Basf Corporation

Morton International, Inc.

Morton Coatings, Inc.

Jack C Allman

Ronald J Lewarchik

Victor J Scaricamazza

Joseph James Zupancic

Marc L Smith

Edward J Holzrichter

Mitchell T Keck

Ronald J Lewarachik

James V Lang

A coil coating system for embedding discrete masses of material in a resinous coating on sheet metal as it is pulled from a dispensing coil through a series of rollers, said system comprising a paint pan, a roller rotating in the pan and picking up said resinous coating composition and transferring it to an applicator roller; thenceforth to the moving sheet metal, an oven, and a sprayer that can heat thermoplastic resin particles to a molten or plastic state and spray the particles to the moving sheet metal.

Metal roofing shingle stock and method for making it

This invention relates to a method for embedding a multiplicity of discrete masses of material in a resinous coating on a sheet of metal in a coil coating system. The sheet is coated, the masses are embedded in the wet resinous coating, and the coating is dried in a one-pass system. The resinous coating and the embedded masses are preferably resistant to ultra-violet radiation. The wet resinous coating, therefore, is preferably a liquid fluorocarbon resin. The discrete masses comprise pigmented particulate minerals and resins in the form of granules, beads, vesiculated beads, pellets, flakes, platelets, cylinders, coating powders, and coating powder precursor chips. The minerals include glass, quartz, mica, pebbles, and ceramics. The particulate resins include polyesters, acrylics, nylons, polyurethanes, polycarbonates, solid fluorocarbon resins, and solid mixtures of a fluorocarbon resin and an acrylate or methacrylate polymer or copolymer. Sheet metal decorated in such a manner is useful as stock in the manufacture of metal roofing shingles simulating the appearance of traditional asphalt shingles.

The invention provides thermosetting coating compositions in which acrylic copolymers are used as carriers for fluorocarbon resins. The compositions have a combination of high fluorocarbon content, high solids content, and a low viscosity suitable for coil coating. Thus, the solids are borne in organic solvent systems which permit minimization of the viscosity and a moderate evaporation rate. The solvent system has a &dgr;,of from 1.7 to 2.6 (calories/cubic centimeter),and a &dgr;,of from 8 to 9.5 (calories/cubic centimeter),and is exemplified by a mixture of 4 or more of the following solvents: aliphatic ketones having from 4 to 10 carbon atoms, alkyl esters having a total of from 5 to 7 carbon atoms, aromatic acid esters having from 8 to 12 carbon atoms, lactones, and aromatic solvents. The acrylic polymer is comprised of (a) acrylic esters having no additional functionality, (b) acrylic esters having additional functionality by which the acrylic polymer may be cross-linked, and (c) an acryloxyalkyl oxazolidine.

High volume solids fluorocarbon coatings

A thermosetting, organic solvent-based, primer coating composition for protecting metal surfaces which includes a solvent solution of: (a) a hydroxy-functional polyester resin; (b) a thermosetting acrylic resin; (c) a hydroxy-terminal polybutadiene resin, a hydroxy-terminal epoxidized polybutadiene resin, or mixtures thereof; (d) a blocked isocyanate crosslinker including at least one dimethyl pyrazole blocked isocyanate; (e) an aminoplast crosslinker including at least one melamine-formaldehyde condensate; (f) a catalyst; and, (g) a pigment. The primer exhibits excellent flexibility after curing to allow the primer to be coil coated onto metals as a thicker film and to have the metal subsequently formed without film fracture or loss of adhesion. The primer also has improved solvent release properties during curing to allow volatiles to readily escape therefrom, which facilitates coil coating of the primer onto metals as thicker films that, when cured into thick film hardened surface finishes, do not exhibit the typical blisters, craters, pops, voids and other surface defects. The primer can be cured as well at reduced temperatures which contributes to the reduction in surface defects. A fluorocarbon topcoat is usually coil coated and cured over the non-blistering primer coating, to yield a composite coated metal substrate having a surface finish that is free of blisters, craters, pops, and voids, and other surface defects.

Non-blistering thick film coating compositions and method for providing

The invention provides novel acrylic resins particularly useful for formulating polyvinylidene fluoride/thermosetting acrylic polymer coating compositions. The acrylic polymer is comprised of (a) acrylic acids and acrylic esters having no additional functionality, (b) acrylic acids and acrylic esters having additional functionality by which the acrylic polymer may be cross-linked, and (c) an acryloxyalkyl oxizolidine.

Growing community of inventors

Twin Lakes, WI, United States of America

Jack C Allman