U.S. patent application number 15/421587 was filed with the patent office on 2017-05-18 for films and coatings containing borosilicate flake glass.
The applicant listed for this patent is INSULATING COATINGS OF AMERICA, INC.. Invention is credited to Thomas H. Curtis, Terrance M. McInerney.
Application Number | 20170137638 15/421587 |
Document ID | / |
Family ID | 52782174 |
Filed Date | 2017-05-18 |
United States Patent
Application |
20170137638 |
Kind Code |
A1 |
McInerney; Terrance M. ; et
al. |
May 18, 2017 |
FILMS AND COATINGS CONTAINING BOROSILICATE FLAKE GLASS
Abstract
A coating material containing borosilicate flake glass is
disclosed, together with methods for the preparation and use
thereof.
Inventors: |
McInerney; Terrance M.;
(Atlanta, GA) ; Curtis; Thomas H.; (Decatur,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INSULATING COATINGS OF AMERICA, INC. |
Atlanta |
GA |
US |
|
|
Family ID: |
52782174 |
Appl. No.: |
15/421587 |
Filed: |
February 1, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14636610 |
Mar 3, 2015 |
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15421587 |
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13040932 |
Mar 4, 2011 |
9005748 |
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14636610 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/252 20150115;
C09D 5/004 20130101; C09D 7/61 20180101; C08K 3/34 20130101; C09D
5/028 20130101; C09D 7/70 20180101; Y10T 442/2664 20150401; Y10T
428/264 20150115; Y10T 428/26 20150115; C03C 3/064 20130101; B05D
3/06 20130101; C03C 3/089 20130101; C08K 7/10 20130101; C09D 5/26
20130101; Y10T 428/265 20150115; C09K 5/14 20130101; C09D 5/32
20130101 |
International
Class: |
C09D 7/12 20060101
C09D007/12; C03C 3/089 20060101 C03C003/089; C03C 3/064 20060101
C03C003/064; C09D 5/32 20060101 C09D005/32; C09K 5/14 20060101
C09K005/14 |
Claims
1. A thermal barrier film, said film comprising: a flexible sheet,
without having a cross-linkable silicone component, that is
configured to be applied to at least a portion of a substrate, the
flexible sheet formed of a coating material having a quantity of
flaked borosilicate glass, wherein upon exposure of the substrate
having the flexible sheet disposed thereon to a source of thermal
radiation, the substrate has a temperature that is less than a
temperature of a comparable substrate that does not have the
flexible sheet disposed thereon and similarly exposed to the source
of thermal radiation, and wherein the substrate is a textile
material, a woven material, a non-woven material, a membrane
material, or combinations thereof
2. The thermal barrier film of claim 1, wherein at least a portion
of the flaked borosilicate glass has an aspect ratio of about 100:1
or greater.
3. The thermal barrier film of claim 1, wherein the flexible sheet
is from about 10 .mu.m to about 5,000 .mu.m thick.
4. The thermal barrier film of claim 1, wherein the flaked
borosilicate glass has an average particle size in at least one
dimension of from about 5 .mu.m to about 100 .mu.m.
5. The thermal barrier film of claim 1, wherein the coating
material comprises from about 10 wt. % to about 80 wt. % flaked
borosilicate glass.
6. The thermal barrier film of claim 1, wherein the coating
material comprises from about 10 wt. % to about 25 wt. % flaked
borosilicate glass.
7. The thermal barrier film of claim 1, wherein the source of
thermal radiation comprises solar radiation, infrared radiation,
convective heating, or combinations thereof.
8. The thermal barrier film of claim 1, wherein upon exposure to
the source of thermal radiation the temperature of the substrate
having the flexible sheet disposed thereon is less than about
5.degree. F. or greater than the temperature of the comparable
substrate that does not have the flexible sheet disposed thereon
and similarly exposed to the source of thermal radiation.
9. A coated substrate comprising: a substrate that comprises a
textile material, a woven material, a non-woven material, a
membrane material, or combinations thereof; and a coating material,
without having a cross-linkable component, disposed on and at least
partially impregnated in at least a portion of the substrate,
wherein the coating material is a paint that comprises flaked
borosilicate glass, wherein upon exposure of the coated substrate
to a source of thermal radiation, the coated substrate has a
temperature that is less than a temperature of a comparable
substrate that is not coated with the coating material and
similarly exposed to the source of thermal radiation.
10. The coated substrate of claim 9, wherein at least a portion of
the flaked borosilicate glass has an aspect ratio of about 100:1 or
greater.
11. The coated substrate of claim 9, wherein the coating material,
once disposed on the substrate, is from about 10 .mu.m to about
5,000 .mu.m thick.
12. The coated substrate of claim 9, wherein the flaked
borosilicate glass has an average particle size in at least one
dimension of from about 5 .mu.m to about 100 .mu.m.
13. The coated substrate of claim 9, wherein the coating material
comprises from about 10 wt. % to about 80 wt. % flaked borosilicate
glass.
14. The coated substrate of claim 9, wherein the coating material
comprises from about 10 wt. % to about 25 wt. % flaked borosilicate
glass.
15. The coated substrate of claim 9, wherein the source of thermal
radiation comprises solar radiation, infrared radiation, convective
heating, or combinations thereof.
16. The coated substrate of claim 9, wherein the coating material
has a density in the range of about 1.16 g/mL to about 1.21
g/mL.
