Coated articles exhibiting transparency to electromagnetic radiation and methods of mitigating contaminant buildup on substrates

文档序号：914022 发布日期：2021-02-26 浏览：6次中文

阅读说明：本技术 显示电磁辐射透明性的涂覆的物品以及减轻在基底上的污染物聚积的方法 (Coated articles exhibiting transparency to electromagnetic radiation and methods of mitigating contaminant buildup on substrates ) 是由 D·F·莫亚诺 S·斯瓦鲁普 M·S·卢查恩斯基徐相凌 K·M·克鲁斯泽维斯基于 2019-07-18 设计创作，主要内容包括：本发明涉及一种显示具有在70％至100％范围内的22GHz至81GHz的频率的电磁辐射透射的涂覆的物品。该物品包括涂覆有可固化成膜组合物的基底,该可固化成膜组合物包括由至少一种疏水性单体制备的第一成膜聚合物、由至少一种疏水性单体制备的第二成膜聚合物和固化剂。在将可固化成膜组合物施涂到基底以形成涂层时,该第一成膜聚合物分布在整个涂层中,并且该第二成膜聚合物在涂层的表面的浓度大于该第二成膜聚合物在涂层的本体内的浓度。本发明还涉及一种使用以上描述的可固化成膜组合物来减轻基底上的污染物聚积的方法。(The present invention relates to a coated article exhibiting transmission of electromagnetic radiation having a frequency in the range of from 70% to 100% of 22GHz to 81 GHz. The article includes a substrate coated with a curable film-forming composition including a first film-forming polymer prepared from at least one hydrophobic monomer, a second film-forming polymer prepared from at least one hydrophobic monomer, and a curing agent. Upon application of the curable film-forming composition to a substrate to form a coating, the first film-forming polymer is distributed throughout the coating, and the concentration of the second film-forming polymer at the surface of the coating is greater than the concentration of the second film-forming polymer within the bulk of the coating. The present invention also relates to a method of mitigating the accumulation of contaminants on a substrate using the curable film-forming composition described above.)

1. A coated article comprising:

(1) a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81 GHz; and

(2) a curable film-forming composition applied to at least one surface of the substrate and cured thereon, the curable film-forming composition comprising:

(a) a first film-forming polymer prepared from at least one hydrophobic monomer and having a reactive functional group, wherein the first film-forming polymer (a) is present in the curable film-forming composition in an amount of 20% to 40% by weight, based on the total weight of resin solids in the curable film-forming composition;

(b) a second film-forming polymer different from the film-forming polymer (a) and prepared from at least one hydrophobic monomer, wherein the second film-forming polymer (b) is present in the curable film-forming composition in an amount of from 0.5% to 15% by weight, based on the total weight of resin solids in the curable film-forming composition; and

wherein upon application of the curable film-forming composition to a substrate to form a coating, the first film-forming polymer (a) is distributed throughout the coating and the concentration of the second film-forming polymer (b) in a surface region of the coating is greater than the concentration of the second film-forming polymer (b) in a bulk region of the coating; and wherein the coated article exhibits a transmittance in the range of 70% to 100% for electromagnetic radiation having a frequency of 22GHz to 81 GHz.

2. The coated article of claim 1, wherein the second film-forming polymer (b) is more hydrophobic than the first film-forming polymer (a).

3. The coated article of claim 1, wherein the first film-forming polymer (a) comprises an acrylic polymer prepared from a reaction mixture comprising a hydrophobic monomer comprising a fluorinated monomer and/or a siloxane.

4. The coated article of claim 3, wherein the hydrophobic monomer in the reaction mixture used to prepare the first film-forming polymer (a) is present in the reaction mixture in an amount of 4% to 15% by weight, based on the total weight of monomers in the reaction mixture.

5. The coated article of claim 1, wherein the second film-forming polymer (b) comprises an acrylic polymer prepared from a reaction mixture comprising a hydrophobic monomer and a monomer having a functional group that reacts with the functional group on the curing agent (c), wherein the hydrophobic monomer in the reaction mixture used to prepare the second film-forming polymer (b) comprises a fluorinated monomer and/or a siloxane.

6. The coated article of claim 5, wherein the hydrophobic monomer in the reaction mixture used to prepare the second film-forming polymer (b) is present in the reaction mixture in an amount of 15% to 60% by weight based on the total weight of monomers in the reaction mixture.

7. The coated article of claim 1, wherein the curing agent (c) comprises a polyisocyanate.

8. The coated article of claim 1 wherein the curable film-forming composition further comprises (d) an additional film-forming resin component that: (i) is different from the first film-forming polymer (a) and the second film-forming polymer (b); and (ii) has a functional group that reacts with at least one other component of the curable film-forming composition.

9. The coated article of claim 8 wherein the additional film-forming resin component (d) comprises an acrylic and/or polyester polyol and an aminoplast.

10. The coated article of claim 1 wherein the curable film-forming composition is transparent to visible light.

11. The coated article of claim 1 wherein the substrate comprises a plastic and the curable film-forming composition further comprises (d') a saturated fatty acid and (e) a tin catalyst.

12. The coated article of claim 1, wherein the substrate comprises a component of a vehicle.

13. The coated article of claim 12, wherein the vehicle comprises an autonomous vehicle.

14. The coated article of claim 12, wherein the first film-forming polymer (a) comprises an acrylic polymer prepared from a reaction mixture comprising hydrophobic monomers, wherein the hydrophobic monomers in the reaction mixture used to prepare the first film-forming polymer (a) comprise fluorinated monomers and/or siloxanes, and are present in the reaction mixture in an amount of 4 to 15% by weight, based on the total weight of monomers in the reaction mixture.

15. The coated article of claim 12, wherein the second film-forming polymer (b) comprises an acrylic polymer prepared from a reaction mixture comprising a hydrophobic monomer and a monomer having a functional group that reacts with the functional group on the curing agent (c), wherein the hydrophobic monomer in the reaction mixture used to prepare the second film-forming polymer (b) comprises a fluorinated monomer and/or a siloxane and is present in the reaction mixture in an amount of 15% to 60% by weight based on the total weight of monomers in the reaction mixture.

16. A method of mitigating contaminant accumulation on a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81GHz, comprising:

(1) applying a first coating comprising a pigmented curable film-forming composition to at least a portion of the substrate to form a coated substrate;

(2) applying a transparent curable film-forming composition to at least a portion of the coated substrate formed in step (1) to form a multilayer coated substrate prior to substantially curing the first coating, wherein the transparent curable film-forming composition comprises:

(3) heating the multilayer coated substrate formed in step (2) to a temperature and for a time sufficient to cure all of the film-forming composition.

17. A method of mitigating contaminant accumulation on a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81GHz, comprising:

(1) applying a curable film-forming composition to at least a portion of the substrate to form a coated substrate, wherein the curable film-forming composition comprises:

(2) heating the coated substrate formed in step (1) to a temperature and for a time sufficient to cure the film-forming composition.

Technical Field

The present invention relates to coated articles that exhibit transparency to electromagnetic radiation having a frequency of 22GHz to 81GHz and methods of mitigating the accumulation of dirt on a substrate.

