HIGH-PERFORMANCE TEXTURED COATING
A coated article is described, including a substrate with a coating composition applied thereon to provide a coated article with a textured surface. In one aspect, the coated article is a steel rebar used to reinforce concrete. The textured surface provides optimal surface roughness and demonstrates superior pullout strength relative to an uncoated standard.
1 . A coated article, comprising:
a structural insert member; and
at least a powder coating composition applied thereon, the composition comprising:
a binder resin component; and
an agglomerate comprising
a texturizing additive; and
at least one functionalized filler,
wherein the coated article has a textured surface.
2 . The coated article of claim 1 , comprising:
a powder coating composition applied on the structural insert member, the powder coating composition comprising:
about 40 to 70% by weight of a binder resin component;
about 0.5 to 5% by weight of a texturizing additive; and
about 0.5 to 20% by weight of a functionalized filler,
wherein the powder coating, when applied to a test bar, demonstrates an increase in pullout strength of at least 10% relative to an uncoated test bar.
3 . A method of coating a structural insert member, comprising:
providing a structural insert member;
heating the structural insert member to a temperature of about 150° C. to 300° C.;
applying a powder coating composition to the heated insert member, wherein the powder coating composition comprising:
a binder resin component;
a texturizing additive; and
a functionalized filler; and
curing the applied powder coating composition.
4 . The article of claim 1 , wherein the textured surface is produced by including a texturizing additive in the powder coating composition.
5 . The article of claim 1 , wherein the textured surface is produced by forming a non-continuous cured film from the powder coating composition applied on the structural insert member.
6 . The method of claim 3 , wherein the binder resin component is selected from epoxy, polyester, polyurethane, polyamide, acrylic, polyvinyl chloride, nylon, fluoropolymer, silicone, and mixtures or combinations thereof.
7 . The method of claim 3 , wherein the binder resin component is an epoxy-functional resin.
8 . The method of claim 3 , wherein the binder resin component is fusion-bonded epoxy resin.
9 . The article of claim 1 , wherein the structural insert member is an article made of material selected from metal, glass, polymeric materials, ceramic, and mixtures or combinations thereof.
10 . The article of claim 1 , wherein the structural insert member is an article selected from rebar, dowel, fiber, mesh, plate, and combinations thereof.
11 . The article of claim 1 , wherein the structural insert member is made of a first material and incorporated into a second material to reinforce the second material.
12 . The article of claim 11 , wherein the second material is an aggregate material selected from concrete, cement, asphalt, soil, and mixtures or combinations thereof.
13 . The article of claim 1 , wherein the structural insert member is steel rebar used to reinforce concrete.
14 . The method of claim 3 , wherein the texturizing additive is selected from polytetrafluoroethylene (PTFE), polyvinylidine fluoride (PVDF), polyphenylene sulfide (PPS), ultra-high molecular weight polyethylene (UHMWPE), perfluoroalkoxyalkane (PFA); tetrafluoroethylene perfluoropropylene (FEP), polyether ether ketone (PEEK), high density polyethylene (HDPE), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), para-aramid fibers (KEVLAR), and mixtures or combinations thereof.
15 . The method of claim 3 , wherein the texturizing additive is PTFE.
16 . The article of claim 1 , wherein the texturizing additive is present in an amount of about 0.05 to 5 wt %, based on the total weight of the coating composition.
17 . The article of claim 1 , wherein the texturizing additive has median particle size (D50) of about 75 to 300 micron prior to extrusion with the binder resin component of the powder coating composition.
18 . The article of claim 1 , wherein the functional filler and texturizing additive combine to form an agglomerate.
19 . The article of claim 1 , wherein the pullout strength of the coating composition, when applied to a structural insert member and tested by ASTM A944-10 is at least 20% greater than an uncoated structural insert member.
20 . The article of claim 1 , wherein the pullout strength of the coating composition, when applied to a structural insert member and tested by ASTM A944-10 is at least about 30% greater than an uncoated structural insert member.