Patent · US9815083B2 · B2 · US
Method for coating a five-sided container with sag-resistant water-based coating compositions
- (11) Publication number
- US9815083B2
- (21) Application number
- 15/046,554
- (22) Filing date
- 2016-02-18
- (30) Priority date
- 2011-03-08
- (43) Publication date
- 2017-11-14
- (45) Date of grant
- 2017-11-14
- (51) IPC
- B05D 3/00; B65D 88/12; B65D 90/02; B05B 12/08; B05D 3/12; B05D 7/00; B05D 7/14; B05D 7/22; B65D 1/22; B65D 23/02; B65D 23/08; B65D 25/14; B65D 25/34; B65D 6/02; C09D 127/08; C09D 5/02; C09D 5/04; C09D 7/00; F26B 15/16; F26B 21/00; G05D 7/06
- (52) CPC
- C09D Coating compositions, e.g. paints, varnishes or lacquers; filling pastes; chemical paint or ink removers; inks; correcting fluids; woodstains; pastes or solids for colouring or printing; use of materials therefor: 127/08, 5/024, 5/04, 7/002, 7/43
- B05B Spraying apparatus; atomising apparatus; nozzles: 12/085
- B05D Processes for applying fluent materials to surfaces, in general: 1/00, 1/02, 2401/20, 2504/00, 2520/00, 3/007, 3/0413, 3/0486, 3/12, 7/14, 7/227, 7/56
- B65D Containers for storage or transport of articles or materials, e.g. bags, barrels, bottles, boxes, cans, cartons, crates, drums, jars, tanks, hoppers, forwarding containers; accessories, closures, or fittings therefor; packaging elements; packages: 1/22, 23/02, 23/08, 25/14, 25/34, 7/06, 88/121, 88/123, 90/02
- C08K Use of inorganic or non-macromolecular organic substances as compounding ingredients: 3/346
- C08L Compositions of macromolecular compounds: 63/00
- F26B Drying solid materials or objects by removing liquid therefrom: 15/16, 21/006, 2210/12
- G05D Systems for controlling or regulating non-electric variables: 7/0688
- Y02P Climate change mitigation technologies in the production or processing of goods: 20/141, 20/149
- (73) Assignee
- Valspar Sourcing Inc
- (72) Inventors
- Channing Charles Beaudry; William C. Nowack; James A. Prevost; Feng Zhang; Wylie H. Wetzel
- (54) Title
- Method for coating a five-sided container with sag-resistant water-based coating compositions
- (57) Abstract
The present invention provides a water-based coating and/or coating system used to form sag resistant wet layers or coatings on a wide range of substrates. The coating system is effective for protecting metal-containing substrates, such as intermodal cargo containers, against corrosion. As an overview, the present invention provides water-based compositions as primer coats on substrates, and methods for applying the same to substrates. The method includes steps of applying a water-based paint to the interior surfaces of a substrate and drying the substrate by continuously forcing heated air onto the substrate as it moves through a drying chamber. Desirably, the primer incorporates a high level of one or more CAS agents for excellent sag resistance while drying in a broad range of relative humidity environments. Alternatively, modifications can be made to control temperature and humidity during spray application and drying as a way to increase sag resistance of the coating.
- Full text
- View on Google Patents
Claims (15)
- A method, comprising: providing a five-sided container, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, and wherein each of the first wall and the four side walls have an interior surface; applying a water-based paint to the interior surfaces of the first wall and the side walls of the container; and continuously forcing heated air at a temperature of about 50 to 200° C. and a velocity of about 0.1 to 10 m/s into the open side of the container as the container moves through a drying chamber to at least partially dry the paint on the interior surfaces of the container, wherein the heated air is directed such that the heated air: travels in a second direction opposite to the first direction to contact an interior surface of the first wall and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; flows in the first direction along the interior surfaces of the walls of the container; and exits the container.
- The method of claim 1, wherein the heated air is forced into the container for less than about 20 minutes.
- The method of claim 1, wherein applying a water-based paint comprises: applying at least one primer coat to the interior surfaces of the container, wherein the primer coat comprises a dried coating prepared from a coating composition including an aqueous carrier; a first resin component comprising polyvinylidene chloride in admixture with the aqueous carrier; at least one aqueous epoxy-functional compound; and one or more fillers; and optionally, applying at least one topcoat over the primer coat.
- The method of claim 3 wherein the primer coat has dry film thickness of about 20 to 100 μm.
- The method of claim 1, wherein the five-sided container is an intermodal cargo container.
- The method of claim 5, wherein the intermodal cargo container substantially conforms to ISO R-668.
- The method of claim 1, wherein the partially dry paint has a film thickness of 20 to 100 μm.