Background

Recent advances have been made in technology relating to autonomous driving ("autonomous") vehicles and other objects in the surroundings of the vehicle that contain markers detectable by sensors mounted on the autonomous vehicle. Autonomous vehicles use a combination of detection systems, such as sensors, cameras, radar, ultrasound, and lasers to detect and locate obstacles so that the autonomous vehicle can safely bypass these objects. Some detection systems have limited ability to detect objects over long distances or in non-ideal environments, such as in inclement weather or due to the accumulation of dirt and other contaminants, including ice and water in the form of water droplets, thin streams, or laminar streams on the surfaces of the detection system. Such a restriction may prevent the autonomous vehicle from safely circumventing the obstacle. In both the consumer and industrial markets, easy-to-clean coated surfaces are an important selling point for the autonomous vehicle market as well as many other industries.

For products such as automobiles and autonomous vehicles, it is a desirable property to easily remove dirt or other contaminants and prevent the accumulation of contaminants. Environmental contaminants (such as tar, asphalt, animal manure, de-icing salts, detergents, etc.) can damage surfaces of coated vehicles, architectural surfaces, and other industrial substrates. Damage may be caused by a chemical reaction of the contaminant with the coated surface (such as by chemical etching), or may involve the physical removal of some or all of the coating from the substrate (i.e., "cohesive failure") as the contaminant is removed during cleaning. Cohesive failure may also involve incomplete removal of contaminants from the coated surface during cleaning.

The use of hydrophobic acrylates as additives has been the primary method to produce easy-to-clean ("E2C") coatings such as automotive varnishes. However, the incompatibility of conventional film-forming binders and hydrophobic additives that tend to be hydrophilic limits the applicability of this method, as delamination of the material upon application to the substrate results in irregular distribution of the hydrophobic additive and an undesirable increase in haze. Additionally, the short duration of the contaminant mitigation properties of current E2C compositions has limited their use due to poor durability.

To overcome the disadvantages of the prior art, it would be desirable to provide coated articles that exhibit transparency to electromagnetic radiation and methods of mitigating the accumulation of contaminants on a substrate.

Disclosure of Invention

The present invention relates to a coated article comprising:

(1) a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81 GHz; and

(2) a curable film-forming composition applied to at least one surface of the substrate and cured thereon. The curable film-forming composition comprises:

(c) a curing agent comprising a functional group that reacts with the reactive functional group in (a). Upon application of the curable film-forming composition to a substrate to form a coating, the first film-forming polymer (a) is distributed throughout the coating, and the concentration of the second film-forming polymer (b) in a surface region of the coating is greater than the concentration of the second film-forming polymer (b) in a bulk region of the coating; and the coated article exhibits a transmittance in the range of 70% to 100% for electromagnetic radiation having a frequency of 22GHz to 81 GHz.

The invention also relates to a method of mitigating the accumulation of contaminants on a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81GHz, the method comprising applying one or more coatings to at least a portion of the substrate to form a coated substrate; and heating the coated substrate to a temperature and for a time sufficient to cure all of the film-forming composition. The outermost coating layer comprises the curable film-forming composition described above.

Detailed Description

Other than in any operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, i.e., having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

As used in this specification and the appended claims, the articles "a," "an," and "the" include plural referents unless expressly and unequivocally limited to one referent.

The term "curable" as used, for example, in connection with a curable composition means that the indicated composition can be polymerized or crosslinked by functional groups, for example, by means including, but not limited to, heat (including environmental curing) and/or catalytic exposure.

The terms "cure," "cured," or similar terms (e.g., some specifically described "cured compositions") as used in connection with a cured or curable composition means that at least a portion of the polymerizable and/or crosslinkable components forming the curable composition are polymerized and/or crosslinked. Additionally, curing of the polymerizable composition refers to subjecting the composition to curing conditions, such as, but not limited to, thermal curing, resulting in the reactive functional groups of the composition reacting and causing polymerization and formation of a polymer. When the polymerizable composition is subjected to curing conditions, the reaction rate of the remaining unreacted reactive end groups gradually slows as polymerization proceeds and after most of the reactive end groups have reacted. The polymerizable composition may be subjected to curing conditions until it is at least partially cured. The term "at least partially cure" means subjecting the polymerizable composition to curing conditions wherein at least a portion (such as at least 10% or at least 20%) of the reactive groups of the composition react to form a polymer. The polymerizable composition may also be subjected to curing conditions such that substantially complete curing is obtained (such as at least 70% or at least 80% or at least 90% up to 100% of the reactive groups are reacted), and wherein further curing results in no further significant improvement in polymer properties (such as hardness).

The various embodiments and examples of the invention set forth herein are intended to be non-limiting with respect to the scope of the invention.

The first film-forming polymer (a) in the curable film-forming composition used to prepare the coated article of the present invention is prepared from at least one hydrophobic monomer and has reactive functional groups. "Polymer" refers to polymers including homopolymers and copolymers, as well as oligomers. By "hydrophobic" is meant a material (e.g., monomer or polymer) so described that is of a non-polar nature and has a tendency to interact with, be miscible with, or be dissolved by non-polar solvents such as alkanes and oils. By definition, a molecule can be non-polar, either when there is equal electron sharing between the two atoms of a diatomic molecule, or because of the more complex symmetrical arrangement of polar bonds in a molecule, such that there is no overall dipole in the molecule.

The first film-forming polymer is typically an acrylic polymer. The acrylic polymer may be prepared from a reactive mixture including a hydrophobic monomer and a monomer having a reactive functional group. Examples of suitable hydrophobic monomers include ethylenically unsaturated monomers such as lauryl (meth) acrylate, stearyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, n-octyl (meth) acrylate, and the like. The term "(meth) acrylate" refers to a molecular structure comprising acrylate and/or methacrylate esters present therein. It is noted that when the phrase "and/or" is used in the list, it is intended to encompass alternative embodiments, including each individual component in the list, as well as any combination of components. For example, the list "A, B and/or C" is intended to include seven separate embodiments that include a or B or C or a + B or a + C or B + C or a + B + C.

The first film-forming polymer (a) typically comprises an acrylic polymer prepared from a reaction mixture comprising hydrophobic monomers, wherein the hydrophobic monomers comprise fluorinated monomers and/or siloxanes. Suitable hydrophobic monomers that include siloxanes include ethylenically unsaturated monomers that include polydialkylsiloxane functionality (typically polydimethylsiloxane functionality). Such monomers may be prepared, for example, by reacting polydialkylsiloxanes having hydroxyl end groups with ethylenically unsaturated monomers having functional groups which react with hydroxyl groups, such as acid or epoxy functional groups.

Examples of suitable ethylenically unsaturated monomers that include a polydialkylsiloxane functional group include (meth) acrylate monomers such as X-22-2426 (available from Shin-Etsu Chemical Co), MCR-M07, MCR-M11, MCR-M17, MCR-M22, MCS-M11, MFR-M15, and MFS-M15 (available from Gelest, Inc), FM-0711, FM-0721, and FM-0725 (available from JNC Corporation).

The ethylenically unsaturated monomers comprising a polydialkylsiloxane functional group typically have a weight average molecular weight of 1000Da to 30000Da as measured by GPC, using a polystyrene calibration standard, 2PL gel MIXED-C as a column, THF as an eluent at 1ml/min, and a refractive index detector. The polydialkylsiloxane groups are typically at least oligomeric, such that the resulting ethylenically unsaturated monomers are typically macromers.

