The present invention generally relates to polymerized compositions which are useful for difficult to coat substrates, such as ceramics, glass, polyolefins, polyamides, polyimides, polyfluoro plastics, stainless steel and the like. More specifically, the present invention relates to the use of such composition in the decoration and coating of glass containers, glass windows, glass screens and the like and plastic containers and substrates, automotive, medical, maintenance and general industrial coatings and inks. The composition provides non air inhibited rapid cure, abrasion and scratch resistance and durability.
Compositions containing thiol-ene chemistry are known in the art. For example, U.S. Pat. Nos. 8,378,052 and 8,557,346 and patent applications Ser. Nos. 11/586,501 and 12/879,117 and 2013/0171454 disclose the radiation activation of a metal catalyst, which is passivated by a mercapto compound to cure and convert hydroxyl isocyanate entities into a urethane. The patents/applied patents do not disclose or suggest the use of a functional silane compound or a stable compound not requiring the passivation of the catalyst.
U.S. Pat. No. 6,844,373 discloses a radiation cured composition containing one fluorine substituent, a reactive dye and a methacrylate urethane oligomer. This patent does not disclose or suggest the use of a functional silane compound.
U.S. Pat. No. 5,876,805 discloses the use of vinyl monomer or oligomer and a (meth) acrylic monomer or oligomer and a thiol compound radiation cured by photointiators more prevalent in the visible light range. This patent does not disclose or suggest the use of a functional silane compound.
WO 1996/012749 discloses a silane oligomer and urethane, area and thiourethanes cured by radiation for optical fiber coating. This patent does not disclose or suggest the use of a halogenated acoylated acrylic compound nor a hybrid cure mechanisms.
U.S. Pat. No. 4,849,649 discloses a radiation curable coating for optical glass fibers containing a monofunctional mercapto silane compound and a polyurethane acrylate. This patent does not disclose or suggest the use of a halogenated acrylated acrylic or a separate thio compound to regulate hybrid cure mechanisms.
WO 2004/101649 discloses a radiation curable coating for fiber optics and medical applications containing a multifunctional thio group, acyclicene and a carbonyl. This patent does not disclose the use of a functional silane compound.
WO 2006/055409 discloses the use of mercapto silanes with acrylated oiligomers to provide ultra-thin film non-air inhibited radiation curable coatings. This patent does not discuss or suggest the use of a thiol substituent separate from a mercapto silane, nor in a disclosure air inhibition is achieved through U.S. Pat. No. 6,541,537.
The present invention relates to a stable composition capable of radiation activated catalysis and/or low thermal activated catalysis which comprises a mercapto group, unsaturated oligomer(s), unsaturated polymer(s), unsaturated monomer(s), functional silane(s) photoinitiators and/or thermal catalysts and optional adjuvants, such as stabilizers, pigments, amine acrylates fillers, cationic intiators, film forming and rheology additives and polymerization inhibitors. A characteristic of the composition is its reduced surface tension, another characteristic is its rapid cure as compared to other radiation curable compounds. The combination of these two characteristics provides excellent adhesion and low shrinkage during cure. The composition may be formulated to serve as a protective, functional or decorative ink or coating for hard to adhere to substrates including for example, alloys of stainless steel, plastic, glass, and ceramic, as well as most other wood, metal or composite substrates. For extreme abrasion, temperature cycling and harsh environments, the use of a water based hybrid thermal radiation cure acrylated acrylic, methacryl functional silane and silane terpolymer pretreatment/primer/tiecoat such as those compositions embodied in U.S. Pat. No. 6,541,537 can further enhance the film properties.
Still other objects and advantages of the present invention will become reading apparent by those skilled in the art from the detailed description, where in it is shown and described only in the preferred embodiments, simply by illustration of the best mode. As will be realized, the present invention is capable of other and different embodiments, and its several details are capable of modifications in various respects, without departing from the present invention. Accordingly, the description is to be regarded as illustrative, in nature, and not as restrictive.
