoat contains solids in an amount of 10 to 30 percent by weight, based on the total weight of the basecoat. Example [9] Process according to Example [1] or one of Examples [2] to [8], wherein: the formation of the CPO intermediate comprises the formation of the CPO intermediate, wherein the chlorinated polyolefin comprises maleic anhydride-modified chlorinated polyolefins. Example

[10] Process according to Example [1] or one of Examples [2] to [9], wherein: the formation of the CPO intermediate comprises dissolving the chlorinated polyolefin in the CPO solvent. Example

[11] Method according to Example [1] or one of Examples [2] to

[10] , wherein: forming the colour intermediate includes dispersing the colour additive in the colour solvent. Example

[12] Process according to Example [1] or one of Examples [2] to

[11] , wherein: the formation of the CPO intermediate comprises the formation of the CPO intermediate, wherein the chlorinated polyolefin comprises chlorine in an amount of 15 to 45 percent by weight, based on the total weight of the chlorinated polyolefin. Example

[13] Use of a basecoat in a process for coating a substrate, comprising: Forming a CPO intermediate comprising a CPO solvent and a chlorinated polyolefin, wherein the CPO intermediate comprises 5 to 20 percent by weight of the chlorinated polyolefin, based on the total weight of the CPO intermediate; wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds having 6 to 10 carbon atoms and combinations thereof; Forming a color intermediate comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent; wherein the color solvent is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons and combinations thereof; combining the CPO intermediate with the color intermediate to form a basecoat, wherein the basecoat comprises the chlorinated polyolefin in an amount of 1 to 3 percent by weight, based on the total weight of the basecoat, and wherein the basecoat comprises solids in an amount of 5 to 30 percent by weight, based on the total weight of the basecoat. Applying the basecoat to the substrate so that the basecoat directly contacts the substrate, the substrate mainly comprising polyolefin; and Curing of the base coat to form a hardened coating layer in direct contact with the substrate. Example

[14] Use according to Example

[13] , furthermore comprehensive: Applying a clear coat over the cured coating layer; and curing the clear coat to form a hardened clear coat. Example

[15] Use as shown in example

[13] or

[14] , furthermore including: Adding the coating resin to the base coat, wherein the coating resin comprises a crosslinkable component; Forming a crosslinking catalyst part, wherein the crosslinking catalyst part comprises a crosslinking component configured to crosslink with the crosslinkable component of the coating resin; and Combine the crosslinking catalyst component with the basecoat before applying the basecoat to the substrate. Example

[16] Use according to Example

[13] or one of Examples

[14] and

[15] , wherein: the formation of the CPO intermediate includes the formation of the CPO intermediate, wherein the chlorinated polyolefin contains chlorine in an amount of 15 to 45 percent by weight, based on the total weight of the chlorinated polyolefin. Example

[17] Use according to Example

[13] or one of Examples

[14] to

[16] , wherein: the formation of the CPO intermediate comprises the formation of the CPO intermediate, the CPO intermediate comprising the chlorinated polyolefin in an amount of 5 to 10 percent by weight, based on the total weight of the CPO intermediate. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present revelation is described in connection with the following figures, where identical reference symbols denote identical elements. They show: Fig. 1. A schematic diagram of a mixing and packaging system and operation; and Fig. 2 and Fig. 3. Coating a substrate. DETAILED DESCRIPTION

[0013] The following detailed description is merely exemplary and is not intended to limit the application or uses of the described embodiment. Furthermore, there is no intention to be bound by any theory presented in the preceding sections Technical Field, Background, Summary, or the following detailed description.

[0014] Many items, such as car parts, helmets, frames, etc., contain polymer substrates. Generally, coatings like paints exhibit poor adhesion to some polymers. Many coatings adhere poorly to thermoplastic polyolefins, and especially to polypropylene, because thermoplastic polyolefins and polypropylene have low surface energy. Therefore, a primer layer is typically applied to such substrates before a basecoat, with the primer enhancing the basecoat's adhesion. In some embodiments, the primer layer contains chlorinated polyolefins to aid adhesion to the substrate, and the basecoat contains a different polymer. Chlorinated polyolefins are relatively soft, so the basecoat contains a harder polymer to better protect the substrate. Chlorinated polyolefins are nonpolar and only sparingly soluble in many solvents.