17. The coated substrate of claim 9, wherein upon exposure to the
source of thermal radiation the temperature of the coated substrate
is less than about 5.degree. F. or greater than the temperature of
the comparable substrate that is not coated with the coating
material and similarly exposed to the source of thermal radiation.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/636,610, filed Mar. 3, 2015, which is a
continuation of U.S. patent application Ser. No. 13/040,932, filed
Mar. 4, 2011, now U.S. Pat. No. 9,005,748, each of which is
incorporated by reference herein in its entirety.
BACKGROUND
[0002] TechnicalL Field
[0003] The present disclosure relates to coating materials, and
specifically to coating materials containing borosilicate flake
glass.
[0004] TechnicalL Background
[0005] Coatings, such as paints, have traditionally been used to
protect an underlying substrate from, for example, oxidation or
corrosion, or to impart desirable surface properties to an article.
It would be advantageous if a coating could impart other functional
properties to a substrate or article, such as, for example, thermal
management properties. These needs and other needs are satisfied by
the compositions and methods of the present disclosure.
SUMMARY
[0006] In accordance with the purpose(s) of the invention, as
embodied and broadly described herein, this disclosure, in one
aspect, relates to coating materials, and specifically to coating
materials containing borosilicate flake glass.
[0007] In one aspect, the present disclosure provides a substrate
comprising a coating material, wherein the coating material
comprises flaked borosilicate glass, and wherein the substrate
comprises a textile, a polymeric film, or a combination
thereof.
[0008] In another aspect, the present disclosure provides a method
for improving the thermal properties of a material, the method
comprising contacting a coating composition comprising borosilicate
flake glass with a substrate, wherein the substrate comprises a
textile, a polymeric film, or a combination thereof.
[0009] In another aspect, the present disclosure provides a method
for preparing a thermal barrier material, the method comprising
forming a film from a coating composition, wherein the coating
composition comprises borosilicate flake glass and a plurality of
threads, fibers, or a combination thereof.
DESCRIPTION
[0010] The present invention can be understood more readily by
reference to the following detailed description of the invention
and the Examples included therein.
[0011] Before the present compounds, compositions, articles,
systems, devices, and/or methods are disclosed and described, it is
to be understood that they are not limited to specific synthetic
methods unless otherwise specified, or to particular reagents
unless otherwise specified, as such can, of course, vary. It is
also to be understood that the terminology used herein is for the
purpose of describing particular aspects only and is not intended
to be limiting. Although any methods and materials similar or
equivalent to those described herein can be used in the practice or
testing of the present invention, example methods and materials are
now described.
[0012] All publications mentioned herein are incorporated herein by
reference to disclose and describe the methods and/or materials in
connection with which the publications are cited.
[0013] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Although
any methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the present
invention, example methods and materials are now described.
[0014] As used in the specification and the appended claims, the
singular forms "a," "an" and "the" include plural referents unless
the context clearly dictates otherwise. Thus, for example,
reference to "a ketone" includes mixtures of two or more
ketones.
[0015] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint. It is
also understood that there are a number of values disclosed herein,
and that each value is also herein disclosed as "about" that
particular value in addition to the value itself. For example, if
the value "10" is disclosed, then "about 10" is also disclosed. It
is also understood that each unit between two particular units are
also disclosed. For example, if 10 and 15 are disclosed, then 11,
12, 13, and 14 are also disclosed.
[0016] As used herein, the terms "optional" or "optionally" means
that the subsequently described event or circumstance can or can
not occur, and that the description includes instances where said
event or circumstance occurs and instances where it does not. For
example, the phrase "optionally substituted alkyl" means that the
alkyl group can or can not be substituted and that the description
includes both substituted and unsubstituted alkyl groups.
[0017] Disclosed are the components to be used to prepare the
compositions of the invention as well as the compositions
themselves to be used within the methods disclosed herein. These
and other materials are disclosed herein, and it is understood that
when combinations, subsets, interactions, groups, etc. of these
materials are disclosed that while specific reference of each
various individual and collective combinations and permutation of
these compounds can not be explicitly disclosed, each is
specifically contemplated and described herein. For example, if a
particular compound is disclosed and discussed and a number of
modifications that can be made to a number of molecules including
the compounds are discussed, specifically contemplated is each and
every combination and permutation of the compound and the
modifications that are possible unless specifically indicated to
the contrary. Thus, if a class of molecules A, B, and C are
disclosed as well as a class of molecules D, E, and F and an
example of a combination molecule, A-D is disclosed, then even if
each is not individually recited each is individually and
collectively contemplated meaning combinations, A-E, A-F, B-D, B-E,
B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any
subset or combination of these is also disclosed. Thus, for
example, the sub-group of A-E, B-F, and C-E would be considered
disclosed. This concept applies to all aspects of this application
including, but not limited to, steps in methods of making and using
the compositions of the invention. Thus, if there are a variety of
additional steps that can be performed it is understood that each
of these additional steps can be performed with any specific aspect
or combination of aspects of the methods of the invention.
[0018] References in the specification and concluding claims to
parts by weight, of a particular element or component in a
composition or article, denotes the weight relationship between the
element or component and any other elements or components in the
composition or article for which a part by weight is expressed.
Thus, in a compound containing 2 parts by weight of component X and
5 parts by weight component Y, X and Y are present at a weight
ratio of 2:5, and are present in such ratio regardless of whether
additional components are contained in the compound.
[0019] A weight percent of a component, unless specifically stated
to the contrary, is based on the total weight of the formulation or
composition in which the component is included.
