# US 9,428,670 B2 · Process of forming a coating on a substrate

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- Number: US 9,428,670 B2
- Document ID: US9428670B2
- Status: Granted
- Kind: B2
- Application number: 14/387,997
- Filed: 2013-01-29
- Published: 2015-02-19
- Granted: 2016-08-30
- Earliest claimed: 2012-03-29
- Assignees: Axalta Coating Systems IP Co., LLC
- Applicants: Axalta Coating Systems IP Co., LLC
- Inventors: Ayumu Yokoyama; Eric C. Houze
- Web page: https://patentgrep.com/patent/US9428670B2

## CPC

- C09D 175/12: from compounds containing nitrogen and active hydrogen, the nitrogen atom not being part of an isocyanate group
- C08K 5/34922: {Melamine; Derivatives thereof}
- C09D 5/024: {characterised by the additives}
- C09D 175/04: Polyurethanes
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

The present disclosure relates to a process for forming a layer of a coating composition on a substrate wherein the coating composition comprises a waterborne film forming polymer, an isocyanate and a melamine. The process involves forming a mixture of the waterborne film forming polymer and the isocyanate and allowing the mixture to mature before adding the melamine component. The result is a layer of the coating composition with a high degree of gloss and gassing resistance.

## Claims

### Claim 1

A process for forming a layer of a coating composition on a substrate comprising the steps of:
forming a first coating mixture, said first coating mixture comprising:
a film forming polymer having at least two different functional groups, a hydroxyl group and an amine neutralized carboxylic acid group, and
a polyisocyanate,
allowing said first coating mixture to mature for about 0.5 to about 60 minutes,
forming a second coating mixture, said second coating mixture comprising:
an alkylated melamine that is essentially unreactive to isocyanates; and
an acid catalyst,
forming the coating composition by mixing together the matured first coating mixture and the second coating mixture,
applying a layer of the coating composition onto the substrate; and
curing the applied layer of coating composition.

### Claim 2 (depends on 1)

The process of claim 1 wherein forming a first coating mixture comprises forming the first coating mixture further comprising a catalyst.

### Claim 3 (depends on 2)

The process of claim 2, wherein forming a first coating mixture comprises forming the first coating mixture comprising the catalyst chosen from dibutyl tin dilaurate, dibutyl tin diacetate, dibutyl tin dichloride, dibutyl tin dibromide, zinc naphthenate; triphenyl boron, tetraisopropyl titanate, triethanolamine titanate chelate, dibutyl tin dioxide, dibutyl tin dioctoate, tin octoate, aluminum titanate, aluminum chelates, zirconium chelate, ethyl triphenyl phosphonium iodide or a combination thereof.

### Claim 4 (depends on 1)

The process of claim 1, wherein the curing is conducted at a temperature in the range of from about 10° C. to about 32° C.

### Claim 5 (depends on 1)

The process of claim 1 wherein the curing is conducted at a temperature in the range of from about 32° C. to about 82° C.

### Claim 6 (depends on 1)

The process of claim 1, wherein forming the second coating mixture comprises forming the second coating mixture with the acid catalyst chosen from a carboxylic acid, a sulfonic acid, a phosphoric acid and a combination thereof.

### Claim 7 (depends on 1)

The process of claim 1, wherein forming the second coating mixture comprises forming the second coating mixture with the alkylated melamine chosen from hexamethoxymethylmelamine and hexabutoxymethylmelamine.

### Claim 8 (depends on 1)

The process of claim 1, wherein the coating composition is a waterborne coating composition comprising in the range of from about 50 to 100 percent by weight of water, based on the total amount of liquid carrier in the coating composition.

### Claim 9 (depends on 1)

The process of claim 1, wherein the second coating mixture is formed prior to forming the first coating mixture or wherein the second coating mixture is formed during the maturation period of the first coating mixture.

### Claim 10 (depends on 1)

The process of claim 1, wherein the coating composition is a primer, a basecoat, a topcoat or a clearcoat.

### Claim 11

A process for producing a coating composition, the process comprising the steps of:
forming a first coating mixture, the first coating mixture comprising:
a film-forming polymer having at least two different functional groups, a hydroxyl group and an amine neutralized carboxylic acid group, and
a polyisocyanate;
allowing the first coating mixture to mature for about 0.5 to about 60 minutes,
forming a second coating mixture, the second coating mixture comprising:
an alkylated melamine that is essentially unreactive to isocyanates; and
an acid catalyst, and
forming the coating composition by mixing together the matured first coating mixture and the second coating mixture.

### Claim 12 (depends on 11)

The process of claim 11, wherein the forming the first coating mixture comprises forming the first coating mixture further comprising a catalyst.

### Claim 13 (depends on 12)

The substrate process of claim 12, wherein forming the first coating mixture further comprising the catalyst comprises forming the first coating mixture using a catalyst chosen from dibutyl tin dilaurate, dibutyl tin diacetate, dibutyl tin dichloride, dibutyl tin dibromide, zinc naphthenate; triphenyl boron, tetraisopropyl titanate, triethanolamine titanate chelate, dibutyl tin dioxide, dibutyl tin dioctoate, tin octoate, aluminum titanate, aluminum chelates, zirconium chelate, ethyl triphenyl phosphonium iodide and a combination thereof.

### Claim 14 (depends on 11)

The process of claim 11, wherein forming the second coating mixture comprising the acid catalyst comprises forming the second coating mixture comprising the acid catalyst chosen from a carboxylic acid, a sulfonic acid, a phosphoric acid and a combination thereof.

### Claim 15 (depends on 11)

The substrate process of claim 11, wherein forming the second coating mixture comprising the alkylated melamine comprises forming the second coating mixture comprising the alkylated melamine chosen from hexamethoxymethylmelamine and hexabutoxymethylmelamine.

### Claim 16 (depends on 11)

The substrate process of claim 11, wherein the coating composition is a waterborne coating composition comprising in the range of from about 50 to about 100 percent by weight of water, based on the total amount of liquid carrier in the coating composition.

### Claim 17 (depends on 11)

The process of claim 11, wherein the second coating mixture is formed prior to forming the first coating mixture or wherein the second coating mixture is formed during the maturation period of the first coating mixture.

### Claim 18 (depends on 11)

The process of claim 11, wherein the coating composition is a primer, a basecoat, a topcoat or a clearcoat.

### Claim 19 (depends on 11)

The process of claim 11, wherein forming a first coating mixture comprises forming a first coating mixture comprising a film-forming polymer with a hydroxyl number in the range of from about 10 to about 200 mg KOH/g polymer.

### Claim 20 (depends on 11)

The process of claim 11, wherein forming a first coating mixture comprises forming a first coating mixture comprising a film-forming polymer chosen from (meth)acrylic polymers, polyester polymers, polyurethane polymers, alkyd resins and combinations thereof.