All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
The present invention is a method of forming a polymerizable thiolene ink and coating composition which provides excellent adhesion and low shrinkage when cured onto an imprintable surface. An imprintable surface is any surface which can be printed or coated to the aesthetic preference of the user. In order to carry out the present invention, a number of chemical compounds are provided including: a quantity of mercapto compounds, a quantity of functional silane compounds, a quantity of unsaturated polymers, a quantity of unsaturated oligomer compounds, a quantity of unsaturated monomers, and an activation catalyst which impart desired properties to the present invention. In accordance to
The quantity of mercapto compounds is any mercapto compounds that can react with an olefinic compound. The quantity of mercapto compounds provides increased reactivity of the radiation and/or thermal cure properties through the almost instantaneous mercapto “Click Chemistry”. The quanity of mercapto compounds also enhances rheology, durability and adhesion properties. In accordance to the preferred embodiment of the present invention, the quantity of mercapto compounds is appoximately 1-25% by weight (wt.) of the coating mixture. Typically, the quantity of mercapto compounds is selected from a group consisting of: trimethylolpropane tri(3-mercapto-thiopropionate); pentaerythrital tetra-(3-mercapto-thiopropionate); glycol di-(3-mercapto-thiopropionate); dipentaerythritol hexa-(3-mercapto-thiopropionate); trimethylolpropane trithioglycate; mercapto diallyl ether; mercaptopropionic acid and esters thereof; thiophenol; methylthioglycolate; mercaptosilanes; pentaerythritol tetra (3-mercaptobutylate); and combinations thereof. In some embodiments of the present invention the quantity of mercapto compounds additionally includes, but is not limited to: glycol mercapto acetate; ethane dithiol; thiolactic acid; thio acetic acid; 2-mercaptoethanol; 1,4-butanedithiol; 2,3 mercapto propanol; toluene-3,4-dithiol, alpha, alphadimercapto-para-xylene; thiosalisylic acid; mercapto acetic acid; dodecane dithiol; didodecane dithiol; di-thio-phenol; di-para-chlorothiophenal; dimercapto benzothiazole; 3,4 dimercapto toluene; 1-octane thiol, parathiocresol; 2,3,5,6-tetrafluorothiophenol; cyclohexylmercaptan; various mercapto pyridines; dithiocrythritol; 6-ethoxy-2-mercaptobenzothiazole; dilmonene dimercaptan y-mercapto silane; and combinations thereof.
The quantity of unsaturated monomers is an unsaturated monomer compound that can react with a mercapto compound in a thiolene type reaction. The quantity of unsaturated monomers provides viscosity adjustment and improved wetting and rheology characteristics, as well as preventing polymer entanglement and shorter polymer chains during the cure process. Typically, the quantity of unsaturated monomers is approximately 0-70% wt. of the coating mixture. The quantity of unsaturated monomers is selected from a group consisting of: ethoxylated nonylphenol acraylated; isobornyl acrylate; phenoxyethyl acrylate; o-phenyl phenoxyethyl acrylate; 2-(2-ethoxyethoxy)ethyl acrylate; octyl decyl acrylate; isodecyl acrylate; laurel acrylate; hexanediol diacrylate; ethoxylated bisphenol A diacrylate; neopentylglycol diacrylate; dipropylene glycol diacrylate; ethoxylated hexanediol diacrylate; trimethylolpropane triacrylate; pentaerythrital triacrylate; pentaerythrital tetraacrylate; laurel methacrylate; stearyl methacrylate; tridecyl methacrylate; vinyl pyrrilodone; vinyl capralactam; allyl methacrylate; ethylene glycol dimethacrylate; 1,4 butanediol dimethacrylate; 1,6 hexanediol dimethacrylate; neopentyl glycol dimethacrylate; ethoxylated bisphenol A dimethacrylate; trimethylolpropane trimethacrylate; dipentaerythritol pentaacrylate; trimethylolpropane monoallyether; trimethylolpropane diallylether; and combinations thereof. In some embodiments for the quantity of unsaturated monomers, the quantity of unsaturated monomers additionally includes, but are not limited to: ethoxylated phenol acrylate; ethoxylated nonylphenol monoacrylate; cyclic trimethyl propane formal acrylate; tetrahydrafurfuryl acrylate; 2-((butylamino)carbonyl)oxy)ethyl acrylate; propoxylated neopentylglycol; monomethyl ether acrylate polyethylene glycol 200, 400, and 600, diacrylate; tripropylene glycol diacrylate; propoxylated hexanediol diacrylate; propoxylated trimethylolpropane triacrylate; propxylated glyceryl triacrylate; tris(2-hydroxy ethyl)isocyanurate triacrylate; pentaerythrital triacrylate; pentaerythrital tetraacrylate; ethoxylated pentaerythritol tetracrylate; ditrimethyl propane tetra-acrylate; dipentaerythritol; hexa acrylate; tetrahydrofurfuryl methacrylate; cyclohexyl methacrylate; n-hexyl methacrylate; 2-ethoxyethyl methacrylate; isodecyl methacrylate; 2-methoxy acrylate; stearyl acrylate; caprolactone acrylate; polypropylene glycol monomethacrylate; polypropylene glycol monoacrylate; trietheylene glycol dimethacrylate tetraethylene glycol dimethacrylate; polyethylene glycol dimethacrylate; 1,4 butandiol diacrylate; polyethylene glycol dimethacrylate; 1,3 butylene glycol dimethacrylate; tris(2-hydroxy ethyl)isocyanurate trimethylacrylate; and combinations thereof.