[0020] A residue of a chemical species, as used in the
specification and concluding claims, refers to the moiety that is
the resulting product of the chemical species in a particular
reaction scheme or subsequent formulation or chemical product,
regardless of whether the moiety is actually obtained from the
chemical species. Thus, an ethylene glycol residue in a polyester
refers to one or more --OCH.sub.2CH.sub.2O-- units in the
polyester, regardless of whether ethylene glycol was used to
prepare the polyester. Similarly, a sebacic acid residue in a
polyester refers to one or more --CO(CH.sub.2).sub.8CO-- moieties
in the polyester, regardless of whether the residue is obtained by
reacting sebacic acid or an ester thereof to obtain the
polyester.
[0021] The term "alkyl group" as used herein is a branched or
unbranched saturated hydrocarbon group of 1 to 24 carbon atoms,
such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl,
t-butyl, pentyl, hexyl, heptyl, octyl, decyl, tetradecyl,
hexadecyl, eicosyl, tetracosyl and the like. A "lower alkyl" group
is an alkyl group containing from one to six carbon atoms.
[0022] The term "alkoxy" as used herein is an alkyl group bound
through a single, terminal ether linkage; that is, an "alkoxy"
group may be defined as -OR where R is alkyl as defined above. A
"lower alkoxy" group is an alkoxy group containing from one to six
carbon atoms.
[0023] The term "alkenyl group" as used herein is a hydrocarbon
group of from 2 to 24 carbon atoms and structural formula
containing at least one carbon-carbon double bond. Asymmetric
structures such as (AB)C=C(CD) are intended to include both the E
and Z isomers. This may be presumed in structural formulae herein
wherein an asymmetric alkene is present, or it may be explicitly
indicated by the bond symbol C.
[0024] The term "alkynyl group" as used herein is a hydrocarbon
group of 2 to 24 carbon atoms and a structural formula containing
at least one carbon-carbon triple bond.
[0025] The term "aryl group" as used herein is any carbon-based
aromatic group including, but not limited to, benzene, naphthalene,
etc. The term "aromatic" also includes "heteroaryl group," which is
defined as an aromatic group that has at least one heteroatom
incorporated within the ring of the aromatic group. Examples of
heteroatoms include, but are not limited to, nitrogen, oxygen,
sulfur, and phosphorus. The aryl group can be substituted or
unsubstituted. The aryl group can be substituted with one or more
groups including, but not limited to, alkyl, alkynyl, alkenyl,
aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy,
carboxylic acid, or alkoxy.
[0026] The term "cycloalkyl group" as used herein is a non-aromatic
carbon-based ring composed of at least three carbon atoms. Examples
of cycloalkyl groups include, but are not limited to, cyclopropyl,
cyclobutyl, cyclopentyl, cyclohexyl, etc. The term
"heterocycloalkyl group" is a cycloalkyl group as defined above
where at least one of the carbon atoms of the ring is substituted
with a heteroatom such as, but not limited to, nitrogen, oxygen,
sulphur, or phosphorus.
[0027] The term "aralkyl" as used herein is an aryl group having an
alkyl, alkynyl, or alkenyl group as defined above attached to the
aromatic group. An example of an aralkyl group is a benzyl
group.
[0028] The term "hydroxyalkyl group" as used herein is an alkyl,
alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or
heterocycloalkyl group described above that has at least one
hydrogen atom substituted with a hydroxyl group.
[0029] The term "alkoxyalkyl group" is defined as an alkyl,
alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or
heterocycloalkyl group described above that has at least one
hydrogen atom substituted with an alkoxy group described above.
[0030] The term "ester" as used herein is represented by the
formula --C(O)OA, where A can be an alkyl, halogenated alkyl,
alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl,
heterocycloalkyl, or heterocycloalkenyl group described above.
[0031] The term "carbonate group" as used herein is represented by
the formula --OC(O)OR, where R can be hydrogen, an alkyl, alkenyl,
alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or
heterocycloalkyl group described above.
[0032] The term "carboxylic acid" as used herein is represented by
the formula --C(O)OH.
[0033] The term "aldehyde" as used herein is represented by the
formula --C(O)H.
[0034] The term "keto group" as used herein is represented by the
formula --C(O)R, where R is an alkyl, alkenyl, alkynyl, aryl,
aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group
described above.
[0035] The term "carbonyl group" as used herein is represented by
the formula C=O.
[0036] The term "ether" as used herein is represented by the
formula AOA.sub.1, where A and A.sub.1 can be, independently, an
alkyl, halogenated alkyl, alkenyl, alkynyl, aryl, heteroaryl,
cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl
group described above.
[0037] Each of the materials disclosed herein are either
commercially available and/or the methods for the production
thereof are known to those of skill in the art.
[0038] It is understood that the compositions disclosed herein have
certain functions. Disclosed herein are certain structural
requirements for performing the disclosed functions, and it is
understood that there are a variety of structures that can perform
the same function that are related to the disclosed structures, and
that these structures will typically achieve the same result.
[0039] As briefly described above, the present disclosure provides
a coating that can improve the thermal management properties of an
underlying material. In one aspect, the coating comprises a
borosilicate flake glass. In another aspect, the coating can be
applied to a textile and/or sheet good. In yet another aspect, the
coating can be in the form of a textile and/or sheet good.
[0040] Historically, coatings have been utilized to protect an
underlying material and/or to impart desirable surface properties,
for example, color and/or gloss, thereto. Glass materials have also
been added to coatings, such as paints, to impart fire resistant
properties. For example, glass beads have been added to paints,
such that when exposed to high heat or flame, the glass beads can
melt and provide a flame resistant barrier. Glass materials, such
as hollow glass spheres, have also been added to reduce the density
of paints and coating materials.
