DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES
This invention relates to methods and apparatus for making coated articles with one or more layers by dip, spray or flow coating. In one aspect, this invention relates to an apparatus and method for making coated containers, preferably comprising polyethylene terephthalate, from coated preforms. In preferred embodiments, the apparatus and method permit the coated container or preform to be made in an energy-efficient manner that reduces the danger of coating damage and thus increases the efficacy of the final container.
1 . A container comprising:
a substrate layer and a coating layer, the coating layer having at least one layer comprising an acid salt of a thermoplastic epoxy resin coating material disposed on at least a portion of said substrate layer.
2 . The container of claim 1 , wherein the acid salt is a reaction product of a thermoplastic epoxy resin and one or more of phosphoric acid, lactic acid, malic acid, citric acid, acetic acid, or glycolic acid.
3 . The container of claim 1 , wherein the article exhibits substantially no blushing or whitening when exposed to water, wherein the exposure to water occurs for about 24 hours and with the water at a temperature at about 0° C. to about 25° C.
4 . The container of claim 1 , wherein the substrate layer comprises a thermoplastic material selected from the group consisting of polyester, polypropylene, polyethylene, polycarbonate, polyamides and acrylics.
5 . The container of claim 1 , wherein the substrate layer comprises polyethylene terephthalate.
6 . The container of claim 1 , further comprising one or more layers of thermoplastic resin coating material disposed on said substrate layer.
7 . The container of claim 1 , further comprising one or more layers of thermoplastic resin coating material disposed on said coating layer.
8 . The container of claim 1 , further comprising an at least partially crosslinked outer layer.
9 . The container of claim 1 , further comprising a top coat layer of a polyester material.
10 . The container of claim 1 , further comprising a top coat layer of an acrylic.
11 . The container of claim 10 , wherein the acrylic is partially or completed crosslinked.
12 . The container of claim 1 , wherein the article is a preform or bottle having a body portion and a neck portion, and said coating layer is disposed substantially only on the body portion of the preform or bottle.
13 . The container of claim 1 , wherein the coating layer is applied by dip, spray, or flow coating.
14 . A container comprising:
a substrate having at least one layer comprising a thermoplastic epoxy coating material obtained from curing/drying of a solution/dispersion of a thermoplastic epoxy polymer and an acid, the at least one layer disposed on at least a portion of the substrate to form the article.
15 . The container of claim 14 , wherein the acid is one or more of phosphoric acid, lactic acid, malic acid, citric acid, acetic acid, or glycolic acid.
16 . The container of claim 14 , wherein the article exhibits substantially no blushing or whitening when exposed to water for about 24 hours and with the water at a temperature of about 0° C. to about 25° C.
17 . The container of claim 14 , wherein the substrate comprises a thermoplastic material selected from the group consisting of polyester, polypropylene, polyethylene, polycarbonate, polyamides and acrylics.
18 . The container of claim 14 , wherein the substrate comprises polyethylene terephthalate.
19 . The container of claim 14 , further comprising one or more layers of thermoplastic resin coating material disposed on said substrate.
20 . The container of claim 14 , wherein the article is a preform or bottle having a body portion and a neck portion, and said coating layer is disposed substantially only on the body portion of the preform or bottle.
21 . The container of claim 14 , wherein the at least one layer is applied by dip, spray, or flow coating.
22 . A container comprising:
a first substrate layer comprising a thermoplastic material selected from the group consisting of polyesters, polyolefins, polycarbonates, polyamides and acrylics;
a second coating layer comprising a thermoplastic epoxy coating material, the thermoplastic epoxy coating material being a mixing product of a thermoplastic epoxy polymer and an organic acid or phosphoric acid; and
wherein the second coating layer has a mass of about 0.05 g to about 0.55 g.
23 . The container of claim 22 , wherein the second coating layer has a mass of about 0.06 g to about 0.2 g.
24 . The container of claim 22 , wherein the mixing product is a reaction product of a thermoplastic epoxy resin and one or more of phosphoric acid, lactic acid, malic acid, citric acid, acetic acid, or glycolic acid.
25 . The container of claim 22 , wherein the second coating layer is disposed on at least a portion of the first substrate layer.
26 . The container of claim 22 , wherein one or more layers of thermoplastic resin coating material are disposed between the first substrate layer and the second coating layer.
27 . The container of claim 22 , wherein the article comprises one or more layers having one or more characteristics selected from the group consisting of gas-barrier protection, UV protection, scuff resistance, blush resistance, and chemical resistance.
28 . The container of claim 22 , wherein the article comprises amorphous or semi crystalline polyethylene terephthalate.
29 . The container of claim 22 , wherein the second coating layer is applied by dip, spray, or flow coating.
30 . A container comprising an acid salt of a thermoplastic epoxy resin.
31 . The container of claim 30 , wherein the acid salt is a reaction product of the thermoplastic epoxy resin and one or more of phosphoric acid, lactic acid, malic acid, citric acid, acetic acid, or glycolic acid.
32 . The container of claim 30 , wherein the container comprises about 0.05 g to about 0.55 g of the acid salt.
33 . The container of claim 30 , wherein the container comprises about 0.06 g to about 0.2 g of the acid salt.