[0015] The solvents suitable for chlorinated polyolefins are typically not suitable for pigments or other color additives and other typical coating materials, so chlorinated polyolefins are not incorporated into a basecoat containing a color additive and a coating resin. For this reason, the chlorinated polyolefins, the basecoat polymer, and the color additive are typically applied in separate layers (i.e., a primer layer and a basecoat layer). It has been discovered that chlorinated polyolefins, color additives, and coating resins can be combined in a basecoat without separation or other incompatibility issues if the correct solvents and formulation steps are used.Accordingly, a basecoat containing chlorinated polyolefins, color additives, and coating resins can be applied directly to a polymer substrate, such as one primarily composed of thermoplastic polyolefins. Generally, the chlorinated polyolefins are incorporated into a first CPO solvent in a CPO intermediate, while the color additive is incorporated into a second color solvent in a color intermediate, where the color solvent differs from the CPO solvent. Once the color additive and the chlorinated polyolefin are incorporated into their respective solvents, they can be successfully combined, provided the solids content of the resulting basecoat remains low and the overall concentration of chlorinated polyolefins in the resulting basecoat is also low.

[0016] As used herein, an ingredient that “contains” a compound contains that compound in an amount of approximately 1 to approximately 100 percent by weight of the ingredient, unless otherwise specified. Furthermore, an ingredient that “contains mainly” a compound contains that compound in an amount of approximately 50 to approximately 100 percent by weight of the ingredient.

[0017] It will be on Fig. Reference is made to Figure 1. A CPO intermediate 60 and a color intermediate 70 are produced, and the CPO intermediate 60 and the color intermediate 70 are combined to form a basecoat 10. The term “basecoat” 10, as used herein, refers to a liquid formulation of a coating prior to curing. The basecoat 10 is mixed, as with a mixer 14, to combine the various components. The basecoat 10 is mixed in a container 12, where the container 12 may be a tank, a pipe, a mixing tube, or a variety of shapes capable of containing a liquid. Similarly, the mixer 14 may be a stirrer, a static mixer, or a variety of components capable of mixing the various components. Once the components are mixed within the container 12 to produce the basecoat 10, the basecoat 10 may be packaged for distribution in one or more containers 16.Container 16 can be a can, a bottle, a wastepaper basket, or almost any container 16 that is capable of holding a liquid.

[0018] The CPO intermediate 60 comprises a chlorinated polyolefin 62 and a CPO solvent 64. The chlorinated polyolefin 62 can be introduced into the CPO intermediate 60 as a solid powder or as a liquid in an organic solvent. In one embodiment, the chlorinated polyolefin 62 contains chlorine in an amount of 15 to 45 percent by weight, based on the total weight of the chlorinated polyolefin (where the chlorinated polyolefin 62 can be dissolved). In other embodiments, the chlorinated polyolefin 62 contains chlorine in an amount of about 18 to about 30 percent by weight or about 20 to about 25 percent by weight, all based on the total weight of the chlorinated polyolefin 62.

[0019] Several different embodiments of the chlorinated polyolefin 62 are possible. For example, the chlorinated polyolefin 62 can be anhydride-modified, including maleic anhydride-modified. In alternative embodiments, the chlorinated polyolefin 62 is modified to include acrylic units, carboxyl units, hydroxyl units, etc. However, in some embodiments, the chlorinated polyolefin 62 is unmodified and has other functional groups.

[0020] The chlorinated polyolefin 62 is incorporated into the CPO solvent 64 in the CPO intermediate 60, and in some embodiments, the chlorinated polyolefin 62 is dissolved in the CPO solvent 64. In alternative embodiments, however, the chlorinated polyolefin 62 is dispersed in the CPO solvent 64. In all embodiments, the chlorinated polyolefin 62 forms a stable compound in the CPO intermediate 60, where a "stable compound," as used herein, means a solution or mixture that does not separate, coagulate, or settle within 48 hours when stored without mixing at 25 degrees Celsius (°C) and 1 atmosphere pressure. In some embodiments, the CPO intermediate 60 is a stable solution, where a "stable solution" is a stable compound that is a solution as opposed to a dispersion or emulsion.

