A METHOD FOR MAKING THERMOPLASTIC COATED ARTICLES USING CATAPHORETIC ELECTRODEPOSITION

Abstract: A cataphoretic electrodeposition process for forming a thermoplastic coated article using a stable emulsion comprising a thermoplastic resin, neutralization agent, cosolvent, solvent, ring opening agent, and water. The substrate and an anode are placed in the emulsion, a current is applied, and the thermoplastic coats the substrate.

Description: A METHOD FOR MAKING THERMOPLASTIC COATED ARTICLES USING CATAPHORETIC ELECTRODEPOSITION FIELD OF THE INVENTION The invention relates to thermoplastic coated articles made via a cataphoretic electrodeposition process. BRIEF DESCRIPTION OF THE RELATED ART Polyetherimide resins have been applied to substrates utilizing various techniques including anionic electrodeposition. Generically, anionic, also known as anodic, electrodeposition chemically combines resin R with ion forming group, e.g., -COOH, to form acidic resin RCOOH, which reacts bases to form macro-ions RCOO- for anodic deposition. Essentially, two electrodes inserted into an aqueous dispersion of film forming macro-ions (RCOO-) and counter ions (Y + ) cause water insoluble resin (RCOOH) to deposit on the positive electrode (anode), while water soluble YOH forms on the negative electrode (cathode). During this process metal ions freed from the substrate enhance the precipitation of the polyanion. ROOH + YOH aq. RCOO" + Y + + H2O where: ROOH is the resin YOH = external solubilizer RCOO- = film forming macro-ions Y + = counter ions and the electrode reactions are: 2H + + 20H H2O + O + 2H + + 2e- + RCOO RCOOH Me Me n+ + ne- The disadvantages of this process range from the dissolution of the metal substrate, need for corrosion protection pretreatment, discoloration caused by metal ions to sensitivity to alkali due to non-consumed carboxylic groups (-COOH). Unlike anodic electrodeposition, cathodic electrodeposition produces a product with no dissolution of the substrate, no staining, and better alkali resistance. This process employs the poly cation, typically converting tertiary amines (NR3) to cations (NR + ) using aqueous acid and electrode reaction. 2H + + 20H 2e ■ H 2 + 20H- + 2R-N + -H 2R-N + 2H 2 0 where: R 3 N = water insoluble oligomer HX = external solubilizer R 3 NH + = film forming macro-ions X = counter ions Although cathodic electrodeposition solves some of the problems of anodic electrodeposition, this process has not been commercially viable for polyetherimide compositions due to poor emulsion stability, limited storage abilities, solvent toxicity and irritating odor, and low throwing power, i.e., the ability of the coating to uniformly coat remote areas of a substrate with the desired thickness, resulting in limited consistent layer thickness. Coating processes for fiber components, particularly coatings with polyetherimide, have proven to be exceptionally difficult with complex geometries, i.e., hollow or complex substrates. Typically complex and hollow components are based upon thermoset materials, such as unsaturated polyesters and epoxy resins, having a high glass temperature because of the need for complete impregnation of the fibers in order to produce a substantially void-free composite, whereby complete impregnation is only attained with low viscosity polymers. However, the brittle nature of the thermoset systems, low damage tolerance of the components, and the limitations relating to recycling force the industry to utilize thermoplastics having difficult production requirements. Consequently, conventional processes for forming polyetherimide carbon fiber composites have been limited to two dimensional, regular surfaces. Furthermore, these processes, the melt process, dry powder process, and solution process, typically employ toxic or otherwise environmentally harmful chemicals or processes which require expensive secondary operations and long cycle times. The melt process comprises applying a molten thermoplastic material to the fibers by either using a cross-head extruder which feeds the molten material to a die directed through which the fibers pass, or the fibers pass through a molten material bath. Disadvantages of this process include fiber damage caused by