The hydrophobic monomer may also (or alternatively) comprise a fluorinated monomer. Non-limiting examples of suitable ethylenically unsaturated monomers containing fluorine include vinyl fluoride, chlorotrifluoroethylene, vinylidene fluoride, and hexafluoropropylene. Other fluorinated monomers include 2, 2, 3, 3, 4, 4,5, 5, 6, 6, 7, 7-dodecafluoroheptyl (meth) acrylate, 3, 3, 4, 4,5, 5, 6, 6, 7, 7, 8, 8, 9, 9, 10, 10, 11, 11, 12, 12-heneicosylfluorododecyl (meth) acrylate, 3, 3, 4, 4,5, 5, 6, 6, 7, 7, 8, 8, 9, 9, 10, 10, 10-heptadecafluorodecyl (meth) acrylate, 2, 3, 3, 4, 4, 4-heptafluorobutyl (meth) acrylate, 2, 3, 4, 4-hexafluorobutyl (meth) acrylate, 1, 1, 1, 3, 3, 3-hexafluoroisopropyl (meth) acrylate, 2, 3, 3, 4, 4,5, 5-octafluoropentyl (meth) acrylate, 2, 2, 3, 3, 3-pentafluoropropyl (meth) acrylate, 1H, 2H, 2H-perfluorodecyl (meth) acrylate, 2, 2, 3, 3-tetrafluoropropyl (meth) acrylate, 3, 3, 4, 4,5, 5, 6, 6, 7, 7, 8, 8, 8-tridecafluorooctyl (meth) acrylate, 2, 2, 2-trifluoroethyl (meth) acrylate, and 2- [ (1 ', 1 ', 1 ' -trifluoro-2 ' - (trifluoromethyl) -2 ' -hydroxy) propyl ] -3-norbornyl (meth) acrylate.

The first film-forming polymer has reactive functional groups. The term "reactive" refers to a functional group that is capable of chemically reacting with itself and/or other functional groups either spontaneously or upon the application of heat or in the presence of a catalyst or by any other means known to those skilled in the art. The functional group on the first film-forming adhesive may be selected from at least one of: carboxylic acid groups, amine groups, epoxy groups, hydroxyl groups, thiol groups, carbamate groups, amide groups, urea groups, (meth) acrylate groups, styrene groups, vinyl groups, allyl groups, aldehyde groups, acetoacetate groups, hydrazide groups, cyclic carbonates, acrylates, maleic acid, and thiol groups. The functional groups on the film-forming polymer are generally selected so as to react with the functional groups on the curing agent (c). The reactive functional groups on the first film-forming polymer are typically active hydrogen groups known to those skilled in the art, such as hydroxyl, carboxyl, carbamate, primary and/or secondary amines, amides, thiols, and the like.

Useful hydroxy-functional ethylenically unsaturated monomers include hydroxyalkyl (meth) acrylates typically having 2 to 4 carbon atoms in the hydroxyalkyl group, such as hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, hydroxy-functional adducts of caprolactone and hydroxyalkyl (meth) acrylate, as well as the β -hydroxy ester functional monomers described below.

The beta-hydroxy ester functional monomer can be prepared from an ethylenically saturated epoxy functional monomer and a carboxylic acid having from about 13 to about 20 carbon atoms, or from an ethylenically unsaturated acid functional monomer and an epoxy compound containing at least 5 carbon atoms that is not polymerizable with the ethylenically unsaturated acid functional monomer.

Useful ethylenically unsaturated epoxy-functional monomers for preparing the β -hydroxy ester-functional monomer include, but are not limited to, glycidyl (meth) acrylate, allyl glycidyl ether, methallyl glycidyl ether, 1: 1 (mole) adducts of ethylenically unsaturated monoisocyanates with hydroxy-functional monoepoxides (such as glycidol), and glycidyl esters of polymerizable polycarboxylic acids (such as maleic acid). Glycidyl (meth) acrylate is preferred. Examples of carboxylic acids include, but are not limited to, saturated monocarboxylic acids such as isostearic acid and aromatic unsaturated carboxylic acids.

Useful ethylenically unsaturated acid-functional monomers for preparing the beta-hydroxy ester-functional monomer comprise: monocarboxylic acids such as acrylic acid, methacrylic acid, crotonic acid; dicarboxylic acids such as itaconic acid, maleic acid, and fumaric acid; and monoesters of dicarboxylic acids such as monobutyl maleate and monobutyl itaconate. (note that these acid functional monomers may also be used in the reaction mixture to prepare the first film-forming polymer, thereby providing it with acid functional reactive groups.) the ethylenically unsaturated acid functional monomer and the epoxy compound are typically reacted in an equivalent ratio of 1: 1. The epoxy compound is free of ethylenic unsaturation that would participate in a free radical initiated polymerization reaction with the unsaturated acid functional monomer. Useful epoxy compounds include 1, 2-pentene oxide, styrene oxide and glycidyl esters or ethers, typically containing from 7 to 30 carbon atoms, such as butyl glycidyl ether, octyl glycidyl ether, phenyl glycidyl ether and p- (tert-butyl) phenyl glycidyl ether. Commonly used glycidyl esters comprise glycidyl esters of the following structure:

wherein R is a hydrocarbyl group containing from about 4 to about 26 carbon atoms. Preferably, R is a branched hydrocarbon group having from about 8 to about 10 carbon atoms, such as neopentyl, neoheptyl or neodecyl. Suitable glycidyl esters of carboxylic acids include VERSATIC ACID 911 and CARDURA E, each of which is available from Shell Chemical Co.

Carbamate functionality may be included in the acrylic polymer via transcarbamylation by copolymerizing an acrylic monomer with a carbamate-functional vinyl monomer (such as a carbamate-functional alkyl ester of methacrylic acid), or by reacting a hydroxy-functional acrylic polymer with a low molecular weight carbamate-functional material (such as a material that may be derived from an alcohol or a glycol ether). In this reaction, a low molecular weight urethane functional material derived from an alcohol or glycol ether reacts with the hydroxyl groups of the acrylic polyol to produce a urethane functional acrylic polymer and an initial alcohol or glycol ether. Low molecular weight carbamate functional materials derived from alcohols or glycol ethers may be prepared by reacting an alcohol or glycol ether with urea in the presence of a catalyst. Suitable alcohols include lower aliphatic, cycloaliphatic, and aromatic alcohols (i.e., typically having eight or less carbon atoms), such as methanol, ethanol, propanol, butanol, cyclohexanol, 2-ethylhexanol, and 3-methylbutanol. Suitable glycol ethers include ethylene glycol methyl ether and propylene glycol methyl ether. Propylene glycol methyl ether and methanol are most commonly used. Other carbamate-functional monomers known to those skilled in the art may also be used.

Amide functionality may be incorporated into the acrylic polymer by using appropriate functional monomers in the polymer preparation, or by converting other functional groups to amido groups using techniques known to those skilled in the art. Likewise, if desired, other functional groups can be introduced using suitable functional monomers (if present) or conversion reactions (if necessary).