- A method, comprising: providing a five-sided container substantially conforming to ISO R-668, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, wherein each of the first wall and the four side walls have an interior surface, and wherein the interior surfaces of the first wall of the container and the interior surfaces of at least two side walls of the container intersect to form corner regions; applying a water-based paint to the interior surfaces of the first wall and the side walls of the container; and allowing the paint to dry to a film thickness of about 20 to 100 μm in an environment having a relative humidity in the range of up to about 95% by forcing heated air into the open side of the container as the container moves through a drying chamber for about 10 to 30minutes, wherein the heated air is directed such that the heated air: travels in a second direction opposite to the first direction and enters the open side of the container at a velocity sufficient to provide substantially laminar flow along the interior surface of the first wall of the container, and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; flows in the first direction along the interior surfaces of the walls of the container; and exits the container.
- The method of claim 8, wherein the relative humidity is in the range of 50% to 85%.
- The method of claim 8, wherein the relative humidity is in the range of 50% to 75%.
- A method, comprising: providing a five-sided container substantially conforming to ISO R-668, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, and wherein each of the first wall and the four side walls have an interior surface; applying a water-based paint as a primer coat to the interior surfaces of the first wall and the side walls of the container in process conditions modified to control humidity and temperature, wherein the water-based paint comprises an aqueous carrier; a first resin component comprising polyvinylidene chloride in admixture with the aqueous carrier; one or more aqueous epoxy-functional compounds; one or more fillers; and one or more CAS agents dispersed in the aqueous carrier, wherein the one or more CAS agents are present in a sufficient amount to provide the water-based paint with sag resistance at 80% relative humidity and 25° C. that is at least 60% of the sag resistance of the water-based paint at 50% relative humidity and 25° C.; and forcing heated air into the open side of the container as the container moves through a drying chamber to at least partially dry the paint to a film thickness of about 20 to 100 μm on the interior surfaces of the container, wherein the heated air is directed such that the heated air (i) travels in a second direction opposite to the first direction to contact an interior surface of the first wall and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; (ii) flows in the first direction along the interior surfaces of the walls of the container; and (iii) exits the container.
- The method of claim 11, wherein the one or more CAS agents comprise hydrophilic clay and are present in an amount greater than 0.12 kg per 100 L of the water-based paint.
- The method of claim 11, wherein the one or more CAS agents comprise bentonite.
- The method of claim 11, wherein the one or more CAS agents have average particle size less than 1 μm.
- The method of claim 11, wherein the water-based paint is substantially free of associative thickener(s).
Description
The present invention relates to water-based coating systems and methods used to form protective coatings on substrates and in particular metal containing substrates. More particularly, the present invention relates to coating compositions, methods, and coating systems involving an aqueous coating composition. These coatings are typically used as a primer coat (also referred to as a base coat) or as a direct-to-metal coat (“DTM”), wherein the aqueous coating composition preferably has a sufficiently high loading of one or more clay anti-sag agents (hereinafter “CAS agents”), and/or the coating is applied in a controlled humidity environment, to promote enhanced performance of the resultant coatings with respect to sag resistance.
Intermodal cargo containers (also referred to as freight or shipping containers) are reusable transport and storage units for moving products and raw materials between locations, including between countries. Intermodal cargo containers are standardized to facilitate intermodal transport such as among marine transport, freight train transport, and freight truck transport. Standardization of cargo containers also is referred to as containerization.
Containerization has provided global commerce with many benefits. Shipped goods move more easily and cheaply. Manufacturers know that goods loaded at one location can be readily unloaded at the destination. Cargo security has been improved, as containers are usually sealed and can be locked to discourage tampering and theft. Containers also have a longer service life, and there is a stronger market for used containers.
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- US20130167480A1
- US20120263961A1
- US20130105473A1
Record as JSON
{
"publication_number": "US9815083B2",
"country": "US",
"kind": "B2",
"title": "Method for coating a five-sided container with sag-resistant water-based coating compositions",
"abstract": "The present invention provides a water-based coating and/or coating system used to form sag resistant wet layers or coatings on a wide range of substrates. The coating system is effective for protecting metal-containing substrates, such as intermodal cargo containers, against corrosion. As an overview, the present invention provides water-based compositions as primer coats on substrates, and methods for applying the same to substrates. The method includes steps of applying a water-based paint to the interior surfaces of a substrate and drying the substrate by continuously forcing heated air onto the substrate as it moves through a drying chamber. Desirably, the primer incorporates a high level of one or more CAS agents for excellent sag resistance while drying in a broad range of relative humidity environments. Alternatively, modifications can be made to control temperature and humidity during spray application and drying as a way to increase sag resistance of the coating.",
"claims": [
"1. A method, comprising: providing a five-sided container, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, and wherein each of the first wall and the four side walls have an interior surface; applying a water-based paint to the interior surfaces of the first wall and the side walls of the container; and continuously forcing heated air at a temperature of about 50 to 200° C. and a velocity of about 0.1 to 10 m/s into the open side of the container as the container moves through a drying chamber to at least partially dry the paint on the interior surfaces of the container, wherein the heated air is directed such that the heated air: travels in a second direction opposite to the first direction to contact an interior surface of the first wall and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; flows in the first direction along the interior surfaces of the walls of the container; and exits the container.",