The quantity of unsaturated polymers and the quantity of unsaturated oligomers can react with a mercapto compound in a thiol-ene type reaction. The quantity of unsaturated polymers and the quantity of unsaturated oligomers are the backbone of the product, providing the durability, toughness, crosslink density and weatherability characteristics of the coating mixture in the present invention. Typically, the quantity of unsaturated polymers is approximately 10-80% wt. of the coating mixture. Similarly, the quantity of unsaturated oligomers is approximately 10-80% wt. of the coating mixture. The quantity of unsaturated polymers is acrylated acrylic terpolymers. The acrylated acrylic terpolymers comprise reactive epoxide groups capable of undergoing cationic reactions and conjugated double bonds which undergo actinic reactions, such compounds are detailed in U.S. Pat. No. 6,541,537 (Catena). The quantity of oligomers is selected from a group consisting of: aliphatic epoxy acrylate; aromatic epoxy acrylate; aliphatic urethane; aromatic urethanes; polyester acrylates; epoxidized soybean oil; epoxidized linseed oil; butadiene; poly butadiene; isocyanutates; cationic epoxies; amine acrylates; polyether acrylates; polyamides; modified polyester acrylates; modified polyether acrylates; halogenated polyesters; poly triazole; polymidines; allophonates; biurets; and combinations thereof.
In accordance to the preferred embodiment, the quantity of functional silane compounds reacts with a mercapto compound in a thiol-ene type reaction. The quantity of functional silane compounds provides adhesion and wetting properties to low dyne/cm surface tension substrates. The quantity of functional silane compounds also provides elastomeric properties without sacrificing durability, and also provides reduction in viscosity for better flow and leveling properties and being a reactive component there is no migration issues. Typically, the quantity of functional silane compounds is 1-25% wt. of the coating mixture. The quantity of functional silane compounds is selected from a group consisting of: acryl silanes; acryl polysiloxanes; methacryl silanes; methacryl polysiloxane; acrylimido silanes; methacrylimido silanes; acryl polysilanes; methacryl polysilanes; acrylimido polysilanes; methacrylimido polysilanes; vinyl silanes; vinyl polysiloxanes; vinylpolysilanes; and combinations thereof.
In some embodiments of the present invention as detailed in
In some embodiments of the present invention, the present invention provides a thermal catalyst as the activation catalyst, as shown in
An important note is that the present invention can provide both the photoinitiator and the thermal catalyst as the activation catalysts and therefore incorporates both the actinic radiation and the oven as the energy emission source.
In one application of the present invention on the current durable glass deco business, there is an extremely high energy cost and color limitations due to heavy metal content, such as cadmium for reds and yellows and require long high temperature, greater than 600° Celsius, in a lehr oven for 1-2 hours. The present invention allows curing by UV visible light in the range of 280-700 nanometer wavelength in less than 30 seconds, a combination of actinic radiation and thermal cure of less than 2 seconds, or a thermal cure of 2-10 minutes at a peak surface temperature of less than 150° C. The inks or coatings can be applied by most spray, print, inkjet or laser processes.