The ethylenically unsaturated monomer including a reactive functional group is typically present in the reaction mixture that can be used to prepare the first film-forming polymer in an amount of 1% to 30% by weight (such as 1% to 20% or 1% to 10%) based on the total weight of monomers in the reaction mixture.

One or more libraries of other polymerizable ethylenically unsaturated monomers can be included in the reaction mixture that can be used to prepare the first film-forming polymer. Useful alkyl esters of acrylic or methacrylic acid comprise aliphatic alkyl esters containing from 1 to 30, and preferably from 4 to 18, carbon atoms in the alkyl group. Non-limiting examples include methyl (meth) acrylate, ethyl (meth) acrylate, and butyl (meth) acrylate. Suitable other copolymerizable ethylenically unsaturated monomers include: vinyl aromatic compounds such as styrene and vinyl toluene; nitriles such as acrylonitrile and methacrylonitrile; vinyl and vinylidene halides such as vinyl chloride and vinylidene fluoride; and vinyl esters such as vinyl acetate. Styrene is frequently used.

When used, these additional ethylenically unsaturated monomers are typically present in the reaction mixture used to prepare the acrylic polymer in an amount of from 5% to 50% by weight, more typically from 10% to 30% by weight, based on the total weight of monomers in the reaction mixture.

The first film-forming polymer (a) may be prepared using known addition polymerisation techniques, such as organic solution polymerisation techniques, in particular from the aforementioned reaction mixtures. An exemplary method is set forth in the following examples.

The curable film-forming composition used to prepare the coated articles of the present invention also includes (b) a second film-forming polymer prepared from at least one hydrophobic monomer. The second film-forming polymer may be prepared from any of the monomers listed above for preparing the first film-forming polymer. The second film-forming polymer may also have reactive functional groups, such as those described above. In a specific example of the present invention, the second film-forming polymer (b) comprises an acrylic polymer prepared from a reaction mixture comprising a hydrophobic monomer and a monomer having a functional group that reacts with the functional group on the curing agent (c), wherein the hydrophobic monomer comprises a fluorinated monomer and/or a siloxane. However, the second film-forming polymer (b) is different from the first film-forming polymer (a). Each species is prepared using a monomer such that, upon application of the curable film-forming composition to a substrate to form a coating, the first film-forming polymer is distributed throughout the coating relative to a cross-section of the coating. That is, the concentration of the first film-forming polymer relative to the entire coating composition is substantially uniform throughout the coating. Additionally, the concentration of the second film-forming polymer in the surface region of the coating is greater than the concentration of the second film-forming polymer in the bulk region of the coating. "surface area" means 10% of the outermost coating thickness after application of the coating composition to a substrate. "bulk region" refers to the remainder of the coating thickness below the surface region. For example, after curing, in a coating having a Dry Film Thickness (DFT) of 100 microns, the surface region is the outermost 10 microns of the coating. Thus, the mass ratio of the second film-forming polymer to the first film-forming polymer is greater in the surface region of the coating than in the bulk region of the coating. These distributions of the two polymers can be achieved by preparing the respective film-forming polymers such that the second film-forming polymer (b) is more hydrophobic than the first film-forming polymer (a). This can be achieved by using a greater amount of hydrophobic monomer in the preparation of the second film-forming polymer than in the first film-forming polymer. For example, in the preparation of the first film-forming polymer (a), the hydrophobic monomer is typically present in the reaction mixture in an amount of 4% to 15% by weight (such as 5% to 13% by weight) based on the total weight of monomers in the reaction mixture. In contrast, in the preparation of the second film-forming polymer (b), the hydrophobic monomer is typically present in the reaction mixture in an amount of 15% to 60% by weight (such as 20% to 50% by weight or 20% to 40% by weight) based on the total weight of monomers in the reaction mixture.

In addition, the amount of each polymer in the curable film-forming composition is different. Typically, the first film-forming polymer (a) is present in the curable film-forming composition in an amount of at least 20% by weight, or at least 25% by weight, or at least 30% by weight, and at most 40% by weight, or at most 35% by weight, based on the total weight of resin solids in the curable film-forming composition. The second film-forming polymer (b) is present in the curable film-forming composition in an amount of at least 0.5% by weight (such as at least 1% by weight, and up to 15% by weight, or up to 10% by weight), based on the total weight of resin solids in the curable film-forming composition. While not wanting to be bound by theory, it is believed that the distribution of the first and second film-forming polymers in the coating allows the fouling-reducing properties of the coating to be maintained for an extended duration as compared to coatings that do not have such a distribution of polymers with altered hydrophobicity.

The curable film-forming composition also includes (c) a curing agent that includes functional groups that react with the reactive functional groups in polymer (a) and, when present, with the reactive functional groups in polymer (b).

The curing agent (c) used in the curable film-forming composition may be selected from one or more polyisocyanates, such as biurets and isocyanurates containing diisocyanates and triisocyanates. The diisocyanate comprises toluene diisocyanate, 4, 4 '-methylene-bis (cyclohexyl isocyanate), isophorone diisocyanate, isomer mixtures of 2, 2, 4-and 2, 4, 4-trimethylhexamethylene diisocyanate, 1, 6-hexamethylene diisocyanate, tetramethylxylylene diisocyanate and/or 4, 4' -diphenylmethylene diisocyanate. The biuret of any suitable diisocyanate including 1, 4-tetramethylene diisocyanate and 1, 6-hexamethylene diisocyanate can be used. Also, biurets of cycloaliphatic diisocyanates, such as isophorone diisocyanate and 4, 4' -methylene-bis- (cyclohexyl isocyanate), can be used. Examples of suitable aralkyl diisocyanates from which biurets can be prepared are m-xylylene diisocyanate and α, α, α ', α' -tetramethyl m-xylylene diisocyanate.

Trifunctional isocyanates may also be used as curing agents, such as trimers of isophorone diisocyanate, triisocyanatononane, triphenylmethane triisocyanate, 1, 3, 5-benzene triisocyanate, 2, 4, 6-toluene triisocyanate, the adduct of trimethylol and tetramethylxylene diisocyanate sold by CYTEC Industries under the name CYTHANE 3160, and DESMODUR N3390 (available from Bayer Corporation) which is an isocyanurate of hexamethylene diisocyanate. Specifically, the polyisocyanate used is a trimer of diisocyanate such as hexamethylene diisocyanate and isophorone diisocyanate. Desmodur Z4470 BA, an aliphatic polyisocyanate based on isophorone diisocyanate available from Bayer Corporation, is also suitable.

The polyisocyanate may also be one of those disclosed above, chain extended with one or more polyamines and/or polyols using suitable materials and techniques known to those skilled in the art to form a polyurethane prepolymer having isocyanate functional groups.

Mixtures of aliphatic polyisocyanates are particularly suitable.

The curing agent (c) used in the curable film-forming composition may alternatively or additionally be selected from one or more aminoplast resins. Useful aminoplast resins are based on addition products of formaldehyde with the amino or amido groups of the carrying substance. Condensation products obtained from the reaction of alcohols and formaldehyde with melamine, urea or benzoguanamine are the most common and preferred herein. While the aldehyde used is typically formaldehyde, other similar condensation products can also be made from other aldehydes (such as acetaldehyde, crotonaldehyde, acrolein, benzaldehyde, furfural, glyoxal, and the like).