[0041] In contrast, the coating of the present invention comprises
flaked glass, such as, for example, borosilicate glass. In one
aspect, the addition of a flaked glass can improve the ability of
the resulting coating to dissipate, move, and/or remove heat from
an underlying substrate. In another aspect, the addition of a
flaked glass can reduce the amount of heat energy transferred to or
absorbed by a substrate comprising the inventive coating. While not
wishing to be bound by theory, it is not believed that the improved
thermal properties of the inventive coating composition are due to
the thermal insulation value of the glass itself, such as could be
achieved through the addition of glass spheres.
[0042] As used herein, the term "coating composition" is intended
to refer to a mixture of coating components, such as, for example,
flaked glass and a vehicle and/or resin system, prior to drying
and/or curing to form a coating. Similarly, the terms "coating" and
"coating material" are intended to refer to a cured and/or dried
form of the coating composition. It should be understood that a
coating formed from a coating composition will typically comprise
the same components as the coating composition, except for any
volatile components that can evaporate, and/or any components that
cross-link or react with other components, a substrate, or a
combination thereof.
[0043] In one aspect, the coating composition of the present
invention can comprise a paint. In another aspect, the coating of
the present invention can comprise an epoxy. In another aspect, the
coating of the present invention can comprise one or more
cross-linkable components. In yet another aspect, the coating of
the present invention can comprise any coating capable of binding
to and/or adhering to at least a portion of a substrate for a
period of time. In another aspect, the coating composition does not
comprise an epoxy. In still another aspect, the coating composition
does not comprise a cross-linkable component, such as, for example,
a cross-linkable silicone.
[0044] The coating composition of the present invention comprises a
glass. In various aspects, the glass can be any glass or mixture of
glass materials that can impart the desired thermal management
properties to an underlying or coated material. In one aspect, the
glass comprises boron. In another aspect, the glass comprises a
borosilicate glass. In various aspects, the glass can comprise one
or more of the following: boron, silica, alumina, calcium oxide,
potassium and/or sodium oxides, lead, or a combination thereof. In
another aspect, the glass does not comprise lead. In yet another
aspect, the glass does not comprise a heavy metal. It should be
understood that glass compositions vary, and that the specific
composition of any particular glass or mixture of glasses can
comprise other items not specifically recited herein.
[0045] In an exemplary aspect, the glass comprises from about 20
wt. % to about 50 wt. % boron, for example, about 20, 22, 24, 26,
28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, or 50 wt. % boron. In
other aspects, the amount of boron in a glass composition can be
less than about 20 wt. % or greater than about 50 wt. %, and the
present invention is not intended to be limited to any particular
amount of boron in a glass composition. In another aspect, the
glass comprises from about 30 wt. % to about 70 wt. % silica, for
example, about 30, 33, 36, 39, 42, 45, 48, 51, 54, 57, 60, 63, 66,
69, or 70 wt. % silica. In other aspects, the amount of silica
present can be less than about 30 wt. % or greater than about 70
wt. %, and the present invention is not intended to be limited to
any particular amount of silica. In another aspect, the glass
comprises, if at all, from about 0 wt. % to about 2 wt. % alumina,
for example, about 0, 0.01, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4,
0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7,
1.8, 1.9, or 2 wt. % alumina. In another aspect, the glass does not
comprise alumina. In yet another aspect, the glass can comprise
greater than about 2 wt. % alumina, and the present invention is
not intended to be limited to any particular amount of alumina. In
another aspect, the glass comprises, if at all, from about 0 wt. %
to about 5 wt. % calcium oxide, for example, about 0, 0.01, 0.02,
0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.25, 1.5, 1.75, 2,
2.25, 2.5, 2.75, 3, 3.25, 3.5, 3.75, 4, 4.25, 4.5, 4.75, or 5 wt. %
calcium oxide. In one aspect, the glass does not comprise calcium
oxide. In still another aspect, the glass comprises greater than
about 5 wt. % calcium oxide. In another aspect, the present
invention is not intended to be limited to any particular amount of
calcium oxide in a glass composition. In another aspect, the glass
comprises, if at all, from about 0 wt .% to about 15 wt. % of
potassium and/or sodium oxide, for example, about 0, 0.01, 0.02,
0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5,
4, 4.5, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt. % of potassium
and/or sodium oxide. In one aspect, the glass does not comprise
potassium oxide. In another aspect, the glass does not comprise
sodium oxide. In yet another aspect, the glass does not comprise an
oxide of potassium and sodium. In another aspect, the glass
comprises greater than about 15 wt. % of a potassium and/or sodium
oxide. The present invention is not intended to be limited to any
particular amount of a potassium and/or sodium oxide in the glass
composition. In another aspect, the glass composition can comprise,
if at all, from about 0 wt. % to about 15 wt. % lead, for example,
about about 0, 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5,
0.75, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, or 15 wt. % lead. In another aspect, the glass does not
comprise lead. In yet another aspect, the glass comprises greater
than about 15 wt. % lead. Thus, the present invention is not
intended to be limited to any particular amount of lead in the
glass composition. In a specific aspect, the glass comprises from
about 20 wt. % to about 50 wt. % boron, from about 30 wt. % to
about 70 wt. % silica, from about 0.01 wt. % to about 2 wt. %
alumina, from about 0.01 wt. % to about 5 wt .% calcium oxide, from
about 0.01 wt. % to about 15 wt. % of an oxide of potassium and/or
sodium, and from about 0.01 wt. % to about 15 wt. % lead.
