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  Dry film lubricantUSPTO Application #: 20060003901Title: Dry film lubricant Abstract: The present invention relates to compositions and methods employing a first copolymer that is an acrylic copolymer or styrene/acrylic copolymer having a weight average molecular weight (Mw) of about 8,000 to about 14,000; a second copolymer that is an acrylic copolymer having a Mw of about 90,000 to about 130,000; a wax emulsion or dispersion, and a particulate additive. Optionally, the composition further comprises at least one of a rheological additive, ammonium hydroxide or a defoaming compound. (end of abstract)
Agent: Woodcock Washburn LLP - Philadelphia, PA, US Inventor: Jasdeep Sohi USPTO Applicaton #: 20060003901 - Class: 508139000 (USPTO) Related Patent Categories: Solid Anti-friction Devices, Materials Therefor, Lubricant Or Separant Compositions For Moving Solid Surfaces, And Miscellaneous Mineral Oil Compositions, Lubricants Or Separants For Moving Solid Surfaces And Miscellaneous Mineral Oil Compositions (e.g., Water Containing, Etc.), Silicon Dioxide, Silicic Acid, Orthosilicate, Or Metasilicate, Including Surface-treated (e.g., Clays, Onium Clays, Estersils, Etc.), With Elemental Sulfur, Elemental Metal, Or Alloy As Additional Component Or Surface-treating Agent The Patent Description & Claims data below is from USPTO Patent Application 20060003901. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application claims benefit to U.S. Provisional Application Ser. No. 60/585,058, filed Jul. 2, 2004, which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION [0002] The invention relates generally to dry film lubricants, coatings, coated substrates, and methods related thereto. BACKGROUND OF THE INVENTION [0003] Metal plates or other like materials are often used to form parts, for various uses, including automotive, appliance, and general industrial uses, via stamping. Before stamping, the plates, or more broadly, substrates, are typically stored. During storage, the substrates may be exposed to conditions that can cause corrosion and/or blocking of the parts. Blocking is a surface phenomenon where two substrates adhere to each other, usually due to heat or pressure. [0004] To prevent corrosion and blocking, it is known by those of skill in the art to apply a coating to the substrate prior to stamping. For example, mill oils, pre-lubes, drawing compounds, and dry film lubricants are valuable for preventing corrosion or reducing blocking between substrates, such as stainless steel, galvanized steel, including hot dipped galvanized steel and electro galvanized steel, galvanneal alloy, GALVALUME.RTM. alloy (55% aluminum, 43.5% zinc, 1.5% silicon alloy steel), cold rolled steel, hot rolled steel, or aluminum. [0005] However, while it is a goal to minimize corrosion and blocking between substrates while providing a uniform coating, the coatings must be readily removable before or during subsequent steps, such as stamping. [0006] U.S. Pat. No. 6,187,849 discloses a temporary lubricant coating which has a wax, an acid-neutralized polymer that is derived from polymerization of a ethylenically unsaturated monomer having an acid functionality and at least one different polymerizable, ethylenically unsaturated monomer, and certain amines. [0007] Existing approaches to temporary lubricants have deficiencies. Some compositions provide adequate corrosion protection but can cause blocking. Other compositions provide a smooth coating and good scratch resistance but still allow corrosion. Thus, there is a need in the art for a dry film lubricant with improved anti-blocking and anti-corrosion properties, but which is still readily removable, such as by application of an alkaline cleaner. SUMMARY OF THE INVENTION [0008] The instant invention provides a product that provides good anti-blocking and good anti-corrosion properties while being able to be removed with an alkaline cleaner. In one embodiment, the present invention is directed to compositions and methods employing an acrylic copolymer or styrene/acrylic copolymer having a weight average molecular weight (Mw) of about 8,000 to about 14,000, a thermoplastic acrylic copolymer having a Mw of about 90,000 to about 130,000, water, a wax emulsion or wax dispersion, and a particulate additive. In some embodiments, a rheological additive can be used. Optionally, the composition further comprises at least one of ammonium hydroxide or a defoaming compound. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS [0009] According to one embodiment, the present invention provides a composition, comprising a first copolymer that is an acrylic copolymer or styrene/acrylic copolymer having a weight average molecular weight (Mw) of about 8,000 to about 14,000, a second copolymer that is an acrylic copolymer having a Mw of about 90,000 to about 130,000, water, a wax emulsion or dispersion, and a particulate additive. [0010] In one embodiment, the first copolymer has an acid number (AN) of at least 110. In some embodiments, the acid number is between about 160 and about 220. In one embodiment, AN is about 200. [0011] In certain embodiments, the second copolymer has an acid number of about 90 to about 130. In one preferred embodiment, the acid number is about 116. [0012] It is understood that throughout this application, wherever a range is cited, it includes all combinations and subcombinations of ranges and specific values therein. The present invention also contemplates that acid numbers below or above the ranges cited for the first and second copolymers may be useful, provided that they produce a composition that remains relatively easy to remove with alkaline cleaner and has suitable anti-corrosion properties. [0013] In some embodiments, the first copolymer has a glass transition temperature (Tg) of about 60 to about 80.degree. C. In one embodiment, the Tg of the first copolymer is about 70.degree. C. In certain embodiments, the Tg of the second copolymer is about 35 to about 70.degree. C. In one preferred embodiment the Tg of the second copolymer is about 47.degree. C. [0014] In certain of these embodiments, the first copolymer is a styrene/acrylic copolymer. In some embodiments, the first copolymer has a low Volatile Organic Content (VOC). In one embodiment of the invention, the styrene/acrylic copolymer is a solid with a molecular weight of about 11,000 and an AN of about 200. [0015] Styrene/acrylic polymer compositions are commercially available. Certain of these are copolymers that are commercially available from Noveon, Inc., Cleveland, Ohio, USA, under the trade name "CARBOSET.RTM. GA." One such product is CARBOSET.RTM. GA-2299 copolymer which is a styrenic/acrylic copolymer having the following characteristics ascertained from publicly available sources: Total Solids: 99%; Tg: 70.degree. C.; AN: 200; Molecular Weight (MW): 11000; and VOC: <0.1%. [0016] In some embodiments of the invention, the styrene/acrylic copolymer is a colloidal dispersion. In certain embodiments, the styrene/acrylic copolymer colloidal dispersion has total solids of about 22% to about 35%. Preferably, the total solids are about 27.5% to about 30%. Some styrene/acrylic copolymer colloidal dispersions have a Brookfield viscosity of about 1000 cps to about 4000 cps. Certain styrene/acrylic copolymer colloidal dispersions are in ammonia water (ammonium hydroxide). In some embodiments, the styrene/acrylic copolymer colloidal dispersion has a pH of about 8.4 to about 9.2. [0017] In one embodiment, the styrene/acrylic copolymer colloidal dispersion is present in a range from about 2 to about 30 percent by weight of the composition. In other embodiments, the styrene/acrylic copolymer colloidal dispersion is preferably present in an amount of about 10 to about 23 percent by weight of the composition. In one preferred embodiment, the styrene/acrylic copolymer colloidal dispersion is about 16.7 percent by weight of the composition. [0018] In one embodiment, the styrene/acrylic copolymer colloidal dispersion is a product commercially available from Noveon, Inc., Cleveland, Ohio, USA, under the trade name "CARBOSET.RTM. GA 2300." CARBOSET.RTM. GA-2300 is a high solids solution of a low molecular weight styrene/acrylic copolymer (CARBOSET.RTM. GA-2299) and ammonia water. CARBOSET.RTM. GA-2300 styrene/acrylic copolymer colloidal dispersion has the following characteristics ascertained from publicly available sources: Weight per Gallon: 8.9 lbs.; AN: about 190; VOC: <0.1%, along with excellent freeze/thaw stability, heat stability, and mechanical stability. [0019] The second copolymer comprises an acrylic monomer and at least one additional monomer. Suitable acrylic monomers include methacrylic acid, acrylic acid, and their ester analogs. Suitable esters include C.sub.1-C.sub.12 alkyl esters. In some embodiments, the methyl, ethyl, butyl, or 2-ethylhexyl esters are preferred. Continue reading... Full patent description for Dry film lubricant Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Dry film lubricant patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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