Condensation products of other amines and amides may also be used, for example, aldehyde condensates of triazines, diazines, triazoles, guanidines, guanamines and alkyl-and aryl-substituted derivatives of these compounds, including alkyl-and aryl-substituted ureas and alkyl-and aryl-substituted melamines. Non-limiting examples of such compounds include N, N' -dimethylurea, benzourea, dicyandiamide, guaiamine, acetoguanamine, glycoluril, ammeline, 3, 5-diaminotriazole, triaminopyrimidine, 2-mercapto-4, 6-diaminopyrimidine, and the formula C₃N₃(NHCOXR)₃Wherein X is nitrogen, oxygen or carbon, and R is a lower alkyl group or a mixture of lower alkyl groups having from one to twelve carbon atoms (such as methyl, ethyl, propyl, butyl, n-octyl and 2-ethylhexyl). These compounds and their preparation are described in detail in U.S. Pat. No. 5,084,541.

Aminoplast resins typically contain methylol groups or similar alkyl groups, and in most cases at least a portion of these alkyl groups are etherified by reaction with an alcohol. Any monohydric alcohol may be used for this purpose, including methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, as well as benzyl alcohol and other aromatic alcohols, cyclic alcohols (such as cyclohexanol), monoethers of ethylene glycol, and halogen-substituted or otherwise substituted alcohols (such as 3-chloropropanol and butoxyethanol). Many aminoplast resins are partially alkylated with methanol or butanol.

The curing agent (c) is typically present in the film-forming composition in an amount in the range of from 30% to 79.5% by weight (such as from 40% to 65% by weight, typically from 45% to 60% by weight), based on the total weight of resin solids in the composition.

The curable film-forming composition used to prepare the coated articles of the present invention may also include (d) an additional film-forming resin component, and the film-forming resin component: i) different from the first film-forming polymer (a) and the second film-forming polymer (b); and ii) has a functional group that is reactive with at least one other component of the curable film-forming composition. Such component (d) may comprise one or more film-forming polymers and/or curing agents.

The additional film-forming resin component (d) may comprise an addition (such as an acrylic) polymer, a polyester polymer, a polyurethane polymer, a polyether polymer, a polyester acrylate and/or a polyurethane acrylate. Acrylic polymers and/or polyester polymers having multiple hydroxyl functional groups are commonly used.

Suitable acrylic polymers comprise copolymers of one or more monomers, such as any of those disclosed above.

Polyester polymers may also be used in the additional film-forming resin component (d). Such polymers may be prepared in a known manner by condensation of a polyol and a polycarboxylic acid. Suitable polyols include, but are not limited to, ethylene glycol, propylene glycol, butylene glycol, 1, 6-hexanediol, neopentyl glycol, diethylene glycol, glycerol, trimethylolpropane, and pentaerythritol. Suitable polycarboxylic acids include, but are not limited to, succinic acid, adipic acid, azelaic acid, sebacic acid, maleic acid, fumaric acid, phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, and trimellitic acid. In addition to the polycarboxylic acids mentioned above, functional equivalents of the acids (such as anhydrides (where present)) or lower alkyl esters of the acids (such as methyl esters) may also be used. Polyesters derived from cyclic esters such as caprolactone are also suitable. Polyester acrylates, such as acrylic polymers with polyester side chains, may also be used.

Polyurethanes can also be used in the additional film-forming resin component (d). Among the polyurethanes that may be used are polymer polyols, which are generally prepared by reacting a polyester polyol or an acrylic polyol (such as those mentioned above) with a polyisocyanate such that the OH/NCO equivalent ratio is greater than 1: 1, such that free hydroxyl groups are present in the product. The organic polyisocyanate used to prepare the polyurethane polyol may be an aliphatic or aromatic polyisocyanate or a mixture of both. Any of the above disclosed may be used in the preparation of polyurethanes. Urethane acrylates, such as acrylic polymers with urethane side chains, may also be used.

Examples of polyether polyols are those comprising a polyalkylene ether polyol having the formula:

(i)

or (ii)

Wherein the substituent R₁Is hydrogen or lower alkyl containing 1 to 5 carbon atoms containing mixed substituents, and n is typically from 2 to 6, and m is 8 to 100 or higher. Comprising poly (oxytetramethylene) glycol, poly (oxyethylene) glycol, poly (oxy-1, 2-propylene) glycol and poly (oxy-1, 2-butylene) glycol.

Also useful are polyether polyols formed by the oxidative alkylation of various polyols, for example, diols (such as ethylene glycol, 1, 6-hexanediol, bisphenol a, and the like) or other higher polyols (such as trimethylolpropane, pentaerythritol, and the like). Higher functionality polyols that can be used as indicated can be prepared by, for example, the oxidative alkylation of compounds such as sucrose or sorbitol. One commonly used oxyalkylation method is the reaction of a polyol with an alkylene oxide (e.g., propylene oxide or ethylene oxide) in the presence of an acidic or basic catalyst. Specific polyethers include those sold under the names TERATHANE and TERACOL available from E.I. Du Pont de Nemours and Company, Inc. and POLYMEG available from Q O Chemicals, Inc., a subsidiary of Great Lakes Chemical Corp.

Useful amine-functional film-forming polymers include polyoxypropylene amines, such as those known by the trade nameCommercially available polyoxypropylene amines; prepared amine functional acrylic and polyester polymers known in the art are also suitable.

The additional film-forming resin component (d) may comprise an aminoplast, such as any of those disclosed above. In a particular example of the invention, the additional film-forming resin component (d) comprises an acrylic and/or polyester polyol and an aminoplast.

When used, the additional film-forming resin component (d) is typically present in the film-forming composition in an amount in the range of from 30% to 49.5% by weight, typically from 35% to 45% by weight, based on the total weight of resin solids in the composition.

In certain embodiments of the present invention, the curable film-forming composition further comprises (d') a saturated fatty acid, such as caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, and cerotic acid; and (e) tin-containing catalysts such as triphenyltin hydroxide, butylstannoic acid, dioctyltin oxide, dibutyltin dilaurate, dibutyltin diacetate, and dibutyltin oxide. Curable film-forming compositions containing fatty acids and tin-containing catalysts are particularly useful for plastic substrates that require lower curing temperatures to avoid distortion.

The curable film-forming composition may additionally comprise a variety of optional ingredients and/or additives, which may depend to some extent on the specific application of the curable composition, such as other curing catalysts, pigments or other colorants, reinforcing agents, thixotropic agents, accelerators, surfactants, plasticizers, extenders, stabilizers, corrosion inhibitors, diluents, hindered amine light stabilizers, UV light absorbers, tackifiers, and antioxidants. The curable film-forming composition may be a color coating or a varnish; it may be opaque (less than 10% visible light transmission), translucent (10% to 70% visible light transmission), colored transparent or colorless transparent. The term "transparent" used in conjunction with a varnish means that the indicated coating has the property of transmitting visible light without significant scattering so that objects located outside it are fully visible. As used herein, a clear varnish exhibits a visible light transmission (% transmittance), as defined by the equation using visible light in the examples below, of at least 70%. Additionally, the curable film-forming compositions used to prepare the coated articles of the present invention are transparent to electromagnetic radiation (including short range and long range frequencies) used in signaling devices, such as transmitters and receivers of autonomous vehicles. For example, the curable film-forming composition is generally transparent (i.e., exhibits a transmittance of at least 70%) to electromagnetic radiation having any frequency between 22GHz and 81GHz, particularly between 76GHz and 81 GHz.

