Fluorinated polymer based coatings and methods for applying the same

Abstract

Coatings includes about 60 weight percent to about 90 weight percent of one or more fluorinated polymers, about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments, about 1 weight percent to about 4 weight percent of one or more thixotropic agents, and about 1 weight percent to about 4 weight percent of one or more porosity reducing filler materials.

What is claimed is: 
     
         1 . A coating comprising:
 about 60 weight percent to about 90 weight percent of one or more fluorinated polymers;   about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers;   about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments;   about 1 weight percent to about 4 weight percent of one or more thixotropic agents; and, about 1 weight percent to about 4 weight percent of one or more porosity reducing filler materials.   
     
     
         2 . The coating of  claim 1 , wherein the one or more fluorinated polymers are selected from a group consisting of polytetrafluoroethylenes, perfluoroalkoxy polymers, ethylene tetrafluoroethylenes, polyvinylidene fluorides and polyvinyl fluorides. 
     
     
         3 . The coating of  claim 1 , wherein the one or more erosion resistant fillers are selected from a group consisting of alumina, silica, boron carbide, silicon carbide, titania, tungsten carbide, aluminium nitride, boron nitride, and silicon nitride. 
     
     
         4 . The coating of  claim 1 , wherein the one or more anticorrosive pigments are selected from a group consisting of zinc dust, zinc phosphates, iron sulphide, borates, precipitated silica and titanium dioxide. 
     
     
         5 . The coating of  claim 1 , wherein the one or more thixotropic agents are selected from a group consisting of montmorillonite, mica, and silicon fumes. 
     
     
         6 . The coating of  claim 1 , wherein the one or more porosity reducing filler materials are selected from a group consisting of barium sulphate, calcium sulphate, talc, and calcium carbonate. 
     
     
         7 . The coating of  claim 1 , wherein the coating is from about 10 μm to about 60 μm thick. 
     
     
         8 . The coating of  claim 1  further comprising a plurality of layers, wherein each layer comprises about 60 weight percent to about 90 weight percent of one or more fluorinated polymers; about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers; about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments; about 1 weight percent to about 4 weight percent of one or more thixotropic agents; and, about 1 weight percent to about 4 weight percent of one or more porosity reducing filler materials. 
     
     
         9 . The coating of  claim 1 , wherein the erosion resistant fillers, anticorrosive pigments, thixotropic agents and the porosity reducing filler materials all have an average particle size less than or equal to about 50 μm and have a maximum individual particle size less than or equal to about 100 μm 
     
     
         10 . The coating of  claim 1 , wherein the coating withstands temperatures of at least 300° C. 
     
     
         11 . The coating of  claim 1 , wherein a porosity of the coating is less than or equal to about 1 percent by volume. 
     
     
         12 . The coating of  claim 1 , wherein a surface roughness of the coating is from about 5 Ra to about 20 Ra. 
     
     
         13 . The coating of  claim 1 , wherein the coating is hydrophobic and oleophobic such that it has a contact angle of from about 90 degrees to about 140 degrees. 
     
     
         14 . A coated article comprising:
 a substrate piece comprising an outer surface; and   a coating covering at least a portion of the outer surface of the substrate piece, wherein the coating comprises:
 about 60 weight percent to about 90 weight percent of one or more fluorinated polymers; 
 about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers; 
 about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments; 
 about 1 weight percent to about 4 weight percent of one or more thixotropic agents; and, 
 about 1 weight percent to about 4 weight percent of one or more porosity reducing filler materials. 
   
     
     
         15 . The coated article of  claim 14 , wherein the substrate piece comprises a compressor blade for a turbine. 
     
     
         16 . The coated article of  claim 14 , wherein the outer surface of the substrate comprises a base coat such that the coating covers at least a portion of the base coat. 
     
     
         17 . A method for coating a substrate with a coating, the method comprising:
 applying a coating onto an outer surface of the substrate, wherein the coating comprises:
 about 60 weight percent to about 90 weight percent of one or more fluorinated polymers; 
 about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers; 
 about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments; 
 about 1 weight percent to about 4 weight percent of one or more thixotropic agents; and, 
 about 1 weight percent to about 4 weight percent of one or more porosity reducing filler materials; and, 
 curing the coating on the outer surface of the substrate at a curing temperature of from about 50° C. to about 300° C. 
   
     
     
         18 . The method of  claim 17 , wherein the coating has a viscosity of from about 0.1 Pascal-second to about 0.15 Pascal-second prior to curing. 
     
     
         19 . The method of  claim 17  further comprising applying an additional layer of the coating, wherein the additional layer of the coating comprises:
 about 60 weight percent to about 90 weight percent of one or more fluorinated polymers; 
 about 1 weight percent to about 7 weight percent of one or more erosion resistant fillers; 
 about 3 weight percent to about 9 weight percent of one or more anticorrosive pigments; 
 about 1 weight percent to about 4 weight percent of one or more thixotropic agents; and, 
 about 1 weight percent to about 4 weight percent of one or more filler materials; and, 
 curing the additional layer of the coating at an additional curing temperature of from about 50° C. to about 300° C. 
 
     
     
         20 . The method of  claim 19  wherein the additional curing temperature is higher than the first curing temperature.