the forces exerted on the fibers during processing and difficulty in impregnating in small quantities and in homogeneously impregnating tightly held fibers. The dry powder process comprises sintering very fine, low particle size thermoplastic material into the fibers. This process requires long cycle times and expensive secondary operations such as grinding procedures to obtain sufficiently small polymer particles. In the solution process, the fibers are impregnated with a low viscosity solution of the thermoplastic polymer. With this process, during composite consolidation, the volatilizing solvent, which should be recycled, can form voids. With the melt process, dry powder process, and solution process, once the fibers were coated with the thermoplastic polymer to form a pre- preg, a typical thermoforming process, such as vacuum/ pressure molding, hydroforming, stamp forming, and autoclave forming, would then be employed to convert the fabricated pre-preg into complex shapes. A precise overview of the different processes in fabricating pre- pregs and composites is given by M. Hou, Lin Ye & Yiu-Wing May in "Plastics, Rubber and Composites Processing and Applications", vol. 23, No. 5, 1995, pp. 279-293, and references in this publication. M. Hou et al. also report results on the influence of processing on properties of "Carbon Fiber Polyetherimide Composites," Journal of Reinforced Plastics and Composites, Vol. 15, p. 117, 1996. What is needed in the art is a high stability emulsion, and a cost effective, simplified, environmentally friendly process for forming complex geometry articles. SUMMARY OF THE INVENTION The present invention relates to a method for making an emulsion for a cataphoretic electrodeposition process for forming a thermoplastic coated substrate, and the process itself. This process comprises: forming a thermoplastic emulsion, comprising the steps of: dispersing a thermoplastic resin in a solvent and a substantially water insoluble cosolvent, said thermoplastic resin having at least one imide linkage; reacting a ring opening agent with said imide linkage, wherein amine groups are formed; neutralizing said amine groups with a neutralization agent to form a quaternized mixture; forming the thermoplastic emulsion by adding water to said quaternized mixture; inserting an anode into said emulsion; inserting a substrate into said emulsion, wherein said substrate preform functions as a cathode; applying an electrical current to said emulsion; forming a thermoplastic cation; and reacting said thermoplastic cation at said cathode to form a thermoplastic species which coats said substrate. The method of making the thermoplastic emulsion comprises: dispersing thermoplastic resin in a solvent and a substantially water insoluble cosolvent, said thermoplastic resin having at least one imide linkage; reacting a ring opening agent with said imide linkage to form amine groups; neutralizing said amine groups with a neutralization agent to form a quaternized mixture; and mixing water into said quaternized mixture to form the emulsion. DETAILED DESCRIPTION OF THE INVENTION In a preferred embodiment, the fibers are cataphoretically coated in a thermoplastic emulsion which comprises, thermoplastic resin having imide linkages, a ring opening agent, a neutralization agent, a solvent, a cosolvent, and water. The coating process comprises dissolving the thermoplastic in solvent, adding the cosolvent, opening imide linkages with the ring opening agent, quaternizing the amine groups with the neutralization agent, and finally adding water to form the aqueous thermoplastic emulsion. The fibers and an anode are then placed in the emulsion, a current is applied, and the thermoplastic reacts to coat the substrate. The emulsion comprises up to about 10 volume percent (vol%) thermoplastic resin, up to about 5 vol% ring opening agent, up to about 5 -o- vol% neutralization agent, up to about 20 vol% solvent, and up to about 20 vol% cosolvent, balance water, with about 3 vol% to about 8 vol% thermoplastic resin, about 0.2 vol% to about 3 vol% ring opening agent, about 0.3 vol% to about 3.5 vol% neutralization agent, about 8 vol% to about 15 vol% solvent, and about 9 vol% to about 15 vol% cosolvent, balance