US4753826A — Abrasion-resistant polymer composition and coating

Claim 1

Independent Claim 84 words

An abrasion resistant polymer composition comprising from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, from about 4.2 to 12 wt. % of a rheological additive, from about 10 to 14 wt. % of a curing agent for the epoxide and the isocyanate, from about 1 to 4 wt. % of a plasticizer, and from about 0.1 to 0.6 wt. % of a surface modifying agent containing silane groups.

Claim 2

Dependent Claim 84 words

An abrasion resistant polymer composition comprising from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, from about 4.2 to 12 wt. % of a rheological additive, from about 10 to 14 wt. % of a curing agent for the epoxide and the isocyanate, from about 1 to 4 wt. % of a plasticizer, and from about 0.1 to 0.6 wt. % of a surface modifying agent containing silane groups.

Claim 3

Dependent Claim 56 words

The polymer composition of claim 1 comprising about 36.4 wt. % of the epoxy resin, about 36.4 wt. % of the blocked isocyanate prepolymer, about 9.98 wt. % of the rheological additive, about 12.84 wt. % of the curing agent, about 2.88 wt. % of the plasticizer, and about 0.36 wt. % of the surface modifier.

Claim 4

Dependent Claim 62 words

The polymer composition of claim 1 comprising from about 24 to 48 wt. % epoxy resin, from about 24 to 48 wt. % blocked isocyanate prepolymer, from about 4.2 to 12 wt. % rheological additive, from about 10 to 14 wt. % polyglycol diamine, from about 1 to 4 wt. % dibutyl phthalate, and from about 0.1 to 0.6 wt. % silane.

Claim 5

Dependent Claim 45 words

The polymer composition of claim 3 comprising from about 36.4 wt. % epoxy resin, about 36.4 wt. % blocked isocyanate prepolymer, about 9.98 wt. % rheological additive, about 12.84 wt. % polyglycol diamine, about 2.88 wt. % dibutyl phthalate, and about 0.36 wt. % silane.

Claim 6

Dependent Claim 81 words

An abrasion resistant coating composition comprising from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, from about 4.2 to 12 wt. % rheological additive, from about 10 to 14 wt. % of curing agent for the epoxide and the isocyanate, from about 1 to 4 wt. % of a plasticizer, and from about 0.1 to 0.6 wt. % of a surface modifying agent containing silane groups.

Claim 7

Dependent Claim 81 words

An abrasion resistant coating composition comprising from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, from about 4.2 to 12 wt. % rheological additive, from about 10 to 14 wt. % of curing agent for the epoxide and the isocyanate, from about 1 to 4 wt. % of a plasticizer, and from about 0.1 to 0.6 wt. % of a surface modifying agent containing silane groups.

Claim 8

Dependent Claim 56 words

The coating composition of claim 5 comprising about 36.4 wt. % of the epoxy resin, about 36.4 wt. % of the blocked isocyanate prepolymer, about 9.98 wt. % of the rheological additive, about 12.84 wt. % of the curing agent, about 2.88 wt. % of the plasticizer, and about 0.36 wt. % of the surface modifier.

Claim 9

Dependent Claim 68 words

The coating composition of claim 5 comprising from about 24 to 48 wt. % of epoxy resin, from about 24 to 48 wt. % of blocked isocyanate prepolymer, from about 4.2 to 12 wt. % if rheological additive, from about 10 to 14 wt. % of polyglycol diamine, from about 1 to 4 wt. % of dibutyl phthalate, and from about 0.1 to 0.6 wt. % of silane.

Claim 10

Dependent Claim 51 words

The coating composition of claim 5 comprising from about 36.4 wt. % of epoxy resin, about 36.4 wt. % of blocked isocyanate prepolymer, about 9.98 wt. % of rheological additive, about 12.84 wt. % of polyglycol diamine, about 2.88 wt. % of dibutyl phthalate, and about 0.36 wt. % of silane.

Claim 11

Dependent Claim 14 words

The coating composition of claim 5 containing up to about 2 wt. % pigment.