[0046] In one aspect, the glass can comprise a varying morphology,
such as, for example, can occur from crushing and/or grinding a
glass composition. In one aspect, at least a portion of the glass
comprises a flake morphology. In another aspect, at least a portion
of the glass comprises a needle morphology. In yet another aspect,
at least a portion of the glass particles are flat or substantially
planar. In other aspects, the morphology of all or a portion of the
glass particles is irregular and can vary from at least another
portion of the glass particles. In another aspect, all or
substantially all of the glass comprises a flake morphology. In one
aspect, the glass does not comprise glass spheres, glass
microspheres, or a combination thereof. In another aspect, the
glass does not comprise a plurality of irregular shaped particles
as can occur from crushing and/or grinding a glass composition. In
yet another aspect, the glass is not intended to impart a
reflective property to the resulting coating as can be achieved,
for example, with glass spheres in traffic marking paint. In still
other aspects, the glass does not comprise a coating of iron oxide,
titania, rutile titanium dioxide, pyrolyzed carbon containing ionic
species, silver, or a combination thereof. In yet another aspect,
the glass is not designed or intended to melt and form a flame
resistant barrier upon exposure to heat.
[0047] In one aspect, the glass is particulate, wherein at least a
portion of the particles have an average size in at least one
dimension of from about 5 micrometers to about 100 micrometers, for
example, about 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31,
33, 35, 37, 39, 43, 47, 51, 55, 59, 63, 67, 71, 75, 79, 83, 87, 91,
95, 99, or 100 micrometers. In another aspect, at least a portion
of the particles have an average size in at least one dimension of
from about 5 micrometers to about 45 micrometers, for example,
about 5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34,
36, 38, 40, 42, 44, or 45 micrometers. In still other aspects, at
least a portion of the glass particles can have an average size in
at least one dimension of less than about 5 micrometers or greater
than about 100 micrometers, and the present invention is not
intended to be limited to any particular size glass particles.
Moreover, it should be understood that the size of glass particles
is a distributional property and that the average and standard
deviation for a particular batch of particles can vary.
[0048] In one aspect, at least a portion of the glass particles can
have an aspect ratio of from about 1.001:1 to about 1000:1, for
example, at least about 1.001:1, 1.005:1, 1.01:1, 1.05:1, 1.1:1,
1.2:1, 1.4:1, 1.6:1, 1.8:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1,
10:1, 12:1, 14:1, 16:1, 18:1, 20:1, 22:1, 24:1, 26:1, 28:1, 30:1,
35:1, 40:1, 45:1, 50:1, 55:1, 60:1, 70:1, 80:1, 90:1, 100:1, 125:1,
150:1, 175:1, 200:1, 225:1, 250:1, 300:1, 400:1, 500:1, 600:1,
700:1, 800:1, 900:1, or 1000:1. In other aspects, the aspect ratio
of at least a portion of the glass particles can be greater than
about 1000:1. In another aspect, the aspect ratio of at least half
of the glass particles is greater than about 100:1. In yet another
aspect, the aspect ratio of all or substantially all of the glass
particles is at least about 100:1.
[0049] In one aspect, the glass particles can be contacted with
and/or mixed with a paint or other coating composition component.
In various aspects, the coating composition can comprise a paint,
such as, for example, a latex paint, an alkyd paint, an acrylic
paint, or a combination thereof. In a specific aspect, the coating
composition comprises a latex paint. In other aspects, the coating
material can comprise an epoxy, an elastomeric material, or a
cross-linkable material. In other aspects, the coating composition
can comprise other resin systems or components that can for a
coating upon, for example, curing and/or drying. In one aspect, the
coating composition does not comprise a pyrolyzed carbon containing
ionic species. In another aspect, the coating composition does not
comprise ceramic particles. In still other aspects, the coating
composition does not comprise one or more of a clay, a binder
material, or a combination thereof. In yet another aspect, the
coating composition does not comprise a silicone and/or
cross-linkable silicone component, such as, for example, an
organosilicon. In another aspect, the coating composition and/or
the resulting coating material is not a cosmetic composition that
can be applied to, for example, a living tissue. In another aspect,
the coating composition is not an insulation paste, such as, for
example, an electrical insulation paste that is designed to be used
in an electrical circuit or device.
[0050] Any of the individual components of a coating composition
can be contacted and/or mixed in any order. In one aspect, each of
the components of a coating composition can be contacted
simultaneously. In another aspect, one or more components, such as,
for example, the glass flake, can be added at a different time. In
still another aspect, a commercially available coating composition
can be used, wherein one or more components, such as, for example,
glass flake, are subsequently added. In one aspect, any of the
individual components can be contacted and/or mixed so as to form a
final coating composition prior to contacting with a substrate. In
another aspect, one or more of the individual components can be
contacted and/or mixed after contacting at least one other
component with a substrate. For example, a commercially available
coating composition can be contacted with a substrate, and then a
quantity of glass flake can be added to, mixed with, and/or
dispersed in the coating composition that is in contact with the
substrate.
[0051] It should be understood that the particular composition and
rheology of a coating composition can vary, depending upon, for
example, the specific components and intended application thereof.
In various aspects, the coating composition can comprise an aqueous
or waterborne system. In other aspects, the coating composition can
comprise a nonaqueous system. In still other aspects, the coating
composition and/or the resulting coating can be at least partially
resistant to weathering, such as, for example, a paint intended for
outdoor use.
[0052] The coating composition can comprise any formulation that
can provide a desired final coating. In various aspect, the coating
composition can comprise one or more of: rheological aids, binding
agents, plasticizers, surfactants, pigments, dyes, defoaming
agents, or a combination thereof.