[0021] The chlorinated polyolefin is stable in a limited number of solvents, so the CPO solvent 64 is carefully selected. The CPO solvent 64 is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds with 6 to 10 carbon atoms (including xylene), and combinations thereof. The chlorinated polyolefin 62 is incorporated into the CPO solvent 64 in limited amounts to generate a stable CPO intermediate 60. Chlorinated polyolefins 62 at concentrations above approximately 20% by weight are generally unstable in the CPO solvent 64, based on the total weight of the CPO intermediate.In one embodiment, the CPO intermediate 60 contains chlorinated polyolefins 62 at a concentration of 5 to 20 percent by weight, based on the total weight of the CPO intermediate 60. However, in an alternative embodiment, the CPO intermediate 60 contains chlorinated polyolefin 62 at a concentration of 5 to 10 percent by weight, based on the total weight of the CPO intermediate 60. The CPO intermediate 60 can be blended or mixed to incorporate the chlorinated polyolefin 62 into the CPO solvent 64. In some embodiments, additional components such as additives or other materials, as described below, may also be included in the CPO intermediate 60.

[0022] The color intermediate 70 comprises a coloring additive 72 and a color solvent 74. The coloring additive 72 imparts color to the color intermediate 70 and the basecoat 10. The coloring additive 72 can be a dye, a pigment, another component that imparts a desired color, or a combination thereof, with the coloring additive 72 being used to color the basecoat 10. Typical coloring additives 72 that can be used include filler pigments such as talc, kaolin, barites, carbonates, silicates, and color pigments, including metal oxides such as titanium dioxide, zinc oxide, and iron oxides of various colors. Other coloring additives 72 that can be used include, but are not limited to, carbon black and organic color pigments and dyes.Examples of color pigments and dyes include quinacridones, copper phthalocyanines, perylenes, azo pigments, indanthrone blues, carbazoles such as carbazole violet, isoindolinones, isoindolines, thioindigo reds, and benzimidazolinones. Metallic flake pigments such as aluminum flakes, mica flakes, pearlescent flakes, or a combination thereof may also be used. The coloring additive 72 may optionally contain an effect pigment to impart a special visual effect to the cured coating composition, such as gloss, pearlescence, luminescence, and / or a metallic appearance or increased color depth. The color intermediate 70 contains the coloring additive 72 at a concentration of about 3 to about 60 percent by weight, based on the total weight of the color intermediate 70.

[0023] The color intermediate 70 also comprises the color solvent 74, which is different from the CPO solvent 64. The color solvent 74 is selected to form a stable compound with the coloring additive 72, the coloring additive 72 typically being dispersed in the color solvent 74. In alternative embodiments, the coloring additive 72 is dissolved or emulsified in the color solvent 74, such that the color intermediate 70 is a stable compound. The color solvent 74 can be varied with different coloring additives 72, the properties of each coloring additive 72 influencing the selection of the color solvent 74. The color solvent 74 is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons, and combinations thereof. The color intermediate 70 may also contain other additives or components in various embodiments, as explained below.

[0024] The CPO additive 60 and the color additive 70 are combined such that the chlorinated polyolefins 62 are present in the basecoat 10 at a concentration of 1 to 3 percent by weight, based on the total weight of the basecoat 10. The relative proportions of the CPO additive 60 and the color additive 70 are determined so that the basecoat 10 has the desired concentration of chlorinated polyolefins 62 and other components.

[0025] The basecoat 10 also comprises a coating resin 22 in an amount of about 5 to about 25 percent by weight in one embodiment, based on the total weight of the basecoat 10. In other embodiments, however, the basecoat 10 comprises the coating resin 22 in an amount of about 10 to about 20 percent by weight or about 15 to about 20 percent by weight, all based on the total weight of the basecoat 10. The coating resin 22 is a polymer and can be a relatively hard polymer to protect underlying substrates. In one embodiment, the coating resin 22 is added to the color intermediate 70 before the color intermediate 70 and the CPO intermediate 60 are mixed.In alternative embodiments (not shown), the coating resin 22 can be added to the CPO intermediate 60 before mixing the color intermediate 70 and the CPO intermediate 60, or the coating resin 22 can be added to the basecoat independently of either the CPO intermediate 60 or the color intermediate 70. In general, all components described herein, except (1) the chlorinated polyolefin 62, (2) the CPO solvent 64, (3) the coloring additive 72, and (4) the color solvent 74, can be incorporated into the basecoat 10 either in the CPO intermediate 60, the color intermediate 70, or independently of either the CPO intermediate or the color intermediate. Fig. Figure 1 shows various components that are added to the color intermediate 70, however this is only representative of one of many possible different techniques for adding the various components.