The curable composition used in the present invention may be prepared as a two-pack composition that is typically curable at ambient temperature. "ambient" conditions means that no heat or other energy is applied; for example, when the curable composition undergoes a thermosetting reaction without being baked in an oven, using forced air, radiation, or the like to promote the reaction, the reaction is said to occur under ambient conditions. Typically, ambient temperatures are between 60 ° F and 90 ° F (15.6 ℃ to 32.2 ℃), such as typically 72 ° F (22.2 ℃) at room temperature. Two-pack curable compositions are typically prepared by mixing the components just prior to use. The curable film-forming composition may alternatively be prepared as a one-package system.

To prepare the coated articles of the present invention, the curable film-forming composition described above may be applied to at least one surface of a substrate.

Suitable substrates includeAny substrate that is transparent to electromagnetic radiation having any frequency between 22GHz and 81GHz, in particular between 76GHz and 81GHz (i.e. exhibits a light transmittance (% transmittance, as defined in the examples below) of at least 70%). For example, the curable film-forming composition can be applied to optical substrates known in the art, including non-plastic substrates such as glass. Suitable examples of optical plastic substrates include polyols (allyl carbonates), for example allyl diglycol carbonate, such as diethylene glycol bis (allyl carbonate), which is sold by PPG under the trademark CR-39; polyurea-polyurethane (polyureaurethane) polymers prepared by reaction of, for example, a polyurethane prepolymer and a diamine curing agent, the composition for one such polymer being prepared from PPG under the trademark PPGSelling; a polyol (meth) acryloyl terminated carbonate monomer; diethylene glycol dimethacrylate monomer; ethoxylated phenol methacrylate monomers; diisopropenyl benzene monomer; ethoxylated trimethylolpropane triacrylate monomer; ethylene glycol dimethacrylate monomer; a poly (ethylene glycol) dimethacrylate monomer; urethane acrylate monomers; poly (ethoxylated bisphenol a dimethacrylate); poly (vinyl acetate); poly (vinyl alcohol); poly (vinyl chloride); poly (vinylidene chloride); polyethylene; polypropylene; a polyurethane; polythiocarbamates; thermoplastic polycarbonates, such as the carbonate-linked resins derived from bisphenol a and phosgene, one such material being sold under the trademark LEXAN; polyester, such as the material sold under the trademark MYLAR; poly (ethylene terephthalate); polyvinyl butyral; poly (methyl methacrylate), such as the material sold under the trademark PLEXIGLAS, and polymers prepared by reacting a polyfunctional isocyanate with a polythiol or polysulfide monomer that is homopolymeric or copolymeric and/or terpolymeric with the polythiol, polyisocyanate, polyisothiocyanate, and optionally an ethylenically unsaturated monomer or halogenated aromatic-containing vinyl monomer. Also suitable are copolymers of these monomers and blends of the polymers and copolymers described with other polymers, for example to form interpenetrating networksComplexing the product. Such optical substrates may be used as lenses, screens, or covers (for transmitters, receivers, etc.) on components of autonomous vehicles.

The curable film-forming composition may also be applied to elastomeric, plastic, or composite substrates, such as those found on motor vehicles and used as vehicle parts (such as wheels, bumpers, fenders, hoods, doors, panels, and the like). These vehicle parts may be formed from any of the common thermoplastic or thermoset synthetic materials, including thermoplastic olefins (such as polyethylene and polypropylene), thermoplastic urethanes, polycarbonates, thermoset sheet molding compounds, reaction injection molding compounds, acrylonitrile-based materials, nylons, and the like. By "composite" is meant any substrate made of fibers, usually made of glass or carbon, or of other filler materials combined with polymer or plastic materials, usually made of epoxy-type polymers.

It is common, although not necessary, to remove foreign matter from the surface of the substrate by thoroughly cleaning and degreasing the surface before any coating composition is deposited on the surface. Such cleaning typically occurs after the substrate is formed (molded, etc.) into the end-use shape. The surface of the substrate may be cleaned by physical and/or chemical means, such as mechanically abrading the surface or cleaning/degreasing using commercially available cleaners well known to those skilled in the art.

After the cleaning step, the substrate may be rinsed with deionized water, with an aqueous solution of a solvent or rinsing agent to remove any residue. The substrate may be air dried by briefly exposing the substrate to a higher temperature to flash off the water or by passing the substrate between wringing rollers, for example by using an air knife.

The substrate may be a bare, cleaned surface; it may be oily, pretreated with one or more pretreatment or adhesion promoting compositions, and/or pre-painted with one or more coating compositions, primers, topcoats, and the like, applied by any method including, but not limited to, spray coating, dip coating, roll coating, curtain coating, and the like.

The compositions may be applied to the substrate by one or more of a variety of methods, including spraying, dipping/immersion, brushing or flow coating, but they are most commonly applied by spraying. Common spray techniques and equipment for air spraying and electrostatic spraying, as well as manual or automated methods, may be used. The coating typically has a dry film thickness of 1-25 mils (25.4-635 microns), typically 5-25 mils (127 and 635 microns).

The film-forming composition may be applied directly to the surface of a substrate, or to an adhesion promoter layer, primer, or other coating (such as a topcoat) as described above, of a substrate to form a coated substrate according to the present invention. Alternatively, no primer may be used, and the film-forming composition may be applied directly to an adhesion promoter, pigmented primer, or other coating. Multiple coatings, such as a primer and optionally a color primer, may be applied to the substrate prior to application of the curable film-forming composition of the present invention. Thus, the coated article of the present invention may comprise: A) a pigmented curable film-forming composition applied to at least one surface of the substrate to form a base coated substrate, and B) a transparent curable film-forming composition applied to at least one surface of the base coated substrate, wherein the transparent curable film-forming composition is prepared from the curable film-forming composition described above.

After forming a film of the coating on the substrate, the composition may be cured by heating to a temperature and for a time sufficient to cure the composition; for example, by allowing it to stand at ambient temperature, such as typically room temperature 72 ° F (22.2 ℃), or a combination of ambient temperature curing and baking, or baking alone. The composition may be cured at ambient temperature, typically over a period ranging from about 24 hours to about 36 hours. If ambient temperature and baking are used in combination, the composition is typically allowed to stand ("flash off") at a temperature in the range of ambient temperature to 175 ° F (79.4 ℃) for a period of time from about 2 minutes to about 120 minutes, followed by baking at a temperature of up to about 300 ° F (148.9 ℃), typically 285 ° F (140.6 ℃) for a period of time from about 20 minutes to about 1 hour. For plastic substrates that are heat sensitive and may deform at high temperatures, the curable film-forming composition may be cured at temperatures below 90 ℃.

