High-performance textured coating

Abstract

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.

We claim: 
     
         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.