[0026] In some embodiments, the coating resin 22 comprises a polymer including a crosslinkable component, wherein the crosslinkable component crosslinks in the presence of a crosslinking component. The crosslinking component can be added to the crosslinkable component shortly before the basecoat 10 is applied, the basecoat 10 having a "pot life" once the crosslinkable and crosslinking components are mixed together. In this disclosure, the term "binder" refers to the crosslinkable component and the crosslinking component, as well as any other optional film-forming components. The binder generally includes all film-forming components that contribute to the solid organic portion of the cured composition. "Crosslinkable component" means a component to which functional groups are attached that can react with the crosslinking component to form a crosslinked network.The crosslinkable component can comprise a compound, an oligomer, a polymer, or a combination thereof, with at least one functional group reactive with the crosslinking component. The functional groups in the crosslinkable component can be selected from hydroxy, amino, hydroxysilane, alkoxysilane, epoxy, carbamate, carboxy, anhydride, acetoacetate, cyclic carbonate, acrylate, azide, thiol, or other functional groups, including combinations thereof.

[0027] "Crosslinking component" means a component that can react with the functional groups of the crosslinkable component to form a crosslinked network. The crosslinking component can be selected from the group consisting of melamine, amino resin, ketimine resin, polyisocyanate, blocked polyisocyanate, or other functional groups, including combinations thereof. The crosslinking component can be added to the basecoat 10 in a crosslinking catalyst portion shortly before the basecoat 10 is applied to a substrate, which is described in more detail below. Generally, crosslinking catalyst is used in amounts ranging from about 0.1 to about 8 percent by weight, based on the weight of the binder; however, the amount and type of crosslinking catalyst depend on the type of coating resin 22 used. In alternative embodiments, several different crosslinking catalysts can be used.Some exemplary catalysts include tin catalysts such as dibutyltin dilaurate and dibutyltin diacetate, tertiary amines, bismuth, zinc salts, blocked acid catalysts, zirconium acetylacetonate, or other catalysts. An example of a blocked acid catalyst is an aromatic sulfonic acid blocked with aminomethylpropanol or dimethyloxazoline. Typically suitable aromatic sulfonic acids are para-toluenesulfonic acid, dodecylbenzenesulfonic acid, and decylbenzenesulfonic acid; however, other aromatic sulfonic acids may be used in alternative embodiments. A preferred catalyst is dodecylbenzenesulfonic acid blocked with aminomethylpropanol.

[0028] In alternative embodiments, the coating resin 22 is a non-catalyzed resin. Accordingly, the basecoat 10 cures by solvent evaporation, with crosslinking being limited or absent. In some cases, the non-catalyzed resin crosslinks during curing, for example, by reaction with oxygen in the atmosphere. Examples of non-catalyzed resins include acrylic resins and alkyd resins, but other non-catalyzed resins can also be used.

[0029] The coating resin 22 can comprise a wide variety of polymer types, such as acrylic resins, urethane resins, polyester resins, alkyd resins, epoxy resins, polyurea polyols, cellulose acetate butyrate resins, melamine resins, or combinations thereof. In some embodiments, the coating resin 22 is selected from urethane resins, acrylic resins, polyester resins, or combinations thereof. In some embodiments, the coating resin 22 has an average molecular weight of about 15,000 to about 70,000; however, other average molecular weights may be used in alternative embodiments. In general, catalysts, coloring additives 72 such as pigments, and non-polymeric chemical additives such as the stabilizers described below are not considered part of the binder.Non-binder components that are not color additives usually make up no more than about 5 to 15 percent by weight of the basecoat 10, however, other concentration ranges are possible in some embodiments.