After application of the curable film-forming composition to a substrate and upon curing, the coated article exhibits a transmittance in the range of 70% to 100% (such as 75% to 100% or 80% to 100%) for electromagnetic radiation having any frequency between 22GHz to 81GHz, as measured as shown in the examples below. The coated articles of the present invention also exhibit contaminant mitigation properties as evidenced by radar transparency when subjected to the various tests described in the examples below. According to the present invention, these properties make the curable film-forming composition of the present invention particularly useful in methods of mitigating the accumulation of contaminants on a substrate.

In the method of the present invention, the accumulation of contaminants on a substrate is mitigated by applying the curable film-forming composition described above to at least a portion of the substrate and then at least partially curing the curable film-forming composition. A curable film-forming composition is applied to at least one surface of a substrate. The substrate may have one continuous surface, or two or more surfaces, such as two opposing surfaces. In general, a surface to be coated is any surface that is expected to be exposed to conditions that are favorable for dirt accumulation, such as consumer and industrial vehicles and building structures. "soil" means soil, grease, oil, minerals, detergents, salts, tar, asphalt, animal waste, insects ("carcass"), sap, and the like; contaminants that are commonly found in outdoor or industrial environments and tend to adhere to vehicle surfaces. Other contaminants include water and ice. Water and ice in the form of droplets, thin streams, or laminar flows on the surface of the substrate may impede signal transmission through the substrate. In a particular example of the present invention, there is provided a method of mitigating contaminant buildup on a substrate, comprising:

(1) applying a first coating comprising a pigmented curable film-forming composition to at least a portion of a substrate to form a base coated substrate;

(2) applying a transparent curable film-forming composition to at least a portion of the base coated substrate formed in step (1) to form a multilayer coated substrate prior to substantially curing the first coating, wherein the transparent curable film-forming composition is prepared from the curable film-forming composition described above; and

(3) heating the multilayer coated substrate formed in step (2) to a temperature and for a time sufficient to cure all of the film-forming composition.

The method of the present invention is particularly useful for mitigating the accumulation of contaminants on components of a vehicle. Such vehicles may include land vehicles, such as automobiles, trucks, sport utility vehicles, motorcycles; vessels such as boats, ships and submarines; aircraft, such as airplanes and helicopters; a construction vehicle; and military vehicles such as tanks and hummers.

The method of the present invention is particularly useful for mitigating contaminant buildup on components of an autonomous vehicle. Many vehicles in use today, including autonomous vehicles, utilize transmitters and sensors to send and receive signals for various purposes. It is essential for the continuous accurate and safe operation of such vehicles that these signals, typically electromagnetic radiation in the form of radio waves, are not obstructed in any way. The coated substrate covering the emitter and sensor must allow the signal to pass through it. It is particularly beneficial to mitigate contaminant accumulation by using the method of the present invention.

Each of the embodiments and features described above and combinations thereof can be said to be encompassed by the present invention. For example, the present invention is thus directed to the following non-limiting aspects:

1. a coated article comprising:

(1) a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81 GHz; and

(2) a curable film-forming composition applied to at least one surface of the substrate and cured thereon, the curable film-forming composition comprising:

2. The coated article of aspect 1, wherein the second film-forming polymer (b) is more hydrophobic than the first film-forming polymer (a).

3. The coated article of aspect 1 or 2, wherein the first film-forming polymer (a) comprises an acrylic polymer prepared from a reaction mixture comprising hydrophobic monomers, wherein the hydrophobic monomers in the reaction mixture used to prepare the first film-forming polymer (a) comprise fluorinated monomers and/or siloxanes.

4. The coated article of aspect 3, wherein the hydrophobic monomer in the reaction mixture used to prepare the first film-forming polymer (a) is present in the reaction mixture in an amount of 4% to 15% by weight, based on the total weight of monomers in the reaction mixture.

5. The coated article according to any one of the preceding aspects, wherein the second film-forming polymer (b) comprises an acrylic polymer prepared from a reaction mixture comprising a hydrophobic monomer and a monomer having a functional group that reacts with the functional group on the curing agent (c), wherein the hydrophobic monomer in the reaction mixture used to prepare the second film-forming polymer (b) comprises a fluorinated monomer and/or a siloxane.

6. The coated article of aspect 5, wherein the hydrophobic monomer in the reaction mixture used to prepare the second film-forming polymer (b) is present in the reaction mixture in an amount of 15% to 60% by weight, based on the total weight of monomers in the reaction mixture.

7. The coated article of any of the preceding aspects, wherein the curing agent (c) comprises a polyisocyanate.

8. The coated article according to any one of the preceding aspects, wherein the curable film-forming composition further comprises (d) an additional film-forming resin component: (i) is different from the first film-forming polymer (a) and the second film-forming polymer (b); and (ii) has a functional group that reacts with at least one other component of the curable film-forming composition.

9. The coated article of aspect 8, wherein the additional film-forming resin component (d) comprises an acrylic and/or polyester polyol and an aminoplast.

10. The coated article of any of the preceding aspects, wherein the curable film-forming composition is transparent to visible light.

11. The coated article according to any one of the preceding aspects, wherein the substrate comprises a plastic and the curable film-forming composition further comprises (d') a saturated fatty acid and (e) a tin catalyst.

12. The coated article of any one of the preceding aspects, wherein the substrate comprises a component of a vehicle.

13. The coated article of aspect 12, wherein the vehicle comprises an autonomous vehicle.

14. A method of mitigating contaminant accumulation on a substrate transparent to electromagnetic radiation having a frequency of 22GHz to 81GHz, comprising:

(1) applying a curable film-forming composition to at least a portion of the substrate to form a coated substrate, wherein the curable film-forming composition comprises:

(2) heating the coated substrate formed in step (1) to cure the film-forming composition.

15. The method of aspect 14, comprising:

(1) applying a first coating comprising a pigmented curable film-forming composition to at least a portion of the substrate to form a base coated substrate;

(3) heating the multilayer coated substrate formed in step (2) to cure all of the film-forming composition.

16. The method of aspect 14 or aspect 15, wherein the film-forming composition is a film-forming composition as defined in any one of aspects 1 to 10, 14 or 15 and/or the substrate is a substrate as defined in any one of aspects 10 to 13.

The following examples are intended to illustrate various embodiments of the invention and should not be construed as limiting the invention in any way.

Examples of the invention

The following working examples are intended to further describe the invention. It should be understood that the invention described in this specification is not necessarily limited to the examples described in this section.