water preferred, and about 4 vol% to about 7 vol% thermoplastic resin, about 0.5 vol% to about 1.5 vol% ring opening agent, about 0.5 vol% to about 2 vol% neutralization agent, about 10 vol% to about 13 vol% solvent, and about 10 vol% to about 12.5 vol% cosolvent, balance water especially preferred. The thermoplastic resin can be any thermoplastic resin having an imide linkage and which is soluble in a solvent which will not adversely effect the substrate. Generally, polyimides are used, such as poly(amic acids), poly(urethane imides), poly(amide imides), polyetherimide (including, but not limited to, halogenated poly(etherimide)), poly(thioether imide sulfones), among others and combinations thereof, with polyetherimide preferred. The thermoplastic resin component of the emulsion can be a mixture of a thermoplastic resin having an imide linkage with one or more other compounds, such as epoxies, ketones, and other compounds which do not adversely effect the substrate or the coating properties, or the cataphoretic electrodeposition process. The cataphoretic electrodeposition process of the present invention will be described in relation to polyetherimide. It is understood that when thermoplastic resins, other than polyetherimide, are employed, appropriate solvents and cosolvents compatible therewith will also be employed as can readily be determined by an artisan based upon the teachings herein. Polyetherimide resins suitable for use as the polyetherimide resin component of the emulsion of the present invention are any known polyetherimide compound, including those whose preparation and properties have been describedin U.S. Patent Nos. 3,803,085 and 3,905,942, the respective disclosures of which are incorporated herein by reference. In a preferred embodiment, the polyetherimide resin component of the present invention contains from greater than 1 to 1000 or more, preferably from 10 to 1000, structural units of the formula (I): wherein the divalent T moiety bridges the 3,3', 3,4', 4,3', or 4,4' positions of the aryl rings of the respective aryl imide moieties of formula (I); T is -O- or a group of the formula -O-Z-O- ; Z includes, but is not limited to, a divalent radical of formulae (II): (ii) wherein X is a member selected from the group consisting of divalent radicals of the formulae (III): wherein y is an integer from 1 to about 5, and q is 0 or 1; R is a divalent organic radical including, but is not limited to, (a) aromatic hydrocarbon radicals having from 6 to about 20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals having from 2 to about 20 carbon atoms, (c) cycloalkylene radicals having from 3 to about 20 carbon atoms, and (d) divalent radicals of the general formula (IV): (IV) ϋ^^ , where Q includes, but is not limited to, the formulae (V): — C ,H„ ,— 9 Y 2y' -c— , — s— — o— and -S — (V) where y' is an integer from about 1 to about 5. In one embodiment, the polyetherimide resin may be a copolymer which, in addition to the etherimide units described above, further contains poly imide repeating units of the formula (VI): wherein R is as previously defined for formula (I) and M includes, but is not limited to, the formula (VII), (VIII, and (IX): Polyetherimide resins are made by known methods, such as, for example, those disclosed in U.S. Patent Nos. 3,847,867, 3,814,869, 3,850,885, 3,852,242 3,855,178 and 3,983,093, the disclosures of which are hereby incorporated herein by reference. In a preferred embodiment, the polyetherimide resin is made by the reaction of an aromatic bis(ether anhydride) of the formula (X): with an organic diamine of the formula (XI): H 2 N-R-NH 2 (Λlj wherein T and R are defined as described above in formula (I). In general the reactions can be carried out employing well-known solvents, for example, o-dichlorobenzene, m-cresol/ toluene and the like to effect interaction between the anhydride of formula (X) and the diamine of formula (XI), at temperatures from about 100°C to about 250°C. Alternatively, the polyetherimide resin can be prepared by melt polymerization of aromatic bis(ether anhydride)s and diamines accomplished by heating a mixture of the ingredients at elevated temperatures with concurrent stirring. Generally melt