Highly scratch-resistant coatings having good weathering and crack resistance

Abstract

Disclosed is an at least partly crosslinked coating (K) composed of a near-surface coating zone (K1) and a volume coating zone (K2), the coating obtained from a composition comprising at least two different crosslinkable components (D1) and (D2), at least part of component (D) having one or more surface-active structural units, wherein (i) the coating in zone (K1) and in zone (K2) is at least partly crosslinked, and (ii) the crosslinking density of the coating in zone (K1) is higher than the crosslinking density of the coating in zone (K2). Also disclosed are coatings (K) wherein the concentration of component (D1) in the near-surface coating zone (K1) is higher than in the volume coating zone (K2), and the micropentration hardness and/or the dry scratch resistance of the coating (K) is higher than that of an at least partly crosslinked coating (K′) obtained from a composition with no crosslinkable component (D1).

What is claimed is: 
     
         1 . An at least partly crosslinked coating (K) comprising
 1. a near-surface coating zone (K1) and   2. a volume coating zone (K2),   the coating (K) being obtained from a coating composition (B) comprising at least two different crosslinkable components (D1) and (D2), at least part of component (D1) comprising one or more surface-active structural units (O);   wherein   (i) the coating both in zone (K1) and in zone (K2) is at least partly crosslinked, and   (ii) the crosslinking density of the coating in zone (K1) is higher than the crosslinking density of the coating in zone (K2).   
     
     
         2 . The coating of  claim 1 , wherein the at least partly crosslinked coating (K) exhibits a chemical disuniformity in the form of a gradient perpendicular to the surface (KO). 
     
     
         3 . The coating of  claim 2 , wherein the at least partly crosslinked coating (K) exhibits a chemical disuniformity in the form of a gradient of silicon atoms of type (Si 1) and/or of type (Si 2) 
       
         
           
           
               
               
           
         
         perpendicular to the surface (KO), where 
         R S1 =organic radical, preferably linear and/or branched alkylene or cycloalkylene radical having 1 to 20 carbon atoms, 
         R″=alkyl, cycloalkyl, aryl or aralkyl, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, with Ra=alkyl, cycloalkyl, aryl or aralkyl. 
       
     
     
         4 . The coating of  claim 2 , wherein the gradient in the chemical disuniformity leads to a gradient in the physical properties perpendicular to the surface. 
     
     
         5 . The coating of  claim 2 , wherein the gradient has a half-value depth <1 μm. 
     
     
         6 . An at least partly crosslinked coating (K) comprising
 1. a near-surface coating zone (K1) and   2. a volume coating zone (K2),   wherein   (I) the coating (K) is obtained from a coating composition (B) comprising at least two different crosslinkable components (D1) and (D2), at least part of component (D1) having one or more surface-active structural units (O), and   (II) the concentration of component (D1) in the near-surface coating zone (K1) being higher than in the volume coating zone (K2),   wherein the micropenetration hardness and/or the dry scratch resistance of the at least partly crosslinked coating (K) is higher than the micropenetration hardness and/or the dry scratch resistance of an at least partly crosslinked coating (K) obtainable from a coating composition (B′) which contains no crosslinkable component (D1).   
     
     
         7 . The coating of  claim 1 , wherein the film thickness of the near-surface coating zone (K1) is between 1 nm and 500 nm, and/or the ratio of the dry film thickness of the near-surface coating zone (K1) to the dry film thickness of the volume coating zone (K2) is less than 0.1. 
     
     
         8 . The coating of  claim 1 , wherein the crosslinkable component (D1) has silane groups as crosslinkable groups. 
     
     
         9 . The coating of  claim 1 , wherein the surface-active structural elements (O) comprise at least one member selected from the group consisting of hydrocarbon radicals and their derivatives, fluorinated hydrocarbon radicals, fatty acid radicals, the radicals of fatty acid derivatives, unsubstituted siloxane radicals, and substituted siloxane radicals. 
     
     
         10 . The coating of  claim 1 , wherein the crosslinkable component (D1) has been prepared by modifying at least part of a precursor of component (D1) and/or at least part of component (D1) with one or more surface-active compounds (OV). 
     
     
         11 . The coating of  claim 10 , wherein
 (i) the surface-active compound (OV) comprises at least one member selected from the group consisting of hydroxyl, epoxy, isocyanate, carbamate, carboxyl, anhydride, amine, thiol, ethylenically unsaturated double bond, and combinations thereof, and/or   (ii) the crosslinkable component (D1) and/or a precursor of the crosslinkable component (D1) comprises at least one complementary functional group selected from the group consisting of hydroxyl, epoxy, isocyanate, carbamate, carboxyl, anhydride, amine, thiol, ethylenically unsaturated double bonds, and combinations thereof.   
     
     
         12 . The coating of  claim 11 , wherein the compound (OV) is a siloxane of the formula (I) 
       
         
           
           
               
               
           
         
         where 
         R 1  to R 6  are identical or different radicals and 
         R 1 =alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, or fluorine-substituted alkyl, cycloalkyl, aryl or aralkyl radicals, 
         R 2 =hydroxyl, alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, 
         R 3  and R 6 =hydrogen, alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, or fluorine-substituted alkyl, cycloalkyl, aryl or aralkyl radicals, 
         R 4  and R 5 =hydrogen, hydroxyl, alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, 
         at least one of the radicals R 2 , R 4 , and R 5  additionally carrying a functional group which is reactive toward the complementary functional groups of component (D1), 
         and 
         m 1 =1 to 80, and 
         m 2 =0 to 80. 
       