[0053] An exemplary coating composition can comprise one or more of
the following: water, Tamol.RTM. (available from Rohm & Haas),
Surfynol.RTM. CT-131 and/or Surfynol.RTM. 104 DPM (available from
Air Products), ammonium hydroxide (e.g., 28%), Ti-Pure.RTM. R-706
(available from DuPont), Vicron 15-15 (available from Speciality
Minerals Inc.), Foamaster.RTM. 111 (available from Henkel),
Avanse.RTM. MV-100 (available from Rohm & Haas), Dowanol.RTM.
DPM dipropylene glycol methyh ether (available from Dow Chemicals),
Texanol.RTM. 2,2,4-trimethylpentanediol-1,3-monoisobutyrate
(available from Eastman Chemical Company), TEG-EH (available from
Eastman Chemical Company), sodium nitrate (e.g., 15% solution),
PROXEL.RTM. BD20 (available from Avecia Inc.), Acrysol.RTM. RM-12 W
(available from Rohm & Haas), Degussa Aqua-Chem.RTM. 895
colorant, or a combination thereof.
[0054] In another aspect, a coating composition can be prepared in
concentrated form that can be let-down, wherein the concentrate
comprises water, a dispersant, a grind aid, a surfactant, ammonium
hydroxide, titanium dioxide, calcium carbonate, and a defoamer. In
a specific aspect, a coating composition concentrate can comprise
about 4.95 wt. % water, about 0.15 wt. % dispersant, about 0.59 wt.
% grind aid, about 0.2 wt. % surfactant, about 0.25 wt. % ammonium
hydroxide (28%), about 14.84 wt. % titanium dioxide, about 4.95 wt.
% calcium carbonate, and about 0.4 wt. % defoamer.
[0055] In such an aspect, the concentrate can be let-down to an
end-use composition, wherein the let-down composition can comprise
one or more of: a styrenated acrylic latex, a coalescent, a
plasticizer, a rush inhibitor, a preservative, a thickener, a
colorant, or a combination thereof. In a specific aspect, a
let-down composition comprises about 67.8 wt. % of a styrenated
acrylic latex, about 2.89 wt. % of a DPM coalescent, about 1.33 wt.
% of Texanol.RTM. coalescent, about 0.4 wt. % plasticizer, about
0.4 wt. % rust inhibitor, about 0.1 wt. % preservative, about 0.18
wt. % thickener, and colorant.
[0056] It should be understood that the coating compositions
specifically recited herein are intended to be exemplary only, and
that the present invention is not intended to be limited to any
particular coating composition. As such, one of skill in the art,
in possession of this disclosure, could readily select an
appropriate coating composition for use with a given substrate
and/or for an intended application.
[0057] Exemplary colorants, if present, can comprise one or more
of: Fed 595B, titanium dioxide, red oxide, yellow oxide, phthalo
green, phthalo blue, lamp black, or a combination thereof. In one
aspect, the coating composition comprises at least titanium
dioxide.
[0058] In another aspect, the coating composition can have a low
volatile organic content, such as, for example, about 100 g/L or
less of volatile organics. In another aspect, the coating
composition can have a density of from about 1.16 g/ml to about
1.21 g/ml. In other aspects, the volatile organic content and/or
density of a coating composition can vary, and the present
invention is not intended to be limited to any particular volatile
organic content or density.
[0059] In other aspects, a coating composition can have a pigment
content of from about 17.2 wt. % to about 21.1 wt. %, a shear
viscosity of from about 74 to about 79, a film hardness of at least
about 3B.
[0060] In one aspect, the coating composition comprises no or
substantially no lead. In another aspect, the coating composition
comprises no or substantially no chromium. In yet another aspect,
the coating composition comprises no or substantially no zinc.
[0061] The glass particles can be contacted with the paint and/or
coating material in any manner suitable for providing a resulting
coating. In one aspect, the glass particles and coating material
are mixed using conventional means, for example, stirring and/or
blending. In other aspects, the glass particles and coating
material can be subjected to higher shear forces, such as, for
example, in a media mill. In one aspect, at least a portion of the
glass particles are dispersed in the coating material. In another
aspect, at least a portion of the glass particles, for example,
glass flake, are uniformly or substantially uniformly dispersed in
the coating composition and/or in the resulting coating. In yet
another aspect, all or substantially all of the glass particles are
uniformly dispersed in the coating composition and/or the resulting
coating. In another aspect, no specific degree of dispersion is
necessary, and aggregates or agglomerated glass particles can be
present in the coating material.
[0062] The amount of glass particles present in a coating
composition can be any amount suitable for the intended
application. In one aspect, the amount of glass particles present
in a coating composition can be an amount sufficient to impart
desirable thermal properties to the resulting coating. In another
aspect, the amount of glass particles present in a coating
composition can be an amount that does not adversely affect the
mechanical properties of the resulting coating. In various aspects,
the amount of glass particles present in a coating composition can
comprise from about 5 wt. % to about 50 wt. %, for example, about
5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34,
36, 38, 40, 42, 44, 46, 48, or 50 wt. % of the coating composition.
In another aspect, the amount of glass particles, such as, for
example, glass flake, present in a coating composition can be less
than about 5 wt. % or greater than about 50 wt. %, provided that
the resulting coating can provide the desired thermal properties,
and the present invention is not intended to be limited to any
particular concentration of glass particles in the coating
composition.