Claim 12

Dependent Claim 15 words

The coating composition of claim 5 containing up to about 2 wt. % magnesium silicate.

Claim 13

Dependent Claim 16 words

The coating composition of claim 8 containing from about 0.4 to 2. wt. % magnesium silicate.

Claim 14

Dependent Claim 24 words

The coating composition of claim 5 wherein at least about 50 wt. % of the liquid epoxy resin is a bisphenol A-epichlorohydrin epoxy resin.

Claim 15

Dependent Claim 24 words

The coating composition of claim 5 wherein at least about 80 wt. % of the liquid epoxy resin is a bisphenol A-epichlorohydrin epoxy resin.

Claim 16

Dependent Claim 25 words

The coating composition of claim 5 wherein at least about 80 wt. % of the blocked isocyanate prepolymer is an alkyl phenol blocked toluene diisocyanate.

Claim 17

Dependent Claim 25 words

The coating composition of claim 5 wherein at least about 90 wt. % of the blocked isocyanate prepolymer is an alkyl phenol blocked toluene diisocyanate.

Claim 18

Dependent Claim 15 words

The coating composition of claim 5 wherein the silane is an epoxy or an aminosilane.

Claim 19

Dependent Claim 85 words

An abrasion resistant coating comprising the reaction product of from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, and from about 10 to 14 wt. % of and curing agent for the epoxide and the isocyanate; and from about 4.2 to 12 wt. % of a rheological additive, from about 1 to 4 wt. % of a plasticizer, from about 0.1 to 0.6 wt. % of silane, and auxilliary material.

Claim 20

Dependent Claim 85 words

An abrasion resistant coating comprising the reaction product of from about 24 to 48 wt. % of a liquid epoxy resin, from about 24 to 48 wt. % of a blocked isocyanate prepolymer, and from about 10 to 14 wt. % of and curing agent for the epoxide and the isocyanate; and from about 4.2 to 12 wt. % of a rheological additive, from about 1 to 4 wt. % of a plasticizer, from about 0.1 to 0.6 wt. % of silane, and auxilliary material.

Claim 21

Dependent Claim 81 words

The coating of claim 17 wherein the epoxy resins is a diglycidyl ether of bisphenol A, the blocked isocyanate is an alkyl phenol blocked toluene diisocyanate, the curing agent is an alkyleneamine having the formula NH 2 CH 2 CH 2 CH 2 O (CH 2 CH 2 O) 2 CH 2 CH 2 CH 2 NH 2 , the rheological additive is colloidal silica, the plasticizer is dibutyl phthalate, the silane is gamma-aminopropyltriethoxysilane, and the auxiliary material is magnesium silicate.

Claim 22

Dependent Claim 21 words

The coating of claim 17 wherein up to 50% of the epoxy resin is a low viscosity epoxy phenol novolac resin.

Claim 23

Dependent Claim 26 words

The coating of claim 17 wherein up to 20% of the blocked diisocyanate is a blocked isocyanate prepolymer compatible with the alkyl phenol blocked toluene diisocyanate.

Claim 24

Dependent Claim 12 words

The coating of claim 17 wherein the silane is an epoxy silane.

Claim 25

Dependent Claim 13 words

The coating of claim 17 wherein the curing agent is an epoxy amine.

Claim 26

Independent Claim 124 words

A method of producing an abrasion resistant coating composition, said method comprising: (a) mixing from about 30 to 60 wt. % epoxy resin, from about 40 to 60 wt. % blocked isocyanate prepolymer, and from about 4 to 10 wt. % rheological additive to produce a first portion of said ccoating; (b) mixing from about 50 to 70% wt. % polyglycol diamine, from about 5 to 02 wt. % dibutyl phthalate, from about 0.5 to 3 wt. % silane, and from about 5 to 20 wt. % rheological additive to produce a second portion of said coating; and (c) mixing four parts of the first portion of said coating with one part of the second portion of said coating to produce the coating composition.