polymerizations employ temperatures between about 200°C and 400°C. Chain stoppers and branching agents may also be employed in the reaction. Examples of specific aromatic bis(ether anhydrides) and organic diamines are disclosed, for example, in U.S. Patent Nos. 3,972,902 and 4,455,410, which are incorporated by reference herein. Illustrative examples of aromatic bis(ether anhydride)s of formula (X) include: 2,2-bis(4-(3,4-dicarboxyphenoxy)phenyl)propane dianhydride; 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl ether dianhydride; 4,4' -bis (3,4-dicarboxyphenoxy) diphenyl sulfide dianhydride; 4,4 '-bis (3,4- dicarboxyphenoxy)benzophenone dianhydride; 4,4'-bis(3,4- dicarboxyphenoxy) diphenyl sulfone dianhydride; 2,2-bis[4-(2,3- dicarboxyphenoxy)phenyl] propane dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy) diphenyl ether dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy) diphenyl sulfide dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy)benzophenone dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy) diphenyl sulfone dianhydride; 4-(2,3- dicarboxyphenoxy)-4'-3,4-dicarboxyphenoxy)diphenyl-2,2-propane dianhydride; 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy) diphenyl ether dianhydride; 4-(2,3-dicarboxyphenoxy)- 4'-(3,4-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4-(2,3- dicarboxyphenoxy)-4'-(3,4-dicarboxyphenoxy)benzophenone dianhydride and 4-(2,3-dicarboxyphenoxy)-4'-(3,4-dicarboxyphenoxy)diphenyl sulfone dianhydride, as well as various mixtures thereof. A preferred class of aromatic bis(ether anhydride)s included by formula (X) above includes compounds wherein T is of the formula (XII): and the ether linkages, for example, are preferably in the 3,3', 3,4', 4,3', or 4,4' positions, and mixtures thereof and wherein each Y includes, but is not limited to, the formulae (XIII): (XIII). When polyetherimide/ poly imide copolymers are employed, a dianhydride, such as pyromellitic anhydride, is used in combination with the bis(ether anhydride). The bis(ether anhydride)s can be prepared by the hydrolysis, followed by dehydration, of the reaction product of a nitro substituted phenyl dinitrile with a metal salt of dihydric phenol compound in the presence of a dipolar, aprotic solvent. Suitable organic diamines of formula (XI) include, for example: m- phenylenediamine; p-phenylenediamine; 4,4'-diaminodiphenylpropane, 4,4'-diaminodiphenylmethane (commonly named 4,4'-methylenedianiline); 4,4'-diaminodiphenyl sulfide; 4,4'-diaminodiphenyl sulfone; 4,4'- diaminodiphenyl ether (commonly named 4,4'-oxydianiline); 1,5- diaminonaphthalene; 3,3-dimethylbenzidine; 3,3-dimethoxybenzidine; 2,4- bis(beta-amino-t-butyl)toluene; bis(p-beta-amino-t-butylphenyl)ether; bis(p-beta-methyl-o-aminophenyl)benzene; l,3-diamino-4- isopropylbenzene; l,2-bis(3-aminopropoxy)ethane; benzidine; m- xylylenediamine; 2,4-diaminotoluene; 2,6-diaminotoluene; bis(4- aminocyclohexyl)methane; 3-methylheptamethylenediamine; 4,4- dimethylheptamethylenediamine; 2,11-dodecanediamine; 2,2- dimethylpropylenediamine; 1,18-octamethylenediamine; 3- methoxyhexamethylenediamine; 2,5-dimethylhexamethylenediamine; 2,5- dimethylheptamethylenediamine; 3-methylheptamethylenediamine; 5- methylnonamethylenediamine; 1-4-cyclohexanediamine; 1,18- octadecanediamine; bis(3-aminopropyl)sulfide; N-methyl-bis(3- aminopropyl)amine; hexamethylenediamine; heptamethylenediamine; nonamethylenediamine; decamethylenediamine and mixtures of such diamines. Illustrative of a particularly preferred polyetherimide resin falling within the scope of formula (I) is one comprising repeating units wherein R is paraphenylene, metaphenylene, or mixtures of paraphenylene and metaphenylene and T is a group of the formula -O-Z-O- wherein Z has the formula (XIV): and wherein the divalent group (XIV) preferably bridges the 3,3' positions of the aryl rings of the respective aryl imide moieties of formula (I). In another embodiment, the polyetherimide resin may be a copolymer, a siloxane polyetherimide copolymer made by condensation of 2,2-bis(2,3-dicarboxy phenoxy phenol)propane dianhydride with metaphenylene diamine and an aminopropyl-terminated Dio polydimethylsiloxane, containing 34 weight percent (wt%) structural units