     
     
         13 . The coating of  claim 11 , wherein the compound (OV) is a siloxane of the formula (III) 
       
         
           
           
               
               
           
         
         where 
         R 1 =alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, or fluorine-substituted alkyl, cycloalkyl, aryl or aralkyl radicals, and R 4 =hydrogen, hydroxyl, alkyl, cycloalkyl, aryl or aralkyl radical, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, and 
         m=1 to 80. 
       
     
     
         14 . The coating of  claim 1 , wherein the crosslinkable component (D1) comprises at least one reactive radical of the formula (VI)
   —NR′″—C(O)—N-(L-SiR″ x (OR′)3 −x ) n (L′-SiR″ y (OR′)3 −y ) m   (VI)
   where   R′″=hydrogen, alkyl, cycloalkyl, aryl or aralkyl, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups, with Ra=alkyl, cycloalkyl, aryl or aralkyl,   R′=hydrogen, alkyl or cycloalkyl, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups,   L, L′=linear and/or branched alkylene or cycloalkylene radical having 1 to 20 carbon atoms,   R″=alkyl, cycloalkyl, aryl or aralkyl, the carbon chain possibly being interrupted by nonadjacent oxygen, sulfur or NRa groups,   n=0 to 2,   m=0 to 2,   m+n=2, and   x, y=0 to 2.   
     
     
         15 . The coating of  claim 1 , wherein the coating composition (B) contains component (D1) in an amount of 0.1 to 35% by weight, and/or the catalyst (C) in an amount of 0.1 to 15% by weight, and/or component (D2) in an amount of 50 to 99.8% by weight, based in each case on the nonvolatiles of the coating composition (B). 
     
     
         16 . The coating of  claim 1 , wherein the crosslinkable component (D2) is composed of one or more binders (BM). 
     
     
         17 . The coating of  claim 16 , wherein the binders (BM) are selected from the group consisting of oligomeric and/or polymeric compounds which have acrylate groups, methacrylate groups, hydroxyl groups, carbamate groups, epoxy groups, isocyanate groups, and carboxyl groups, preferably hydroxyl groups and/or carbamate groups. 
     
     
         18 . A multicoat effect and/or color paint system comprising at least one pigmented coating and, disposed thereon, a transparent coating, wherein the transparent coating is the coating of  claim 1 . 
     
     
         19 . A process for producing the multicoat paint system of  claim 18 , wherein a substrate is coated with at least one pigmented coating composition and at least part of the resulting pigmented coating is coated with at least one transparent coating composition (B) of  claim 1 , and curing is carried out. 
     
     
         20 . A method of controlling the properties of at least partly crosslinked coatings (K), wherein the coating (K) is composed of a near-surface coating zone (K1) and a volume coating zone (K2), and the coating (K) is produced from a coating composition (B) comprising at least two different crosslinkable components (D1) and (D2), at least part of component (D1) comprising one or more surface-active structural units (O);
 wherein   (i) the crosslinking density of the network (N1) formed from component (D1) is higher than the crosslinking density of the network (N2) formed from component (D2), and   (ii) the properties of the coating are controlled by way of the ratio of the crosslinking density of the network (N1) formed from component (D1) to the crosslinking density of the network (N2) formed from component (D2).   
     
     
         21 . The method of  claim 20 , wherein the near-surface coating zone (K1) is formed substantially by the at least partly crosslinked component (D1) and the volume coating zone (K2) is formed substantially by the at least partly crosslinked component (D2). 
     
     
         22 . An at least partly crosslinked coating (K) composed of
 1. a near-surface coating zone (K1) and   2. a volume coating zone (K2),   the coating (K) being obtainable from a coating composition (B) which comprises at least two different crosslinkable components (D1) and (D2), at least part of component (D1) having one or more surface-active structural units (O);   wherein   (i) the coating both in zone (K1) and in zone (K2) is at least partly crosslinked, and   (ii) the crosslinking density of the coating in zone (K1) is higher than the crosslinking density of the coating in zone (K2), and   wherein the crosslinkable component (D1) comprises at least one adduct (A) with silane functionality which are prepared by an addition reaction of   (a) at least one silane (S1) which has at least one functional group which is reactive with the complementary functional groups of the surface active compound (OV),   and   (b) at least one surface active compound (OV) which has at least one complementary functional group and at least one surface active radical.   
     
     
         23 . An at least partly crosslinked coating (K) composed of
 1. a near-surface coating zone (K1) and   2. a volume coating zone (K2),   the coating (K) being obtainable from a coating composition (B) which comprises at least two different crosslinkable components (D1) and (D2), at least part of component (D1) having one or more surface-active structural units (O);   wherein   (i) the coating both in zone (K1) and in zone (K2) is at least partly crosslinked, and   (ii) the crosslinking density of the coating in zone (K1) is higher than the crosslinking density of the coating in zone (K2), and   wherein the coating composition (B) comprises at least one amine-blocked phosphoric acid ester as a catalyst (C).   
     
     
         24 . An at least partly crosslinked coating (K) composed of
 1. a near-surface coating zone (K1) and   2. a volume coating zone (K2),   the coating (K) being obtainable from a coating composition (B) which comprises at least two different crosslinkable components (D1) and (D2), at least part of component (D1) having one or more surface-active structural units (O);   wherein   (i) the coating both in zone (K1) and in zone (K2) is at least partly crosslinked, and   (ii) the crosslinking density of the coating in zone (K1) is higher than the crosslinking density of the coating in zone (K2), and   wherein the at least partially crosslinkinked coating has a residual gloss after a Crockmeter test (per EN ISO 105-X 12; 9 um paper grade) of at least 55%.