Method for preparing a high temperature polymer coating

1. A method for coating a substrate, the method comprising:

impacting a substrate with a plurality of particles such that the particles adhere to the substrate, the particles comprising a polyphenyl polymer;

bonding the particles to the substrate to form an overlayer; and

crosslinking the particles in the overlayer to coat the substrate with a crosslinked polymer coating;

wherein the particles further comprise a crosslinker, the crosslinker comprising one or more of the following: sulfur; a peroxy compound; a metal peroxide; or a metal oxide; wherein the metal oxide comprises one or more of the following: zinc oxide;

magnesium oxide; or titanium dioxide.

2. The method of claim 1 , further comprising heating the substrate to a temperature effective to crosslink the polyphenyl polymer prior to forming the crosslinked polymer coating.

3. The method of claim 1 , further comprising post-curing the crosslinked polymer coating subsequent to forming the crosslinked polymer coating.

4. The method of claim 3 , wherein crosslinking and post-curing are independently conducted for a time from 0.5 minutes to 60 minutes.

5. The method of claim 1 , further comprising crosslinking the polyphenyl polymer with the crosslinker prior to impacting the substrate with the particles.

6. The method of claim 5 , wherein the crosslinker is present in an amount from 0.5 wt % to 10 wt %, based on a weight of the polyphenyl polymer.

7. The method of claim 1 , further comprising heating the particles prior to impacting the substrate, wherein heating is to a temperature greater than a melting temperature of the polyphenyl polymer and less than a decomposition temperature of the polyphenyl polymer.

8. The method of claim 7 , wherein heating the particles is conducted at a temperature effective to crosslink the polymer.

9. The method of claim 1 , further comprising accelerating the particles by an electric field prior to impacting the substrate with the particles.

10. The method of claim 1 , further comprising rotating the substrate to induce impacting the substrate with the particles.

11. The method of claim 1 , wherein the polyphenyl polymer comprises polyphenylene sulfide, polyphenylsulfone, self-reinforced polyphenylene, polyaryletherketone, a crosslinked product thereof, or a combination thereof.

12. The method of claim 11 , wherein the self-reinforced polyphenylene comprises a repeat unit which comprises benzoyl-1,4-phenylene, 1,3-phenylene, phenoxybenzoyl-1,4-phenylene, or a combination thereof.

13. The method of claim 1 , wherein the particles further comprise an additive which comprises a nanofiller, silica, glass fiber, carbon fiber, carbon black, pigment, dye, stabilizer, flow improver, plasticizer, or a combination thereof.

14. The method of claim 1 , wherein the substrate comprises a metal, polymer, ceramic, glass, paper, wood, or a combination thereof.

15. The method of claim 1 , wherein the crosslinked polymer coating has a thickness from 10 μm to 3000 μm.

16. The method of claim 1 , wherein the crosslinked polymer coating is impervious to a fluid which comprises an acid, base, gas, completion fluid, oil, polar solvent, nonpolar solvent, or a combination thereof.

17. The method of claim 1 , wherein the crosslinked polymer coating has a decomposition temperature greater than 400° C.

18. The method of claim 1 , wherein the crosslinker comprises sulfur and a metal peroxide.

19. The method of claim 18 , wherein the metal peroxide comprises one or more of the following: magnesium peroxide; calcium peroxide; or zinc peroxide.