Coating System for a Porous Substrate Using an Asphalt-Containing Thermosetting Basecoat Composition and a Thermoplastic Top Coat Composition

A thermosetting basecoat composition comprising, in weight percent based on final formulation:

• a) between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a petroleum asphalt;
• b) between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a hydroxy-terminated homopolymer;
• c) between 0.1 and 30%, preferably 3 and 25, and most preferably 5 and 15% of a functional epoxy reactive diluent for reducing the viscosity of the composition;
• d) up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• e) up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of an anti-oxidant;
• and
• f) up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent.

A preferred topcoat thermoplastic composition comprising, in weight percent, based on final formulation:

• a) between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a modified ethylene terpolymer with a temperature stable ester and high acidic functionality;
• b) between 5 and 95, preferably 20 and 70, and most preferably 30 and 60% of a polyethylene/methacrylic acid copolymer;
• c) between 5 and 95, preferably 5 and 70, and most preferably 7.5 and 20% of a polyethylene/methacrylic acid copolymer ionomer;
• d) up to 50% of a coloring pigment;
• e) up to 5% of an anti-oxidant;
• f) up to 5% of an ultraviolet stabilizer;
• g) up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• and
• h) up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent.

A method of coating at least a portion of a substrate by:

• a) first mixing a thermosetting basecoat composition with an isocyanate hardener to form a thermosetting mixture, the thermosetting basecoat composition comprising, in weight percent based on final formulation:
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a petroleum asphalt;
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a hydroxy-terminated homopolymer;
• between 0.1 and 30%, preferably 3 and 25, and most preferably 5 and 15% of a functional epoxy reactive diluent for reducing the viscosity of the composition;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of an anti-oxidant;
• and
• up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent;
• b) applying the basecoat as a liquid to a substrate, preferably a porous substrate and allowing the basecoat to chemically crosslink to form a heat dampening basecoat;
• c) thermally applying a topcoat thermoplastic composition onto the heat dampening basecoat to a given thickness to coat the substrate, the topcoat thermoplastic composition comprising, in weight percent, based on final formulation:
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a modified ethylene terpolymer with a temperature stable ester and high acidic functionality;
• between 5 and 95, preferably 20 and 70, and most preferably 30 and 60% of a polyethylene/methacrylic acid copolymer;
• between 5 and 95, preferably 5 and 70, and most preferably 7.5 and 20% of a polyethylene/methacrylic acid copolymer ionomer;
• up to 50% of a coloring pigment;
• up to 5% of an anti-oxidant;
• up to 5% of an ultraviolet stabilizer;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• and
• up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent.

A method of coating at least a portion of a substrate by:

• a) first mixing a basecoat thermosetting composition with an isocyanate hardener to form a thermosetting mixture and storing the mixture in the absence of atmospheric moisture;
• the basecoat thermosetting composition the thermosetting basecoat composition comprising, in weight percent based on final formulation:
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a petroleum asphalt;
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a hydroxy-terminated homopolymer;
• between 0.1 and 30%, preferably 3 and 25, and most preferably 5 and 15% of a functional epoxy reactive diluent for reducing the viscosity of the composition;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of an anti-oxidant;
• and
• up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent;
• b) applying the mixture to a substrate, preferably a porous substrate and allowing the basecoat to chemically crosslink to form, a heat dampening basecoat;
• and
• c) thermally applying a topcoat thermoplastic composition onto the heat dampening basecoat to a given thickness to coat the substrate, the topcoat thermoplastic composition comprising, in weight percent, based on final formulation:
• between 10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of a modified ethylene terpolymer with a temperature stable ester and high acidic functionality;
• between 5 and 95, preferably 20 and 70, and most preferably 30 and 60% of a polyethylene/methacrylic acid copolymer;
• between 5 and 95, preferably 5 and 70, and most preferably 7.5 and 20% of a polyethylene/methacrylic acid copolymer ionomer;
• up to 50% of a coloring pigment;
• up to 5% of an anti-oxidant;
• up to 5% of an ultraviolet stabilizer;
• up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a surfactant for improving surface imperfections;
• and
• up to 25%, preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an thickening agent.