Application of Combinatorial Chemistry Methods to The Development of Organic Coatings
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Application of Combinatorial Chemistry Methods to The Development of Organic Coatings Bret Chisholm, Radislav Potyrailo, James Cawse, Michael Brennan, and Ron Shaffer GE Corporate Research and Development One Research Circle Niskayuna, NY 12309 Abstract A combinatorial method for the development of organic clear coatings for plastic substrates has been developed. The combinatorial process or combinatorial factory has a throughput on the order of 100 – 200 coatings per day and possesses all of the aspects of a conventional combinatorial process such as automated sample preparation, miniaturized samples configured in an array format, high throughput screening of the properties of interest, and computer software developed for data management, storage, and analysis. The combinatorial factory greatly enhanced the rate of organic clear coat development. Introduction Combinatorial chemistry has proven to be a valuable tool for the development of new molecules and materials.1 Due to the initial success of the combinatorial approach within the pharmaceutical industry, it was quickly applied to the development of new materials such as catalysts, phosphors, and scintillators.2 In the past few years, considerable effort has been made to apply the combinatorial methodology to the development of organic coatings.3-15 Due to the complexity of most organic coating systems, successful application of combinatorial methods greatly accelerates the rate of coating development. The combinatorial process described in this document and illustrated schematically in Figure 1 was designed to develop new clear coatings for plastic substrates. The function of the clear coats is to protect the plastic substrate from mechanical and chemical damage. Thus, the coatings must be abrasion resistant, chemically resistant, and weatherable. In addition, the coatings must display good adhesion to the plastic substrate. Plan
Analyze
Formulate
Test
Apply
Cure
Figure 1. Schematic of the combinatorial process applied to organic coatings.
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Results and Discussion The combinatorial process produced includes automated methods for preparing arrays of liquid coatings and depositing aliquots of the coatings on the plastic substrate, a novel method for forming uniform coating films on the substrate, curing of coatings in parallel, and evaluating the properties of the coatings using novel, high quality measurement techniques. With regard to the preparation of liquid coatings, a simple method was adopted which involves the utilization of a commercially available liquid handling robot. Stock solutions of the raw materials used to generate the coatings of interest are prepared manually and these solutions placed on the deck of the liquid handling robot. The robot is programmed to transfer aliquots of the stock solutions to an array of small glass vials to produce the array of liquid coatings of interest. In addition to combining components of the coatings, the robot mixes each coating solution by repeatedly aspirating and dispensing a portion of
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