derived from the polydimethylsiloxane and having a molecular weight of about 60,000 grams per mole (g/mole). Generally, useful polyetherimide resins have an intrinsic viscosity [η] greater than about 0.2 deciliters per gram, preferably of from about 0.35 to about 0.7 deciliters per gram measured in m-cresol at 25°C. In a preferred embodiment, the polyetherimide resin of the present invention has a weight average molecular weight of from about 10,000 to about 150,000 g/mole, as measured by gel permeation chromatography, using a polystyrene standard. During the formation of the emulsion, the polyetherimide resin is dissolved in a solvent capable of dissolving that particular polyetherimide resin. One example of a conventional solvent useful with the present invention is an organic solvent such as N-methylpyrolidone. Other conventional solvents capable of dissolving the polyetherimide resin can alternatively be employed. As with the solvent, the cosolvent should be a solvent for polyetherimide, be a liquid at a temperature of 0°C, should be miscible with the solvent over a large temperature range, i.e., up to about 150°C, with up to 250°C preferred, and produce a ratio of solvent/ cosolvent in the deposited coating of less than about 1. The cosolvent should be insoluble or only slightly soluble in water, preferably a solubility in water below about 5.5 grams per liter (g/1), in order to improve the emulsion stability and to obtain high throwing power properties (i.e. a mean voltage approaching zero, or a mean voltage of about zero) and to reduce water content in the deposited layers. Table 1 shows the immisibility point and coupling coefficient of the cosolvent for a 20 ml N-methylpyrrolidone- water (50/50) mixture with the coupling coefficient expressed as the amount of mixture divided by the amount of cosolvent necessary to obtain a heterogeneous mixture. Preferably the cosolvent additionally has a coupling coefficient of about 3.7 or greater in N-methylpyrolidone. Possible cosolvents, include, but are not limited to, aromatic ethers, ketones, etherketones, arylallyl ketones, arylalkylketones, aryletheralcohols, ketones, phenols, and ether containing solvents, among others, with methyl phenyl ether (anisole) and 2-methoxy phenyl acetone preferred. As can be seen from Table 2, the stability of the emulsion correlates to the water solubility of the cosolvent; higher water solubility cosolvent produces a lower stability of the emulsion or incomplete emulsification. Table 3 establishes the effects of the cosolvent on the yield of the polyetherimide in the final coating. Table 4 illustrates the effect of cosolvent on final amperage (current at the end of the coating period) and the time necessary to approach zero. In the preparation of the emulsion, the anhydride groups of the polyetherimide are opened using a ring opening agent. This ring opening agent can be any compound capable of ring opening the imide groups of the polyetherimide, with amines preferred. These amines are secondary or tertiary amines which are miscible with water, and have sufficiently high boiling points to avoid volatilization under standard preparation and storage conditions (i.e. about 1 atmosphere and 25°C), with a boiling point above about 90°C preferred and a boiling point above about 110°C especially preferred. Preferably these amines additionally have -io- hydrophilic groups, such as alcoholic groups. N-methylpiperazine is preferred, with 2-(l-piperazinyl)ethanol (HEP) especially preferred because they produce high polyetherimide yields, efficiently react with polyetherimide, and excess thereof is easily removed during curing of the polyetherimide coating. The ring opening agent reacts with the imide linkage of the polyetherimide to form functionalized amine-acid groups. The amine groups are quaternized using a neutralization agent. Neutralization agents include acids having a sufficient acid strength to attain the desired quaternization. Possible neutralization agents include, but are not limited to, mono-acids having an acid strength K a of about 10 ~5 or greater. Other acids can be employed however additional acid groups on the neutralization agent reduces the stability of the emulsion. Preferably lactic