Use of Specially Coated Powdered Coating Materials and Coating Methods Using Such Coating Materials

Abstract

The present invention relates to the use of a particle-containing powdered coating material, wherein the surface of the particles is at least partially covered with a coating additive, in cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying. Furthermore, the present invention relates to coating methods, in particular the above-named methods, using the powdered coating material according to the invention.

1 . A process for producing a coating comprising:
 introducing a particle-containing powdered coating material in a coating method selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying, wherein the particles on the surface are at least partially covered with at least one coating additive which has a boiling point or decomposition temperature of below 500° C.   
     
     
         2 . The process according to  claim 1 , wherein the weight proportion of the at least one coating additive is at least 0.01 wt.-%, relative to the total weight of the coating material and the coating additive. 
     
     
         3 . The process according to  claim 1 , wherein the weight proportion of the at least one coating additive at most 80 wt.-%, relative to the total weight of the coating material and the coating additive. 
     
     
         4 . The process according to  claim 1 , wherein the particles comprise metal particles, and the metal is selected from the group which consists of silver, gold, platinum, palladium, vanadium, chromium, manganese, cobalt, germanium, antimony, aluminum, zinc, tin, iron, copper, nickel, titanium, silicon, alloys and mixtures thereof. 
     
     
         5 . The process according to  claim 1 , wherein the carbon content of the powdered coating material is from 0.01 wt.-% to 15 wt.-%, in each case relative to the total weight of the coating material and the coating additive. 
     
     
         6 . The process according to  claim 1 , wherein the compounds used as coating additive has at least 6 carbon atoms. 
     
     
         7 . The process according to  claim 1 , wherein the coating method is selected from the group consisting of flame spraying and non-thermal plasma spraying. 
     
     
         8 . The process according to  claim 1 , wherein the at least one coating additive is selected from the group consisting of polymers, monomers, silanes, waxes, oxidized waxes, carboxylic acids, phosphonic acids, derivatives of the above-named and mixtures thereof. 
     
     
         9 . The process according to  claim 1 , wherein the at least one coating additive comprises no is free of stearic acid and/or oleic acid. 
     
     
         10 . The process according to  claim 1 , wherein the coating additive is applied mechanically to the particles. 
     
     
         11 . The process according to  claim 1 , wherein the powdered coating material has a particle-size distribution with a D 50  value from a range of from 1.5 to 53 μm. 
     
     
         12 . A method for coating a substrate selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying,
 the method comprising   (a) introducing a particle-containing powdered coating material into a medium directed onto a substrate to be coated by cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying or non-thermal plasma spraying, wherein the particles are covered with at least one coating additive which has a boiling point or decomposition temperature of below 500° C.   
     
     
         13 . The method according to  claim 12 , wherein the coating method is selected from the group consisting of flame spraying and non-thermal plasma spraying. 
     
     
         14 . The method according to  claim 12 , wherein the powdered coating material is conveyed as an aerosol. 
     
     
         15 . The method according to  claim 12 , wherein the medium directed onto the substrate is air or has been produced from air. 
     
     
         16 . The process and according to  claim 1 , wherein the coating method is non-thermal plasma spraying. 
     
     
         17 . The method according to  claim 12 , wherein the coating method is non-thermal plasma spraying. 
     
     
         18 . The process according to  claim 1 , wherein the at least one coating additive comprises polymer(s), monomer(s), silane(s), wax(es), oxidized wax(es), carboxylic acid(s), phosphonic acid(s), derivatives of carboxylic acid(s), derivatives of phosphonic acid(s), or mixtures thereof. 
     
     
         19 . The process according to  claim 1 , wherein the at least one coating additive comprises acrylate and/or methacrylate. 
     
     
         20 . The process according to  claim 1 , wherein the at least one coating additive comprises organofunctional silane. 
     
     
         21 . The process according to  claim 1 , wherein the weight proportion of carbon atoms in the powdered coating material ranges from 0.01 weight percent to 15 weight percent.