Claim 27

Independent Claim 124 words

A method of producing an abrasion resistant coating composition, said method comprising: (a) mixing from about 30 to 60 wt. % epoxy resin, from about 40 to 60 wt. % blocked isocyanate prepolymer, and from about 4 to 10 wt. % rheological additive to produce a first portion of said ccoating; (b) mixing from about 50 to 70% wt. % polyglycol diamine, from about 5 to 02 wt. % dibutyl phthalate, from about 0.5 to 3 wt. % silane, and from about 5 to 20 wt. % rheological additive to produce a second portion of said coating; and (c) mixing four parts of the first portion of said coating with one part of the second portion of said coating to produce the coating composition.

Claim 28

Independent Claim 156 words

A method for producing an abrasion resistant coating which comprises: (a) mixing from about 30 to 60 wt. % of a liquid epoxy resin, from about 30 to 60 wt. % of a blocked isocyanate prepolymer, and from about 4 to 10 wt. % of rheological additive to produce a first portion of said coating; (b) mixing from about 50 to 70 wt. % of a curing agent for the epoxide and the diamine, from about 5 to 20 wt. % of a plasticizer, from about 0.5 to 3 wt. % of a silane, and from about 5 to 20 wt. % of a rheological additive to produce a second portion of said coating; (c) mixing four parts of the first portion of said coating with one part of the second portion of said coating to produce a coating composition; (d) applying the composition to a surface; and (e) curing the composition to produce the coating.

Claim 29

Independent Claim 156 words

A method for producing an abrasion resistant coating which comprises: (a) mixing from about 30 to 60 wt. % of a liquid epoxy resin, from about 30 to 60 wt. % of a blocked isocyanate prepolymer, and from about 4 to 10 wt. % of rheological additive to produce a first portion of said coating; (b) mixing from about 50 to 70 wt. % of a curing agent for the epoxide and the diamine, from about 5 to 20 wt. % of a plasticizer, from about 0.5 to 3 wt. % of a silane, and from about 5 to 20 wt. % of a rheological additive to produce a second portion of said coating; (c) mixing four parts of the first portion of said coating with one part of the second portion of said coating to produce a coating composition; (d) applying the composition to a surface; and (e) curing the composition to produce the coating.

Claim 30

Dependent Claim 71 words

The method of claim 24 wherein the first portion comprises about 45.50 wt. % of the epoxy resin, about 45.50 wt. % of the blocked isocyanate prepolymer, and about 8.60 wt. % of the rheological additive; the second portion comprises about 64.20 wt. % of the curing agent, about 14.00 wt. % of the plasticizer, about 1.80 wt. % of the silane, and about 15.50 wt. % of the rheological additive.

Claim 31

Dependent Claim 24 words

The method of claim 24 wherein the portions additionally contain a member selected from the group consisting of pigments, mineral fillers, and mixtures thereof.

Claim 32

Dependent Claim 23 words

The method of claim 24 wherein the coating is applied to the surface at a thickness of from about 1/6 to 2 inches.

Claim 33

Dependent Claim 13 words

The method of claim 24 wherein the composition is cured at ambient temperature.

Claim 34

Dependent Claim 80 words

The method of claim 24 wherein the epoxy resin is a diglycidyl ether of bisphenol A, the blocked isocyanate is an alkyl phenol blocked toluene diisocyanate, the curing agent is an alkylene amine havine the formula NH 2 CH 2 CH 2 CH 2 O(CH 2 CH 2 O) 2 CH 2 CH 2 CH 2 NH 2 , the rheological additive is colloidal silica, the platicizer is dibutyl phthalate, the silane gamma-aminopropyltriethoxysilane, and the second portion contains magnesium silicate.

Claim 35

Dependent Claim 14 words

The method of claim 29 wherein the first and second portions contain a pigment.

Claim 36

Dependent Claim 19 words

The method of claim 24 wherein the surface to which the composition is applied is coated with a primer.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-06-28	1991-12-28	1992-06-28	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-06-28	1995-12-28	1996-06-28	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-06-28	1999-12-28	2000-06-28	$7700.00	Window Closed / Lapsed

Abrasion-resistant polymer composition and coating

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