[0030] The term “solids,” as used herein, refers to the non-volatile components of the basecoat 10 that remain after curing and evaporation (including, but not limited to, the CPO solvent 64 and the color solvent 74). In one embodiment, the basecoat 10 is formulated to contain 5 to 30 percent solids by weight, or, in an alternative embodiment, 10 to 30 percent solids by weight. The remaining component of the basecoat 10 is solvent or other volatile components that evaporate or dissolve during curing.

[0031] A basecoat solvent 26, other than the CPO solvent 64 and the color solvent 74, may be added to the basecoat 10 independently of the CPO additive 60 and the color additive 70 in some embodiments. Any solvent added to the CPO additive 60 is included in the CPO solvent 64 described herein, and any solvent added to the color additive 70 is included in the color solvent 74 described herein. In many embodiments, the basecoat solvent 26 is an organic solvent, and water may be present in the basecoat 10 at a concentration of about 1% by weight or less, based on the total weight of the basecoat 10. Representative basecoat solvents 26 that may be used optionally include cyclohexane, methyl amyl ketone, and mixtures of dialkyl and trialkylbenzenes with 9 to 10 carbon atoms.Other organic solvents that may be used include, but are not limited to: aromatic hydrocarbons such as aromatic petroleum naphtha or xylenes; ketones such as methyl propyl ketone, methyl isobutyl ketone, methyl ethyl ketone or acetone; esters such as butyl acetate or hexyl acetate; glycol ether esters such as propylene glycol monomethyl ether acetate; and combinations thereof.

[0032] In addition to the above components, the composition may also include other formulation additives 30, such as impact strengtheners and leveling agents, for example, Resiflow® S (polybutyl acrylate) and BYK® 320 and 325 (high molecular weight polyacrylates). Such additional formulation additives 30 naturally depend on the desired final properties of the basecoat 10, as will be obvious to those skilled in the art. Furthermore, the formulation additives 30 may include rheologically active agents such as Garamite® clay, pyrogenic silica, urea, or other types of sag control agents, and the like. Other formulation additives 30 that may be added include ultraviolet light stabilizers, surfactants, fillers, etc.Any or more of the listed formulation additives 30 or other formulation additives 30 not specifically mentioned herein may be present in the basecoat 10 in an amount of approximately 0 to approximately 25 percent by weight, based on the total weight of the basecoat 10.

[0033] With further reference to Fig. 1 refers to an exemplary embodiment in Fig. 2. The basecoat 10 and an optional crosslinking catalyst component 40 are combined and applied to a substrate 46 using an application device 44. The crosslinking catalyst component 40 is used only in embodiments in which the coating resin 22 of the basecoat 10 comprises a crosslinking component. In exemplary embodiments, the crosslinking catalyst component 40 may also comprise solvents, formulation additives, or other components. In the illustrated exemplary embodiment, the application device 44 is a spray gun; however, in alternative embodiments, the application device 44 may be a brush, a dipping tank, a roller, rotating electrostatic high-speed bells, or other devices capable of applying the basecoat 10 to the substrate 46.In one embodiment, the basecoat 10 directly contacts the substrate 46, so that there is no primer layer between the basecoat 10 and the substrate 46.

[0034] In one embodiment, the substrate 46 mainly comprises a polymer, which may be a polyolefin, and in some embodiments, the substrate 46 primarily comprises a polyolefin. Polypropylene is an example of a polyolefin, but other polyolefins are used in alternative embodiments. In some embodiments, the substrate 46 may comprise acrylonitrile butadiene styrenes, cellulose acetate butyrates, carbon nitrides, ethylene propylene, melamine formaldehyde, polyamides, polycarbonates, polyethylene, polybutylene terephthalate, polyethylene terephthalate, polythiophene, poly(methyl methacrylate), polyoxymethylene, polypropylene, poly(phenylene oxide), photoluminescent polymers, polyvinyl chlorides, styrene acrylonitriles, nylons, benzimidazobenzophenanthrolines, polyesters and reinforced polyesters, polyurethanes and thermoplastic polyurethanes, and other polymers.In some embodiments, the substrate 46 can be a component of an automobile, but in alternative embodiments, the substrate 46 can be a different object.

