Powder thermal spray compositions composing at least two thermoplastics

Abstract

A thermal spray coating composition comprising up to about 90 weight percent of the composition of a first thermoplastic material and up to about 50 weight percent of the composition of at least one additional thermoplastic material that is different from the first thermoplastic material. Additional components can be added to the empirical compositions in order to best additional secondary properties.

Description

Claims

1. A powdered thermal spray composition comprising: up to about 90 weight percent of the composition of a first thermoplastic material and up to about 50 weight percent of the composition of at least one additional thermoplastic material that is different from said first thermoplastic material.

2. The thermal spray composition according to claim 1 wherein said first thermoplastic material is selected from a group consisting of Polyolefins, Vinyls, Polyamides, Polyesters, polyester alloys, Nylons, and Poly (Vinylidene fluoride) polyether amides, poly ether ester Ketones (PEEK) and polyurethanes.

3. The thermal spray composition according to claim 2 wherein said at least one additional thermoplastic material is selected from the group consisting of Polyolefins, Vinyls, Polyamides, Polyesters, polyester alloys, Nylons, and Poly (Vinylidene fluoride), polyether amides, poly ether ester Ketones (PEEK) and polyurethanes and is different from said first thermoplastic material.

4. The thermal spray composition according to claim 1 further comprising at least one fluropolymer selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene resin (FEP), perfluoroalkoxy copolymer resin (PFA), tetrafluroethylene-ethylene copolymer (ETFE), poly(vinylidene fluoride)(PVDF) and mixtures thereof.

5. The thermal spray composition according to claim 4 wherein said composition comprises about 1% by weight to about 30% by weight of the composition of said at least one fluropolymer.

6. The thermal spray composition according to claim 1 wherein said first thermoplastic material is polyethylene and said at least one additional thermoplastic material is ethylene acrylic acid (EAA).

7. The thermal spray composition according to claim 6 wherein said composition comprises about 10% by weight to about 60% by weight of the composition of polyethylene and about 10% by weight to about 60% by weight of the composition of ethylene acrylic acid (EAA).

8. The thermal spray composition according to claim 7 wherein said composition comprises about 50% by weight of the composition of polyethylene and about 50% by weight of the composition ethylene acrylic acid (EAA).

9. The thermal spray composition according to claim 1 wherein said first thermoplastic material is Nylon and said at least one additional thermoplastic material is a co-polyamide.

10. The thermal spray composition according to claim 9 wherein said Nylon is Nylon-11, and said co-polyamide is a mixture of Nylon-6, Nylon-66 and Nylon-12.

11. The thermal spray composition according to claim 10 wherein said composition comprises about 1% by weight to about 67% by weight of said Nylon-11 and about 1% by weight to about 33% by weight of the composition of said co-polyamide.

12. The thermal spray composition according to claim 6 further comprising a metal or ceramic alloy and at least one fluoropolymer.

13. The thermal spray composition according to claim 12 comprising about 10% by weight to about 85% by weight of the composition of said metal alloy or ceramic alloy, about 3% by weight of the composition of said fluoropolymer, about 6% by weight of the composition of ethylene acrylic acid (EAA), and up to about 6% by weight of the composition of polyethylene.

14. The thermal spray composition according to claim 13 wherein the metal alloy is nickel alloy or aluminum oxide.

15. The thermal spray composition according to claim 6 further comprising metal oxides, wear resistant particles, lubricity additives, carbides, vermiculite, neat metals, carbon fibers, crystalline particles, cellulose, fiberglass and mixtures thereof.

16. The thermal spray composition according to claim 12 further comprising metal oxides, wear resistant particles, lubricity additives, carbides, vermiculite, neat metals, carbon fibers, crystalline particles, cellulose, fiberglass and mixtures thereof.

17. The thermal spray composition according to claim 12 wherein said fluoroploymer is selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene resin (FEP), perfluoroalkoxy copolymer resin (PFA), tetra fluroethylene ethylene copolymer (ETFE), poly(vinylidieneflouride)(PVDF) and mixtures thereof.

18. A thermoplastic composition comprising: up to about 50% by weight of the composition of ethylene acrylic acid (EAA), up to about 50% by weight of the composition of poly(vinylidiene fluoride)(PVDF) and about 1% by weight to about 15% of the composition of fluoropolymer particles.

19. A powdered thermal spray composition comprising polyethylene, polytetrafluoroethylene (PTFE) and at least one additive selected from the group consisting of copper oxide, copper pigment, anti-microbial compound, color control particles, wear resistant particles, phosphorescent particles, lubricity particles, anti-slip particles, vermiculite, neat metals, carbon fibers, crystalline particles, cellulose, fiberglass and mixtures thereof.

20. The powdered thermal spray composition of claim 19 wherein the anti-microbial compound is selected from the group consisting of silver ion powder, triclosan, capsasin and mixtures thereof.

21. The thermal spray composition according to claim 9 wherein said first thermoplastic material is selected from the group consisting of polyethylene, ethylene acrylic acid (EAA), and Nylon and said at least one additional thermoplastic material is polyether block amide.

22. The thermal spray composition according to claim 21 wherein the composition comprises up to about 90% by weight of the composition of polyether block amide and up to about 90% by weight of the composition of polyethylene, ethylene acrylic acid (EAA), or Nylon.

23. The thermal spray composition according to claim 22 wherein the Nylon used in the composition is Nylon-11.

24. The thermal spray composition of claim 21 further comprising up to 20% by weight of the composition of fiberglass.