[0063] In another aspect, the amount of glass particles present in
a resulting coating, for example, after curing and/or drying, can
comprise from about 10 wt. % to about 80 wt. %, for example, about
10, 12, 14, 16, 18, 20, 23, 26, 29, 32, 35, 38, 41, 44, 47, 50, 53,
56, 59, 62, 65, 68, 71, 74, 77, or 80 wt. % of the resulting
coating. In other aspects, the amount of glass particles present in
the resulting coating can be less than about 10 wt. % or greater
than about 80 wt. %, and the present invention is not intended to
be limited to any particular concentration of glass particles in a
resulting coating.
[0064] The substrate or material to be coated can be any material
suitable for the coating composition and to which improved thermal
properties are desired. In one aspect, the substrate comprises a
textile. In another aspect, the substrate comprises a sheet good.
In various specific aspects, the substrate can comprise a fabric, a
non-woven material, a polymeric sheet, a membrane material, or a
combination thereof. In one aspect, the substrate can comprise a
plurality of threads and/or fibers disposed in a woven, non-woven
and/or laid manner, or a combination thereof. In one aspect, the
substrate can comprise multiple layers of the same or varying
composition. In another aspect, the substrate comprises vinyl. In
another aspect, the substrate comprises a polyethylene. In another
aspect, the substrate comprises a polyethylene terephthalate. In
still other aspects, the substrate can comprise one or more
polymeric materials. In one aspect, the substrate can comprise a
surface suitable for temporary placement of a resulting coating,
wherein the resulting coating can be removed after curing and/or
drying. In such an aspect, the substrate can comprise a metal
surface, a polymeric surface, such as, for example,
polytetrafluoroethylene. In other aspects, the substrate does not
comprise a refractory material, a refractory fabric, or a
combination thereof. In another aspect, the substrate is not a
printed circuit board. In another aspect, the substrate does not
comprise clay and/or a clay coating. In yet another aspect, the
substrate is not a glass and/or glass-ceramic article. In still
another aspect, the substrate is not a ceramic coated laminate. In
yet another aspect, the substrate is not a copper foil. In another
aspect, the substrate is not adhesive or does not comprise an
adhesive material disposed on a surface thereof, for example, a
surface opposite the resulting coating. In another aspect, the
coating, substrate, and/or combination thereof do not comprise an
adhesive material. In such an aspect, the coating composition's
ability to adhere to and/or bond with the substrate is not to be
construed as an adhesive material. In another aspect, the substrate
and/or coated substrate does not comprise an intermediate backing
material.
[0065] The thickness and dimensions of a substrate can vary, and
the present invention is not intended to be limited to any
particular thickness or dimension substrate. In one aspect, the
substrate can be a flexible material that can be applied to another
material as a layer or surface covering. In another aspect, the
substrate can be a polymeric material having a thickness of from
about 10 .mu.m to about 5,000 .mu.m, for example, about 10, 20, 30,
40, 50, 75, 100, 150, 200, 250, 300, 400, 500, 600, 700, 800, 900,
1,000, 1,250, 1,500, 1,750, 2,000, 2,250, 2,500, 2,750, or 3,000
.mu.m. In other aspects, the substrate can be thinner than about 10
.mu.m or greater than about 3,000 .mu.m.
[0066] The coating composition comprising glass particles, as
described herein, can be contacted with or coated onto a substrate
using any suitable means. In one aspect, the coating composition is
sprayed onto at least a portion of the substrate. In another
aspect, the coating composition is rolled and/or brushed onto at
least a portion of the substrate. In still other aspects, the
coating composition can be applied using, for example, a doctor
blade, screen printing process, or a combination thereof, to at
least a portion of the substrate. In one aspect, one layer of the
coating composition is applied. In another aspect, two or more
layers, for example, two, three, four, or more, can be applied to
at least a portion of the substrate. In another aspect, the coating
can form a continuous layer over all or a portion of the substrate.
In yet another aspect, the coating can form a discontinuous coating
over all or a portion of the substrate. If multiple layers are
used, each individual layer can comprise the same or a different
composition than any other layer. In addition, each individual
layer, if multiple layers are present, can have the same or varying
color, thickness, and/or thermal properties.
[0067] In one aspect, a coating, once applied, can have a thickness
of at least about 3 mil. In another aspect, a coating, once
applied, can have a thickness of from about 4 mil to about 8 mil,
for example, about 4, 5, 6, 7, or 8 mil. In still other aspects,
the thickness of a coating, once applied, can be less than about 3
mil or greater than about 8 mil. In one aspect, the thickness of a
coating can be thicker than about 8 mil to improve, for example,
mechanical properties and/or the durability of the resulting
coating.
[0068] The coated substrate can exhibit improved thermal management
properties as compared to an uncoated substrated and/or a substrate
coated with a conventional paint. In various aspects, the coating
can reduce the amount of thermal energy absorbed by the substrate.
In one aspect, a coated substrate can remain at about ambient
temperature upon exposure to thermal radiation, for example, solar,
infrared, convective, or a combination thereof. In another aspect,
the inventive coating can significantly reduce and/or prevent the
underlying substrate or other materials from absorbing thermal
radiation incident upon the coating. In another aspect, a substrate
or structure coated with the inventive composition can exhibit a
lower temperature upon exposure to, for example, solar radiation,
than a comparable substrate or structure not coated with the
inventive composition. In various aspects, the temperature of a
substrate and/or structure coated with and/or underlying the
inventive coating can, upon exposure to solar radiation, have a
temperature of up to about 50.degree. F., for example, about 5, 7,
9, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, or 50.degree. F.
lower than a comparable uncoated substrate and/or structure. In
other aspects, a coated substrate and/or structure can have a
temperature differential of greater than about 50.degree. F. from a
comparable substrate and/or structure depending on the particular
substrate or structure composition, coating composition, and form
and intensity of radiation. In another aspect, a coated substrate
and/or structure can, upon exposure to thermal radiation, have a
temperature of at least about 50.degree. F., for example, at least
about 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30,
35, 40, 45, 50.degree. F. or more less than a comparable uncoated
substrate and/or structure.