[0035] The basecoat 10 is cured after being applied to the substrate to produce the cured coating layer 50. In an embodiment as described above, the basecoat 10 is applied directly to a surface of the substrate 46 before curing, so that the cured coating layer 50 (after curing) is in direct contact with the substrate 46. The cured coating layer 50 comprises the coating resin 22, which in some embodiments is cross-linked during curing, as well as the coloring additive 72 and the chlorinated polyolefin 62. The solvent, including the CPO solvent 64, the color solvent 74, and the optional primer solvent 26, can be removed by evaporation during the curing process.In one embodiment, the cured coating layer 50 can be about 0.2 to about 3.0 mil thick, but in alternative embodiments, the cured coating layer 50 can be about 0.5 to about 2.5 mil thick, or about 0.5 to about 1.5 mil thick.

[0036] A clear coat 52 can optionally be applied over the cured coating layer 50, as in an embodiment shown in Fig. 3 with further reference to Fig. 1 and Fig.Figure 2 shows that the clearcoat 52 is then cured to form a cured clearcoat 54. A variety of clearcoats 52 can be used, the clearcoat 52 typically being selected based on the type of coating resin 22 within the basecoat 10. The clearcoat 52 can be applied before or after the basecoat 10 has cured in various embodiments. For example, the basecoat 10 can be coated with the clearcoat 52, or with a second layer of the basecoat 10, or with other coatings, either wet-on-wet or after flash-drying the basecoat 10, but before or after it has fully cured. In one embodiment, the cured clear lacquer 54 can be about 0.5 to about 4.0 mil thick, but in alternative embodiments, the cured clear lacquer 54 can be about 1.0 to about 3.0 mil thick, or about 1.5 to about 2.5 mil thick.

[0037] The cured coating layer 50 and / or the cured clear coat 54 can be cured over time, during which the solvent evaporates and the optional crosslinkable component and the optional crosslinking component react to form a crosslinked network. In alternative embodiments, however, the cured coating layer 50 and / or the cured clear coat 54 can be cured by baking, such as at a temperature of approximately 25 degrees Celsius (°C) to about 120°C, or by infrared irradiation, or by other techniques. The curing process for the cured coating layer 50 can be independent of the curing process for the cured clear coat 54 in some embodiments, but in other embodiments, the cured coating layer 50 and the cured clear coat 54 are cured simultaneously.

[0038] The cured clearcoat layer 54 gives the substrate 46 a durable, high-gloss appearance and protects the cured coating layer 50. In one embodiment, the clearcoat 52 is a solvent-based material comprising a film-forming binder, and the clearcoat 52 may also include a crosslinking agent. Accordingly, a crosslinkable component and a crosslinking component of the clearcoat 52 can be combined shortly before application. The term "solvent-based" means that the liquid carrier of a composition contains water in an amount of about 1 percent by weight or less, based on the total amount of the liquid carrier. The film-forming binder of the clearcoat 52 is referred to in this description as the clearcoat binder.In one embodiment, the clearcoat binder comprises approximately 40 to 70 percent by weight of the clearcoat 52, wherein a volatile organic solvent comprises approximately 30 to 60 percent by weight of the clearcoat composition, the organic solvent typically evaporating at temperatures between approximately 35 °C and approximately 100 °C or higher. The clearcoat 52 may also include other formulation additives 30, as explained above, which may be the same as or different from those in the basecoat 10. The clearcoat binder may be present in solution or dispersion in the organic solvent. Alternative embodiments of the clearcoat 52 are also possible.