acid or glycolic acid is employed because the strong solvation of the counter ion of these acids induces an improved hydrophilic character resulting in migration to the water/ solvent/ cosolvent interphase, providing thereby a stable emulsion. Tables 5 and 6 show the improved stability yields of the emulsion and subsequently deposited coating when using lactic acid or glycolic acid as the neutralization agent. The preparation of the emulsion of the present invention is normally achieved by combining the components under conditions suitable for the formation of an emulsion. Suitable conditions include, for example, solution blending or melt mixing in single or twin screw type extruders, mixing bowl, or similar mixing devices which can apply a shear to the components. Twin screw extruders are often preferred due to their more intensive mixing capability over single screw extruders. It is often advantageous to apply a vacuum to the melt through at least one vent port in the extruder to remove volatile impurities in the composition. Essentially, under an inert atmosphere (i.e. nitrogen, argon, or another), a polyetherimide resin is preferably dissolved in a mixture of solvent and cosolvent, while heating the mixture. Although this process can be accomplished at room temperature (RT), heating the mixture is preferred in order to facilitate dissolution of the polyetherimide. After completion of dissolution, a ring opening agent is dissolved in a cosolvent and mixed into the dissolution. The dissolution is then preferably heated to a sufficient temperature, for a sufficient period of time to react the ring opening agent with the desired amount of anhydride groups of the polyetherimide to form amine groups. The desired amount of anhydride groups reacted with the ring opening agent is based upon the particular application, with reaction of substantially all of the anhydride groups possible, between about 50% and about 80% preferred, and about 60% to about 75% especially preferred. After formation of the amine groups, a mixture of cosolvent and neutralization agent is added to quaternize the amine groups. The amount of neutralization agent utilized is based upon the desired amount of amine groups to quaternize. For example, to quaternize 50 vol.% of the amine groups, a 50 vol.% aqueous solution of the neutralization agent is mixed into the dissolution. Preferably, up to about 75% or more of the amine groups are quaternized, with about 42% to about 55% especially preferred. Finally, sufficient water, preferably demineralized water, is added to attain the desired percentage of polyetherimide in aqueous emulsion. Note, it is preferred to mix the ring opening agent and neutralization agent in the cosolvent prior to addition to the dissolution, and to utilize some cosolvent in the dissolution in order to maintain and ensure emulsion stability. Solvent can be utilized in conjunction with or instead of the cosolvent so long as the solventxosolvent ratio is maintained below about 1; at ratios above about 1 the emulsion becomes unstable. Once the emulsion is prepared, the substrate can be coated with the emulsion utilizing a cataphoretic electrodeposition process. The substrate can be a sheet, sphere, cube, or fibers such as woven or non- woven fabrics, unidirectional tapes, random fiber sheets, among others having any length or diameter desired to form the particular component, or other geometry. Possible substrate materials include any material which is either conductive or has a conductive coating and which is compatible with the emulsion, including aluminum, platinum, substrates, glass, carbon, and mixtures thereof preferred, such as a metal coated glass. Possible coatings include conductive coatings such as metal coatings, including, but are not limited to, nickel, iron, steel, copper, and others, and alloys thereof. Prior to coating of the substrate, it is preferred to pretreat the substrate. Pretreatment of the substrate improves coating adhesion and therefore the mechanical properties of the final composite and facilitates homogeneous thickness of the wetted layers. For examples, for fibers and some other substrates, possible pretreatments include, but are not limited to, pretreating