For use on plastic containers, curing the present invention by the actinic radiation allows the user to decrease light energy cure intensity and dwell time by greater than 40% or to increase the line speed if applicable, thus having less distortion and degradation of the plastic container. The inks or coatings can be applied by most spray, print, inkjet or laser processes.
In another application of the present invention, the on-site application of the present invention including actinic radiation for concrete, wood, tiles, and like materials reduces the time and temperature effects while increasing durability and chemical resistance. The coating mixture is cured as quickly as it is exposed to the actinic radiation, rather than 2-48 hours for typical commercial products in current use. Floor maintenance coatings made from the present invention cure faster than 200 linear feet per min. to a hard abrasion and chemical resistant coating. The coatings mixture is applied by the conventional means of coating an imprintable surface.
In another application of the present invention, a quantity of silver nanoparticles may be dispersed in the composition to provide coatings for medical instruments and utilities to help prevent staph transfer infections and kill bacteria, the latter also makes it an ideal coating for inside refrigerated appliances. The present invention may be applied by most spray or deposition processes.
In some embodiments of the present invention, the present invention provides a quantity of adjuvants. In accordance to
The following composition was tested for automotive carbon fiber reinforced polyamide minor housings and bumper fascia:
The present invention is applied to the imprintable surface, an automotive carbon fiber reinforced polyamide mirror housings and bumper fascia, through use of an electrostatic spraying device. The coating mixture was then cured using d-bulb type UV emitter. Without the use of a primer, the coating mixture is exposed to UV visible light at a flux of 300 microjoules per square centimeter (mj/sq.cm). When using a water based terpolymer, which has been previously applied to the imprintable surface, the coating mixture is exposed to the UV visible light at a flux of 300 mj/sq.cm and exposed to a temperature of 250 degrees Fahrenheit for 10 minutes.
When applying a crosshatch and tape test onto the coating mixture after curing, the present invention had approximately half of the coating mixture removed from the imprintable surface when no primer was used in the process and none of the coating mixture removed when a primer has been applied.
When applying a methyl ethyl ketone (MEK) double rubbing test onto the cured coating mixture, the present invention softens after about 200 rubs when there was no primer used in conjunction with the coating mixture, but remains intact and structurally unaffected when the primer is used.
When applying a salt spray test for 500 hours onto the coating mixture once cured, the coating mixture did not remain on the imprintable surface when there was no use of primer in conjunction with the coating mixture. However, when the primer is used in conjunction with the coating mixture, there was not any loss of the present invention on the imprintable surface when exposed to the same salt spray test.
When applying a quick ultraviolet (QUV) to simulate various weather conditions test for 1000 hours onto the cured coating mixture, the coating mixture does not remain adhered to the imprintable surface without the incorporation of the primer; however, with the incorporation of the primer, the cured coating mixture does not degrade over the duration of the test.
When applying a hardness test similar to determining the hardness of a pencil, the cured coating mixture has been determined to have a pencil hardness of 5 H without the incorporation of a primer, and a pencil hardness of 8 H when the primer is incorporated.
The following composition was tested for onsite floor maintenance coatings on new oak wood fine sanded finish and a lightly scuffed concrete floor:
The present invention is applied to concrete and wood floors, constituting the imprintable surface, then cured with a d-bulb type UV visual light emission source covering an area of 300 linear feet per minute with an emission flux of 292 mj/sq.cm. The present invention passes a 200 rubbing MEK double rub test with no mass loss of the cured coating mixture. Both coated surfaces did not have any mass loss of the cured coating mixture when a quart of acetone was poured onto the imprintable surface and let sit for ten minutes. Once the ten minutes elapsed the acetone was wiped dry to reveal no effect on the cured coating mixture over this duration for either of the coated surfaces. Both passed being driven over with a fork lift immediately after curing with no effect.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
The current application claims a priority to the U.S. Provisional Patent application Ser. No. 62/027,902 filed on Jul. 23, 2014.
Number | Date | Country | |
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62027902 | Jul 2014 | US |