US4904502A — Coatings of arylene sulfide polymers

Claim 1

Independent Claim 140 words

A method of coating at least one surface of a substrate selected from the group consisting of an iron-containing alloy, a magnesium-containing alloy, aluminum, glass and ceramic comprising the steps of: (a) providing a clean substrate surface having a temperature of from about 350° C. to about 470° C., (b) spraying said substrate surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, poly(arylene sulfide) and a liquid carrier to provide a coating thereon, wherein said poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (c) further heating said substrate surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 2

Independent Claim 140 words

A method of coating at least one surface of a substrate selected from the group consisting of an iron-containing alloy, a magnesium-containing alloy, aluminum, glass and ceramic comprising the steps of: (a) providing a clean substrate surface having a temperature of from about 350° C. to about 470° C., (b) spraying said substrate surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, poly(arylene sulfide) and a liquid carrier to provide a coating thereon, wherein said poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (c) further heating said substrate surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 3

Dependent Claim 22 words

A method according to claim 1 wherein said metal oxide is selected from the group consisting of titanium dioxide and zirconium dioxide.

Claim 4

Dependent Claim 77 words

A method according to claim 2 wherein said poly(arylene sulfide) comprises poly(p-phenylene sulfide) and is present in said liquid slurry coating formulation in an amount of about 25 to about 40 weight percent, said metal oxide is present in an amount of about 2 to about 20 weight percent, and said liquid carrier is present in an amount of about 40 to about 73 weight percent based on the total weight of said liquid slurry coating formulation.

Claim 5

Dependent Claim 37 words

A method according to claim 3 wherein said poly(p-phenylene sulfide) has an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns.

Claim 6

Independent Claim 178 words

A method of coating at least one surface of a substrate selected from the group consisting of an iron-containing alloy, a magnesium-containing alloy, aluminum, glass and ceramic comprising the steps of: (a) providing a clean substrate surface having a temperature of from about 350° C. to about 470° C., (b) spraying said heated substrate surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, a mixture of a first poly(arylene sulfide) with a second poly(arylene sulfide) selected from the group consisting of poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes, poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone) and a liquid carrier to provide a coating thereon and wherein said first poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (c) further heating said substrate surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 7

Independent Claim 178 words

A method of coating at least one surface of a substrate selected from the group consisting of an iron-containing alloy, a magnesium-containing alloy, aluminum, glass and ceramic comprising the steps of: (a) providing a clean substrate surface having a temperature of from about 350° C. to about 470° C., (b) spraying said heated substrate surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, a mixture of a first poly(arylene sulfide) with a second poly(arylene sulfide) selected from the group consisting of poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes, poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone) and a liquid carrier to provide a coating thereon and wherein said first poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (c) further heating said substrate surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 8

Dependent Claim 22 words

A method according to claim 5 wherein said metal oxide is selected from the group consisting of titanium dioxide and zirconium dioxide.

Claim 9

Dependent Claim 79 words

A method according to claim 6 wherein said first poly(arylene sulfide) comprises poly(p-phenylene sulfide) and wherein said mixture is present in said liquid slurry coating formulation in an amount of about 25 to about 40 weight percent, said metal oxide is present in an amount of about 2 to about 20 weight percent, and said liquid carrier is present in an amount of about 40 to about 73 weight percent based on the total weight of said coating formulation.

Claim 10

Dependent Claim 43 words

A method according to claim 7 wherein the weight ratio of said first poly(p-phenylene sulfide) to said second poly(arylene sulfide) in said mixture is about 0.1:1 to about 10:1 and wherein said second poly(arylene sulfide) is one of poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone).

Claim 11

Dependent Claim 44 words

A method according to claim 8 wherein said second poly(arylene sulfide) comprises poly(phenylene sulfide/sulfone) having an inherent viscosity of about 0.05 to about 0.7 dL/g and wherein said weight ratio of said poly(p-phenylene sulfide) to said poly(phenylene sulfide/sulfone) is about 3:1 to about 7:1.

Claim 12

Dependent Claim 50 words

A method according to claim 8 wherein said second poly(arylene sulfide) comprises poly(phenylene sulfide/ketone) having a melt flow rate measured at 371° C. of about 1 to about 1000 grams/10 minutes and wherein said weight ratio of said poly(p-phenylene sulfide) to said poly(phenylene sulfide/ketone) is about 3:1 to about 9:1.

Claim 13

Dependent Claim 46 words

A method according to claim 7 wherein said second poly(arylene sulfide) comprises poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes and wherein said weight ratio of said first poly(p-phenylene sulfide) to said second poly(p-phenylene sulfide) is greater than about 0.2:1.

Claim 14

Dependent Claim 37 words

A method according to claim 9 wherein said poly(p-phenylene sulfide) has an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns.

Claim 15

Dependent Claim 37 words

A method according to claim 10 wherein said poly(p-phenylene sulfide) has an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns.

Claim 16

Dependent Claim 38 words

A method according to claim 11 wherein said first poly(p-phenylene sulfide) has an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns.