Claims

[1] Method for producing a basecoat, comprising: Forming a chlorinated polyolefin (CPO) intermediate comprising a CPO solvent and a chlorinated polyolefin, wherein the CPO intermediate comprises 5 to 20 percent by weight of the chlorinated polyolefin, based on the total weight of the CPO intermediate; wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds having 6 to 10 carbon atoms and combinations thereof; Forming a color intermediate comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent; wherein the color solvent is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons and combinations thereof; Combining the CPO intermediate with the color intermediate to form the basecoat, wherein the basecoat comprises 1 to 3 percent by weight of the chlorinated polyolefin, based on the total weight of the basecoat, and wherein the basecoat comprises solids in an amount of 5 to 30 percent by weight, based on the total weight of the basecoat. [2] The method of claim 1, wherein the formation of the CPO intermediate comprises the formation of the CPO intermediate in an amount of 5 to 10 percent by weight of the chlorinated polyolefin. [3] Method according to claim 1 or 2, further comprising: Adding a coating resin to the base coat. [4] Method according to claim 3, wherein: This includes adding the coating resin to the basecoat and adding the coating resin to the color intermediate before combining the color intermediate and the CPO intermediate. [5] Method according to claim 3 or 4, wherein: the addition of the coating resin to the base coat includes the addition of the coating resin, wherein the coating resin includes a crosslinkable component. [6] The method of claim 5, further comprising: Forming a crosslinking catalyst part, wherein the crosslinking catalyst part comprises a crosslinking component configured to crosslink the crosslinkable component of the coating resin; and Applying the base coat to the crosslinking catalyst section. [7] Method according to any one of claims 3 to 6, wherein: The addition of the coating resin to the base coat includes the addition of the coating resin, wherein the coating resin is selected from a urethane resin, an acrylic resin, a polyester resin and combinations thereof. [8] Method according to any one of claims 1 to 7, wherein the combination of the CPO intermediate and the color intermediate to form the basecoat comprises combining the CPO intermediate and the color intermediate such that the basecoat comprises solids in an amount of 10 to 30 percent by weight, based on the total weight of the basecoat. [9] Method according to any one of claims 1 to 8, wherein: the formation of the CPO intermediate includes the formation of the CPO intermediate, wherein the chlorinated polyolefin comprises maleic anhydride-modified chlorinated polyolefins. [10] Method according to any one of claims 1 to 9, wherein: The formation of the CPO intermediate includes the dissolution of the chlorinated polyolefin in the CPO solvent. [11] Method according to any one of claims 1 to 10, wherein: The formation of the color intermediate includes the dispersion of the coloring additive in the color solvent. [12] Method according to any one of claims 1 to 11, wherein: the formation of the CPO intermediate includes the formation of the CPO intermediate, wherein the chlorinated polyolefin contains chlorine in an amount of 15 to 45 percent by weight, based on the total weight of the chlorinated polyolefin. [13] Use of a basecoat obtained by forming a CPO intermediate comprising a CPO solvent and a chlorinated polyolefin, wherein the CPO intermediate comprises 5 to 20 percent by weight of the chlorinated polyolefin, based on the total weight of the CPO intermediate; wherein the CPO solvent is selected from butyl acetate, methyl ethyl ketone, cyclohexane, methyl amyl ketone, aromatic compounds having 6 to 10 carbon atoms and combinations thereof; Forming a color intermediate comprising a coloring additive and a color solvent, wherein the color solvent is different from the CPO solvent; wherein the color solvent is selected from methyl acetate, acetone, heptane, aromatic hydrocarbons and combinations thereof; Combining the CPO intermediate with the color intermediate to form a basecoat, wherein the basecoat comprises the chlorinated polyolefin in an amount of 1 to 3 percent by weight, based on the total weight of the basecoat, and wherein the basecoat comprises solids in an amount of 5 to 30 percent by weight, based on the total weight of the basecoat; in a process for coating a substrate, comprising: Applying the basecoat to the substrate so that the basecoat directly contacts the substrate, the substrate mainly comprising polyolefin; and Curing of the base coat to form a hardened coating layer in direct contact with the substrate. [14] Use according to claim 13, wherein the method further comprises: Applying a clear coat over the cured coating layer; and Curing of the clear coat to form a hardened clear coat. [15] Use according to claim 13 or 14, wherein the method further comprises: Adding a coating resin to the base coat, wherein the coating resin comprises a crosslinkable component; Forming a crosslinking catalyst part, wherein the crosslinking catalyst part comprises a crosslinking component configured to crosslink with the crosslinkable component of the coating resin; and Combine the crosslinking catalyst component with the basecoat before applying the basecoat to the substrate. [16] Use according to any one of claims 13 to 15, wherein: the formation of the CPO intermediate includes the formation of the CPO intermediate, wherein the chlorinated polyolefin contains chlorine in an amount of 15 to 45 percent by weight, based on the total weight of the chlorinated polyolefin. [17] Use according to any one of claims 13 to 16, wherein: the formation of the CPO intermediate comprises the formation of the CPO intermediate, wherein the CPO intermediate comprises the chlorinated polyolefin in an amount of 5 to 10 percent by weight, based on the total weight of the CPO intermediate.

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