[0069] In another aspect, the coating can be formed as a
stand-alone material that can, in various aspects, be subsequently
applied to a substate or other material. In an exemplary aspect,
the coating material can be applied to a temporary substrate from
which a dried and/or cured coating can be removed. The coating can
be applied, for example, by spraying, doctor blade, casting, or
other suitable technique. In one aspect, such a coating can
comprise a plurality of threads and/or fibers, such as, for
example, polymeric fibers, carbon fibers, cellulosic fibers,
cotton, jute, or other natural fibers. The threads and/or fibers
can, in various aspects, be woven, non-woven (e.g., laid), or a
combination thereof to provide structural reinforcement to the
coating material. In one aspect, a mat or existing textile can be
contacted with the coating composition such that the resulting
material comprises a coated textile. In one aspect, the coating can
be formed so as to be a layer in contact with a mat or textile. In
another aspect, the coating can surround and/or fill in all or at
least a portion of the voids of a mat or textile. In yet another
aspect, the coating can encapsulate or substantially encapsulate at
least a portion of the mat or textile. In another aspect, the
coating can be incorporated into a substrate or a portion thereof.
In another aspect, the substrate or a portion thereof can be
impregnated with the coating composition. In another aspect,
individual or bundles or threads and/or fibers can be contacted
with a coating composition prior to, during, or after applying to a
temporary substrate, but before the coating composition cures
and/or dries. In one aspect, such a resulting composition can be in
the form of a film and/or flexible sheet. A coating material,
prepared in the above aspects, can be removed from the temporary
substrate, and rolled for storage or transportation.
[0070] While typical aspects have been set forth for the purpose of
illustration, the foregoing descriptions should not be deemed to be
a limitation on the scope of the invention. Accordingly, various
modifications, adaptations, and alternatives may occur to one
skilled in the art without departing from the spirit and scope of
the present invention.
EXAMPLES
[0071] The following examples are put forth so as to provide those
of ordinary skill in the art with a complete disclosure and
description of how the compounds, compositions, articles, devices
and/or methods claimed herein are made and evaluated, and are
intended to be purely exemplary of the invention and are not
intended to limit the scope of what the inventors regard as their
invention. Efforts have been made to ensure accuracy with respect
to numbers (e.g., amounts, temperature, etc.), but some errors and
deviations should be accounted for. Unless indicated otherwise,
parts are parts by weight, temperature is in .degree. F. or is at
ambient temperature, and pressure is at or near atmospheric.
Example 1
[0072] In a first example, a latex coating composition comprising a
flake borosilicate glass can be applied as a slurry onto a thin
(e.g., 25 .mu.m) polymeric substrate, so as to form a coating,
before curing and/or drying, from about 100 .mu.m to about 1,250
.mu.m thick. After curing and/or drying, the resulting coating can
have a thickness of from about 50 .mu.m to about 875 .mu.m.
Example 2
[0073] In a second example, a slurry of a liquid coating
composition comprising flake borosilicate glass and a plurality of
fibrous threads can be applied to a metallic substrate having a
thickness of from about 0.001 inches to about 5 feet. The fibrous
threads can, in various aspects, improve the shear strength of the
resulting coating. After drying and/or curing, the reinforced
coating can be removed from the metallic substrate for later use
as, for example, an applique or a stand-alone material.
Example 3
[0074] In a third example, a vinyl fabric substrate was coated with
the inventive coating comprising borosilicate flake glass to a
dried coating thickness of about 4 mil. The coated substrate and an
uncoated control substrate of the same vinyl composition were each
subjected to intense solar radiation. The ambient air temperature
during the experiment was 108.degree. F. and the ground surrounding
the coated and control substrates was 148.degree. F. After exposure
to the solar radiation, the uncoated control structure reached a
temperature of 130.degree. F., whereas the coated substrate was
105.degree. F. Thus, the coated substrate remained at approximately
the ambient temperature without heating from the solar radiation.
In addition, the partially enclosed area underneath the coated
substrate was approximately 20.degree. F. cooler than the similarly
area underneath the control substrate. Thus, the inventive coating
can significantly reduce the amount of incident radiation absorbed
and/or transferred to a substrate or underlying material.
Example 4
[0075] In a fourth example, a non-woven fabric substrate was
contacted with the inventive coating composition comprising
borosilicate flake glass, such that the dried coated was
incorporated into the substrate, and not merely disposed as a layer
on a surface of the substrate. The resulting composite was
fabricated into a shelter and subjected to equatorially strong
solar heating. A similar control shelter was prepared from an
uncoated portion of the non-woven fabric. After exposure to the
solar radiation, the temperature of the untreated shelter rose to
135.degree. F., whereas the temperature of the shelter formed from
the inventive coating impregnated fabric substrate did not rise
about the ambient temperature of 102.degree. F. The temperature
inside the shelter comprising the inventive coating was
approximately 23.degree. F. cooler than the temperature inside the
control shelter.
[0076] It will be apparent to those skilled in the art that various
modifications and variations can be made in the present invention
without departing from the scope or spirit of the invention. Other
aspects of the invention will be apparent to those skilled in the
art from consideration of the specification and practice of the
invention disclosed herein. It is intended that the specification
and examples be considered as exemplary only, with a true scope and
spirit of the invention being indicated by the following
claims.
* * * * *