Claim 17

Independent Claim 148 words

A method of coating at least one surface of an iron-containing alloy comprising the steps of: (a) providing a clean iron-containing alloy surface, (b) heating said surface from about 350° C. to about 470° C. in an atmosphere comprising oxygen and water vapor for a period of at least about 0.5 hour, (c) spraying said heated surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, at least one poly(arylene sulfide) and a liquid carrier to provide a coating thereon wherein said at least one poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (d) further heating said surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 18

Independent Claim 148 words

A method of coating at least one surface of an iron-containing alloy comprising the steps of: (a) providing a clean iron-containing alloy surface, (b) heating said surface from about 350° C. to about 470° C. in an atmosphere comprising oxygen and water vapor for a period of at least about 0.5 hour, (c) spraying said heated surface with a liquid slurry coating formulation consisting of effective amounts of a metal oxide selected from the group consisting of Group 4b metal oxides, at least one poly(arylene sulfide) and a liquid carrier to provide a coating thereon wherein said at least one poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (d) further heating said surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 19

Dependent Claim 61 words

A method according to claim 15 wherein said liquid carrier is selected from the group consisting of water, aliphatic organic compounds having 3-12 carbon atoms per molecule and at least one hydroxyl group per molecule and mixtures of water with said aliphatic organic compounds and wherein said metal oxide is selected from the group consisting of titanium dioxide and zirconium dioxide.

Claim 20

Dependent Claim 111 words

A method according to claim 16 wherein said poly(arylene sulfide) comprises poly(phenylene sulfide) having an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns and is present in an amount of about 25 to about 40 weight percent, wherein said liquid carrier comprises an alkane diol having 3-6 carbon atoms per molecule and is present in an amount of about 40 to about 73 weight percent and wherein said metal oxide comprises titanium dioxide present in an amount of about 2 to about 20 weight percent based on the total weight of said coating formulation.

Claim 21

Independent Claim 180 words

A method of coating at least one surface of an iron-containing alloy comprising the steps of: (a) providing a clean iron-containing alloy surface, (b) heating said surface from about 350° C. to about 470° C. in an atmosphere comprising oxygen and water vapor for a period of at least about 0.5 hour, (c) spraying said heated surface with a liquid slurry coating formulation consisting of effective amounts of a liquid carrier, a metal oxide selected from the group consisting of Group 4b metal oxides, and a mixture of a first poly(arylene sulfide) and a second poly(arylene sulfide) wherein said second poly(arylene sulfide) is selected from the group consisting of poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes, poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone) and wherein said first poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (d) further heating said surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 22

Independent Claim 180 words

A method of coating at least one surface of an iron-containing alloy comprising the steps of: (a) providing a clean iron-containing alloy surface, (b) heating said surface from about 350° C. to about 470° C. in an atmosphere comprising oxygen and water vapor for a period of at least about 0.5 hour, (c) spraying said heated surface with a liquid slurry coating formulation consisting of effective amounts of a liquid carrier, a metal oxide selected from the group consisting of Group 4b metal oxides, and a mixture of a first poly(arylene sulfide) and a second poly(arylene sulfide) wherein said second poly(arylene sulfide) is selected from the group consisting of poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes, poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone) and wherein said first poly(arylene sulfide) has an extrusion rate of about 80 to about 400 grams/10 minutes, and (d) further heating said surface having said coating thereon from about 350° C. to about 470° C. for at least about 0.05 hour to provide a cured coating substantially free of pinhole defects.

Claim 23

Dependent Claim 97 words

A method according to claim 21 wherein said liquid carrier is selected from the group consisting of water, aliphatic organic compounds having 3-12 carbon atoms per molecule and at least one hydroxyl group per molecule and mixtures of water with said aliphatic organic compounds and wherein said metal oxide is selected from the group consisting of titanium dioxide and zirconium dioxide and wherein said first poly(arylene sulfide) comprises poly(p-phenylene sulfide) having an extrusion rate of about 120 to about 300 grams/10 minutes and a particle size principally in the range of about 10 to about 250 microns.

Claim 24

Dependent Claim 118 words

A method according to claim 19 wherein said liquid carrier comprises an alkane diol having 3-6 carbon atoms per molecule and is present in an amount of about 40 to about 73 weight percent and wherein the weight ratio of said first poly(p-phenylene sulfide) to said second poly(arylene sulfide) in said mixture is about 0.1:1 to about 10:1 and wherein said second poly(arylene sulfide) is one of poly(phenylene sulfide/sulfone) and poly(phenylene sulfide/ketone) and wherein said mixture is present in an amount of about 25 to about 40 weight percent and wherein said metal oxide is present in an amount of about 2 to about 20 weight percent based on the total weight of said liquid slurry coating formulation.

Claim 25

Dependent Claim 43 words

A method according to claim 20 wherein said second poly(arylene sulfide) comprises poly(phenylene sulfide/sulfone) having an inherent viscosity of about 0.05 to about 0.7 dL/g and wherein said weight ratio of poly(p-phenylene sulfide) to said poly(phenylene sulfide/sulfone) is about 3:1 to about 7:1.

Claim 26

Dependent Claim 51 words

A method according to claim 20 wherein said second poly(arylene sulfide) comprises poly(phenylene sulfide/ketone) having a melt flow rate measured at 371° C. of about 1 to about 1000 grams/10 minutes and wherein said weight ratio of said first poly(p-phenylene sulfide) to said poly(phenylene sulfide/ketone) is about 2:1 to about 9:1.

Claim 27

Dependent Claim 46 words

A method according to claim 19 wherein said second poly(arylene sulfide) comprises poly(p-phenylene sulfide) having an extrusion rate of about 5 to about 75 grams/10 minutes and wherein said weight ratio of said first poly(p-phenylene sulfide) to said second poly(p-phenylene sulfide is greater than about 0.2:1.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-02-26	1993-08-28	1994-02-27	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-02-26	1997-08-28	1998-02-27	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-02-26	2001-08-28	2002-02-27	$7700.00	Window Closed / Lapsed

Coatings of arylene sulfide polymers

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