"2. The method of claim 1, wherein the heated air is forced into the container for less than about 20 minutes.",
"3. The method of claim 1, wherein applying a water-based paint comprises: applying at least one primer coat to the interior surfaces of the container, wherein the primer coat comprises a dried coating prepared from a coating composition including an aqueous carrier; a first resin component comprising polyvinylidene chloride in admixture with the aqueous carrier; at least one aqueous epoxy-functional compound; and one or more fillers; and optionally, applying at least one topcoat over the primer coat.",
"4. The method of claim 3 wherein the primer coat has dry film thickness of about 20 to 100 μm.",
"5. The method of claim 1, wherein the five-sided container is an intermodal cargo container.",
"6. The method of claim 5, wherein the intermodal cargo container substantially conforms to ISO R-668.",
"7. The method of claim 1, wherein the partially dry paint has a film thickness of 20 to 100 μm.",
"8. A method, comprising: providing a five-sided container substantially conforming to ISO R-668, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, wherein each of the first wall and the four side walls have an interior surface, and wherein the interior surfaces of the first wall of the container and the interior surfaces of at least two side walls of the container intersect to form corner regions; applying a water-based paint to the interior surfaces of the first wall and the side walls of the container; and allowing the paint to dry to a film thickness of about 20 to 100 μm in an environment having a relative humidity in the range of up to about 95% by forcing heated air into the open side of the container as the container moves through a drying chamber for about 10 to 30minutes, wherein the heated air is directed such that the heated air: travels in a second direction opposite to the first direction and enters the open side of the container at a velocity sufficient to provide substantially laminar flow along the interior surface of the first wall of the container, and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; flows in the first direction along the interior surfaces of the walls of the container; and exits the container.",
"9. The method of claim 8, wherein the relative humidity is in the range of 50% to 85%.",
"10. The method of claim 8, wherein the relative humidity is in the range of 50% to 75%.",
"11. A method, comprising: providing a five-sided container substantially conforming to ISO R-668, the container including an open side, a first steel wall opposite the open side, and four steel side walls connected to the first wall, wherein the side walls extend in a first direction with respect to the first wall, and wherein each of the first wall and the four side walls have an interior surface; applying a water-based paint as a primer coat to the interior surfaces of the first wall and the side walls of the container in process conditions modified to control humidity and temperature, wherein the water-based paint comprises an aqueous carrier; a first resin component comprising polyvinylidene chloride in admixture with the aqueous carrier; one or more aqueous epoxy-functional compounds; one or more fillers; and one or more CAS agents dispersed in the aqueous carrier, wherein the one or more CAS agents are present in a sufficient amount to provide the water-based paint with sag resistance at 80% relative humidity and 25° C. that is at least 60% of the sag resistance of the water-based paint at 50% relative humidity and 25° C.; and forcing heated air into the open side of the container as the container moves through a drying chamber to at least partially dry the paint to a film thickness of about 20 to 100 μm on the interior surfaces of the container, wherein the heated air is directed such that the heated air (i) travels in a second direction opposite to the first direction to contact an interior surface of the first wall and flows in a third direction and a fourth direction thereover, wherein the third direction and the fourth direction are substantially opposite one another and substantially normal to the second direction and the first direction; (ii) flows in the first direction along the interior surfaces of the walls of the container; and (iii) exits the container.",
"12. The method of claim 11, wherein the one or more CAS agents comprise hydrophilic clay and are present in an amount greater than 0.12 kg per 100 L of the water-based paint.",
"13. The method of claim 11, wherein the one or more CAS agents comprise bentonite.",
"14. The method of claim 11, wherein the one or more CAS agents have average particle size less than 1 μm.",
"15. The method of claim 11, wherein the water-based paint is substantially free of associative thickener(s)."
],
"description_excerpt": "The present invention relates to water-based coating systems and methods used to form protective coatings on substrates and in particular metal containing substrates. More particularly, the present invention relates to coating compositions, methods, and coating systems involving an aqueous coating composition. These coatings are typically used as a primer coat (also referred to as a base coat) or as a direct-to-metal coat (“DTM”), wherein the aqueous coating composition preferably has a sufficiently high loading of one or more clay anti-sag agents (hereinafter “CAS agents”), and/or the coating is applied in a controlled humidity environment, to promote enhanced performance of the resultant coatings with respect to sag resistance.\n\nIntermodal cargo containers (also referred to as freight or shipping containers) are reusable transport and storage units for moving products and raw materials between locations, including between countries. Intermodal cargo containers are standardized to facilitate intermodal transport such as among marine transport, freight train transport, and freight truck transport. Standardization of cargo containers also is referred to as containerization.\n\nContainerization has provided global commerce with many benefits. Shipped goods move more easily and cheaply. Manufacturers know that goods loaded at one location can be readily unloaded at the destination. Cargo security has been improved, as containers are usually sealed and can be locked to discourage tampering and theft. Containers also have a longer service life, and there is a stronger market for used containers.",
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"assignees": [
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],
"inventors": [
"Channing Charles Beaudry",
"William C. Nowack",
"James A. Prevost",
"Feng Zhang",
"Wylie H. Wetzel"
],
"filing_date": "2016-02-18",
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"priority_date": "2011-03-08",
"application_number": "US-201615046554-A",
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