Poly(arylene sulfide) coating compositions containing alkali metal alkylbenzenesulfonate

Claim 2

A composition comprising at least one poly(arylene sulfide) resin and at least one alkali metal alkylbenzenesulfonate.

Claim 3

A composition in accordance with claim 1 wherein said alkali metal alkylbenzenesulfonate is present in an amount in the range of about 0.01 to about 10 weight percent, based on the weight of said resin.

Claim 4

A composition in accordance with claim 2 wherein said alkali metal alkylbenzenesulfonate has the general formula: ##STR2## wherein M is an alkali metal, R is an alkyl radical having 6 to 30 carbon atoms, and each R' is individually selected from the group consisting of hydrogen and alkyl radicals having 1 to 18 carbon atoms.

Claim 5

A composition in accordance with claim 3 wherein at least 3 of the R' radicals are hydrogen.

Claim 6

A composition in accordance with claim 4 wherein said alkali metal is sodium.

Claim 7

A composition in accordance with claim 5 wherein said sodium alkylbenzenesulfonate is present in an amount in the range of about 0.1 to about 7 weight percent, based on the weight of said resin.

Claim 8

A composition in accordance with claim 6 wherein said resin is in particulate form, and further comprising a sufficient amount of a suitable liquid diluent to form a dispersion of the particles of said resin in said diluent, said suitable liquid diluent being inert to the other components of the dispersion and being readily volatilized during the curing of said resin.

Claim 9

A composition in accordance with claim 7 wherein said diluent is water.

Claim 10

A composition in accordance with claim 8 wherein said poly(arylene sulfide) resin is poly(phenylene sulfide).

Claim 11

A composition in accordance with claim 9 wherein said alkali metal alkylbenzenesulfonate is at least one sodium dodecylbenzenesulfonate.

Claim 12

A composition in accordance with claim 9 wherein said sodium alkylbenzenesulfonate is present in the form of a sodium petroleum sulfonate.

Claim 13

A composition in accordance with claim 1 wherein said resin is in particulate form, and further comprising a sufficient amount of a suitable liquid diluent to form a dispersion of the particles of said resin in said diluent, said suitable liquid diluent being inert to the other components of the dispersion and being readily volatilized during the curing of said resin.

Claim 14

A process of coating a substrate which comprises applying to a surface of said substrate a layer of the dispersion of claim 12, and then heating the thus applied layer in the presence of oxygen to a suitable temperature for a sufficient time to fuse and cure said poly(arylene sulfide) resin, said diluent being inert to said substrate and readily volatilized during said step of heating the thus applied layer, the concentration of the particles of said resin in said dispersion being sufficient for the particles to be closely enough associated on deposit on said substrate to permit the particles to fuse together on melting.

Claim 15

A process in accordance with claim 13 wherein said alkali metal alkylbenzenesulfonate is present in said dispersion in an amount in the range of about 0.01 to about 10 weight percent, based on the weight of said resin in said dispersion.

Claim 16

A process in accordance with claim 14 wherein said alkali metal alkylbenzenesulfonate has the general formula: ##STR3##

Claim 17

A process in accordance with claim 15 wherein said alkali metal is sodium, and wherein at least 3 of the R' radicals are hydrogen. wherein M is an alkali metal, R is an alkyl radical having 6 to 30 carbon atoms, and each R' is individually selected from the group consisting of hydrogen and alkyl radicals having 1 to 18 carbon atoms.

Claim 18

A process in accordance with claim 16 wherein said sodium alkylbenzenesulfonate is present in said dispersion in an amount in the range of about 0.1 to about 7 weight percent, based on the weight of said resin in said dispersion.

Claim 19

A process in accordance with claim 17 wherein said diluent is water.

Claim 20

A process in accordance with claim 18 wherein said poly(arylene sulfide) resin is poly(phenylene sulfide).

Claim 21

An article of manufacture comprising a substrate having at least a portion of a surface of said substrate coated in accordance with the process of claim 13.

Claim 22

An article of manufacture in accordance with claim 20 wherein said alkali metal alkylbenzenesulfonate has the general formula: ##STR4## wherein M is an alkali metal, R is an alkyl radical having 6 to 30 carbon atoms, and each R' is individually selected from the group consisting of hydrogen and alkyl radicals having 1 to 18 carbon atoms.

Claim 23

An article in accordance with claim 21 wherein said alkali metal alkylbenzenesulfonate is present in the coating in an amount in the range of about 0.01 to about 10 weight percent, based on the weight of said resin in said coating.

Claim 24

An article of manufacture in accordance with claim 22 wherein said poly(arylene sulfide) resin is poly(phenylene sulfide).

Claim 25

An article of manufacture in accordance with claim 23 wherein said alkali metal alkylbenzenesulfonate is at least one sodium dodecylbenzenesulfonate.

Claim 26

An article of manufacture in accordance with claim 23 wherein said sodium alkylbenzenesulfonate is present in the form of a sodium petroleum sulfonate.

Claim 27

A composition in accordance with claim 1 wherein said resin is in the form of particles having a size in the range of about 3 to about 150 microns, and further comprising a sufficient amount of a suitable liquid diluent to form a dispersion of the particles of said resin in said diluent, said suitable liquid diluent being inert to the other components of the dispersion and being readily volatilized during the curing of said resin, the concentration of said particles in said dispersion being in the range of about 10 to about 65 weight percent based on the weight of the total dispersion, and wherein said alkali metal alkylbenzenesulfonate is present in said dispersion in an amount in the range of about 0.01 to about 10 weight percent, based on the weight of said resin in said dispersion.

Claim 28

A process of coating a substrate which comprises applying to a surface of said substrate a layer of the dispersion of claim 26, and then heating the thus applied layer in the presence of oxygen to a suitable temperature for a sufficient time to fuse and cure said poly(arylene sulfide) resin, said diluent being inert to said substrate and readily volatilized during said step of heating the thus applied layer.

Claim 29

A process in accordance with claim 27 wherein said poly(arylene sulfide) resin is poly(phenylene sulfide), and wherein said alkali metal alkylbenzenesulfonate has the general formula: ##STR5## wherein M is an alkali metal, R is an alkyl radical having 6 to 30 carbon atoms, and each R' is individually selected from the group consisting of hydrogen and alkyl radicals having 1 to 18 carbon atoms.

Claim 30

A process in accordance with claim 28 wherein said alkali metal alkylbenzensulfonate is at least one sodium dodecylbenzenesulfonate.

Claim 31

A composition in accordance with claim 1 wherein said resin is in the form of particles having a size in the range of about 3 to about 150 microns, and further comprising a sufficient amount of water to form a dispersion of the particles of said resin in the water, the concentration of said particles in said dispersion being in the range of about 10 to about 65 weight percent based on the weight of the total dispersion, and wherein said alkali metal alkylbenzenesulfonate is present in said dispersion in an amount in the range of about 0.01 to about 10 weight percent, based on the weight of said resin in said dispersion.

Claim 32

A composition in accordance with claim 30 wherein said alkali metal alkylbenzenesulfonate is at least one sodium dodecylbenzenesulfonate.