Example A

The hydrophobic polyol (containing 4.8% by weight of PDMS functional methacrylate monomer) used as the first film-forming polymer in the composition of the present invention was synthesized by the following procedure. 2331g of amyl acetate are charged to a four-necked round bottom flask equipped with a thermocouple, mechanical stirrer and condenser, and charged with N₂And (6) covering. The mixture was heated to 150 ℃ and held for 10 minutes. Thereafter, an initiator mixture of 341g of amyl acetate and 135g of LUPEROX 7M50 (a polymerization initiator available from Arkema) was added to the flask over a period of 4 hours. At the same time, the flask was charged with 407g of butyl methacrylate, 1035g of isobornyl methacrylate, 635g of 2-hydroxypropyl methacrylate, 574g of hydroxyethyl methacrylate, 453g of butyl acrylate, 195g of KF-2012 silicone fluid available from Shin-Etsu, and 87g of pentyl acetate mono-ester over a period of 3 hoursA bulk mixture. Immediately after the monomer mixture was charged, the flask was charged with a second monomer mixture of 136g of butyl methacrylate, 211g of 2-hydroxypropyl methacrylate, 191g of hydroxyethyl methacrylate, 105g of butyl acrylate and 39g of pentyl acetate within 45 minutes. After the initiator mixture charge was complete, the reaction was held at 150 ℃ for an additional 30 minutes. Thereafter, the system was cooled to 110 ℃ and 35g of butyl acrylate was charged into the flask at a time. The flask was charged with a mixture of 142g of amyl acetate and 57g of LUPEROX 26 (a polymerization initiator available from Arkema) over 1 hour, followed by holding at 110 ℃ for 1 hour. The final measured solid content (by weight) of the above resin was 57.0% based on gel permeation chromatography using polystyrene standards, with a weight average molecular weight of 6498g/mol and a number average molecular weight of 2490 g/mol.

Example B

The hydrophobic polyol (containing 23.0% by weight of Polydimethylsiloxane (PDMS) functional methacrylate monomer) used as the second film-forming polymer in the composition of the present invention was synthesized by the following procedure. A mixture of 2404g of amyl acetate, 841g X-22-2426 (a reactive silicone fluid available from Shin-Etsu), 534g of isobornyl methacrylate, and 147g of 4-hydroxybutyl acrylate was charged to a four-necked round bottom flask equipped with a thermocouple, mechanical stirrer, and condenser, and charged with N₂And (6) covering. The mixture was heated to 135 ℃ and held for 10 minutes. Thereafter, the flask was charged over 3 hours with an initiator mixture of 641g amyl acetate and 140g LUPEROX 7M 50. At the same time, the flask was charged with a monomer mixture of 1603g of isobornyl methacrylate and 444g of 4-hydroxybutyl acrylate over a period of 3 hours. Thereafter, the reaction was held at 135 ℃ for an additional 30 minutes. Then, the flask was charged with a mixture of 320g of amyl acetate and 32g of LUPEROX 26 over 1 hour, followed by holding at 135 ℃ for 1 hour. The final measured solid content (by weight) of the above resin was 49.4% based on gel permeation chromatography using polystyrene standards, with a weight average molecular weight of 8300g/mol and a number average molecular weight of 1100 g/mol.

Formulation examples

A clear coat layer is applied to a Thermoplastic Polyolefin (TPO) substrate. The coating was applied under controlled conditions of 20-22 ℃ temperature and 60-65% relative humidity using conventional spray equipment (SPRAYMATION, available from spraymetion, Inc). The coating was sprayed in two successive applications without any intermediate drying between the spray applications. The two coats of the varnish system were then allowed to dry at ambient conditions for 7 minutes and then baked at 80 ℃ for 30 minutes. After final curing, the film thickness of the system was approximately 50 microns.

The varnish was prepared by mixing component a and component B using the components listed in table 1.

TABLE 1

Components	Parts by weight
		Acetic acid n-amyl ester	21.0
Diethylene glycol n-butyl ether acetate	5.0
		TINUVIN 928¹	2.0
TINUVIN 292²	3.2
		Melamine³	7.2
Poly siliconSiloxane polyol silica⁴	4.1
		Flow/implosion-resistant additives⁵	0.05
Acrylic polyol⁶	17.6
		Hydrophobic polyol of example B	20.4
Hydrophobic polyol of example A	54.1
		Saturated fatty acid⁷	4.0
SOLVESSO 100^8*	9.0
		Crosslinking agent⁹*	40.0
Dibutyl tin dilaurate^*	0.15

¹2- (2H-benzotriazol-2-yl) -6- (1-methyl-1-phenylethyl) -4- (1, 1, 3, 3-tetramethylbutyl) phenol UV absorber available from Ciba Specialty Chemicals Corp

²Hindered amine light stabilizers available from Ciba-Geigy Corp

³High butyl radicalEsterified melamine (obtainable from Allnex)1156)

⁴A silica dispersion prepared as follows: by using N₂The 4-neck reaction flask equipped for vacuum distillation was rinsed. To a reaction flask was added 1051.1 parts by weight of a silicone polyol, 1125.8 parts by weight of ORGANOSILICAL MT-ST-M (colloidal silica from Nissan Chemicals), and 480.3 parts by weight of methyl amyl ketone. The resulting mixture was distilled under vacuum at 25 ℃ for 4 hours. The silicone polyol was previously prepared by reacting 131.54 parts by weight trimethylolpropane monoallyl ether and 93.21 parts by weight MASILWAX BASE (silicone-containing silicon hydride available from BASF Corporation).

⁵Polyacrylate surface additive in butyl acetate (BYK-390 from BYK).

⁶14.5% by weight BMA at 53% by weight solids in an aromatic hydrocarbon mixture; 14.5% by weight of BA; 20% by weight HEMA; 29% by weight of IBOMA; 22% by weight of HPMA.

⁷Prisorine 3501 available from Croda

⁸Blends of aromatic solvents available from ExxonMobil Corporation

⁹1.6 parts by weight of a mixture of DESMODUR N-3300A (100% solids Hexamethylene Diisocyanate (HDI) trimer (isocyanurate ring) available from Covestro LLC) and 1 part by weight of DESMODUR Z44700 (70% solids isophorone diisocyanate (IPDI) trimer (isocyanurate ring) available from Covestro LLC).

Part of the B pack, mixed separately and added to the rest of the ingredients before application.

The above curable film-forming composition was compared to a control varnish (DC4000 acrylic polyol mixed with DCH 3085 polyisocyanate hardener, both available from PPG). The control varnish was applied on Thermoplastic Polyolefin (TPO) using an HVLP gravity-fed spray gun (SATA jet 4000) with a 12 "fan spray and 27psi at the gun nozzle (1.8mm opening).

The varnished TPO substrate is mounted between an electromagnetic radiation transmitter and receiver antenna with the coated side of the substrate facing the transmitter. Water was sprayed onto the coated substrate prior to measurement. The Insertion Loss (IL) is measured and refers to the amount of transmitted signal that is not detected at the receiver. This method assumes a "lossless" condition in which the substrate does not absorb or absorbs a small amount of the incident radar frequency. The% transmission was calculated according to equation 1. Substrates were tested using 24GHz (primarily short range radar) and 77GHz (primarily long range radar).

Equation 1. transmittance 100x10^IL/10

TABLE 2 Radar testing of varnishes

The results collected for both short range (24GHz) and long range (77GHz) radars show that the coated articles of the invention are effectively water-repellent and significantly reduce insertion loss compared to the control. This correlates to an improvement in radar transmission (table 2). In fact, the% transmission in the presence of water of the coated articles of the present invention is very close to the transmission of these coatings measured when the coating dries, indicating a very effective water repellency capability.

The extended retention of the fouling and water accumulation mitigation properties of the coated articles of the present invention compared to substrates coated with conventional compositions is due to the more uniform distribution of the hydrophobic material throughout the coating, which is not possible with conventional additive-type hydrophobic materials loaded at low concentrations (< 10% final solids) alone.

While specific embodiments of the invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims.

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