with good solvents for the polyetherimide, such as N- methylpyrrolidone and chloroform, among others. One possible pretreatment method comprises rinsing or soaking the fibers in the solvent. Meanwhile, a possible pretreatment for a disk, such as an aluminum disk, is phosphite, as well as other commonly used pretreatments for aluminum substrates. Coating of the substrate with the polyetherimide aqueous emulsion then comprises inserting an anode, i.e. a stainless steel or other rod, and the substrate (cathode) into the emulsion and applying a voltage. The voltage can be up to about 100 volts (V), with about 20 V to about 60 V preferred. As can be seen from Tables 7 and 8, the voltage applied directly effected the yield and the wetting/ impregnation quality. After completion of the deposition process, the coated substrate can be rinsed, such as with de-ionized water or other inert liquid, to remove any organic substances which may be present. Once rinsed, the polyetherimide can be cured at elevated temperatures. The temperature should be sufficient to cure the polyetherimide within the cure period, while not adversely effecting the substrate. Typically, the temperature is between about 250°C and 300°C for up to about 30 minutes, with about 15 minutes to about 20 minutes preferred. Example 1 The following example has been used to produce polyetherimide coated fibers of the present invention using the stable polyetherimide emulsion. In a 500 milliliter (ml) reaction flask 80 grams (g) of polyetherimide resin made by condensation of 2,2-bis(2,3-dicarboxy phenoxy phenol)propane dianhydride with metaphenylene diamine and having a weight average molecular weight of about 55 x 10 3 g/mole was dissolved in 160 ml N-methyl pyrolidinone and 20 ml cosolvent by stirring the mixture while heating to between 85°C to 95°C under a nitrogen environment. Once the polymer was dissolved 18.9 g ring opening agent and 60 ml cosolvent were added at a rate of 1 ml/min. while vigorously stirring and maintaining the temperature between 85°C to 95°C. After the addition, the mixture was heated to 110°C for two hours to form a 70% amine modified polymer solution. Next, 50 vol% of the amine groups were quaternized via stirring 19.9 g cosolvent and an equal molar amount of a 50% aqueous solution of the neutralization agent (i.e., 4.2 g of a 50% aqueous solution of glycolic acid) into 100 g of the polymer solution. A 6 wt% polyetherimide aqueous emulsion was then formed by slowly adding 259.9 g of demineralized water to the quaternized solution. Electrodeposition of the polyetherimide aqueous emulsion comprised inserting a stainless steel rod (anode) and carbon fiber fabric (cathode) into the emulsion, and applying a voltage. After deposition process, the impregnated fabric was rinsed with de-ionized water and cured at elevated temperatures, between about 250°C and 300°C for 15 to 20 minutes. Example 2 The following example has been used to produce a polyetherimide coated aluminum media disk of the present invention (having the coating on both sides of the disk) using the stable polyetherimide emulsion. A 6 wt% polyetherimide aqueous emulsion was first formed in accordance with Example 1. A 10 cm in diameter, 0.6 mm thickness disk (cathode) and two disks of similar dimensions (anode) were immersed in the emulsion, with the cathode disposed between the two anodes. (Note, it is preferable for the anode(s) to have substantially the same surface density as the cathode surface to be coated.) The anodes and cathode where connected to an electrical source and current of 4 amps (a voltage of about 30 volts) was applied across the anodes. After the deposition process, the coated disk was rinsed with de-ionized water and cured in a nitrogen atmosphere for 24 hours at room temperature 30 minutes at 160°C and 2 hours at 250°C. The resulting disk had a thickness of 4 - 7 μm, a R a (a statistical roughness standard) of 0.12 - 0.20 μm, and excellent metal adhesion (peel test), scratch resistance (ISO 1518), and tensile hardness (NEN5350). Tables 9 and 10 show improved stability and yields of the emulsion and subsequently deposited coating using HEP as the ring opening agent compared to a standard ring opening agent (N-methylpiperazine (NMP)). Table 11 shows the solvent and water content of the polyetherimide coatings. As is evident from the table, the solventxosolvent ratio is below 1, with a low water content. Low amounts of water result in improved throwing power, as the conductivity of the polyetherimide coating decreases, while a low solventxosolvent ratio indicates a preference of cosolvent deposition, thereby readily enabling the production of improved coatings since the cosolvent more readily volatilizes during cure of the coating, producing a substantially uniform, adherent coating. Table 12 shows typical mechanical properties of carbon fiber polyetherimide composites (each composite comprises 50 vol% fibers and 50 vol% polyetherimide formed by laminating 26 woven fabric layers) made by the cataphoretic electrodeposition process described in the above example. The fiber polyetherimide composite of the present invention enables simplified, inexpensive environmentally friendly production of simple and complex geometry components even fiber reinforced components, having good mechanical properties.

Claims: We claim: CLAIMS 1. A cataphoretic electrodeposition process for forming a thermoplastic coated substrate, comprising: forming a thermoplastic emulsion, comprising: dispersing a thermoplastic resin in a solvent and a substantially water insoluble cosolvent, said thermoplastic resin having at least one imide linkage; reacting a ring opening agent with said imide linkages to form amine groups; neutralizing said amine groups with a neutralization agent to form a quaternized mixture; forming the thermoplastic emulsion by adding water to said quaternized mixture; inserting an anode into said emulsion; inserting a cathode into said emulsion, wherein said cathode is the substrate; applying an electrical current to said emulsion; forming a thermoplastic cation; and reacting said thermoplastic cation at said cathode to form an insoluble thermoplastic species which coats said substrate. 2. The cataphoretic electrodeposition process of Claim 1, wherein said thermoplastic resin is a polyetherimide resin comprising structural units of the formula (I): wherein the divalent T moiety bridges the 3,3', 3,4', 4,3', or 4,4' positions of the aryl rings of the respective aryl imide moieties of formula (I); T is -O- or a group of the formula -O-Z-O- ; Z is a divalent radical selected from formulae (II): (II) wherein X is a divalent radicals of: wherein y' is an integer from 1 to about 5, and q is 0 or 1; R is a divalent organic radical selected from: (a) aromatic hydrocarbon radicals having from 6 to about 20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals having from 2 to about 20 carbon atoms, (c) cycloalkylene radicals having from 3 to about 20 carbon atoms, and (d) divalent radicals of the general formula (IV): where Q is: ? 9 • •-' -°- • - tf O- — o— or — S — where y' is an integer from about 1 to about 5. 3. The cataphoretic electrodeposition process of Claim 1, wherein said thermoplastic resin is, and wherein said polyetherimide resin comprises the reaction product formed by melt polymerization of 2,2-bis[4-(3,4- dicarboxyphenoxy)phenyl]propane dianhydride with metaphenylene diamine. 4. The cataphoretic electrodeposition process of Claim 1, wherein said solvent and said cosolvent each have a solubility in water of less than about 5.5 g/1. 5. The cataphoretic electrodeposition process of Claim 1, wherein said solvent is N-methyl pyrolidinone. 6. The cataphoretic electrodeposition process of Claim 1, wherein said cosolvent is a ketone, phenol or ether solvent. 7. The cataphoretic electrodeposition process of Claim 1, wherein said cosolvent is anisole. 8. The cataphoretic electrodeposition process of Claim 1, wherein said opening agent is amine. 9. The cataphoretic electrodeposition process of Claim 8, wherein said opening agent is a secondary or tertiary amine. 10. The cataphoretic electrodeposition process of Claim 1, wherein said opening agent is N-methylpiperazine or 2-(piperazinyl)ethanol. 11. The cataphoretic electrodeposition process of Claim 1, wherein said neutralization agent has an acid strength, K a , of greater than about 10' 5 . 12. The cataphoretic electrodeposition process of Claim 1, wherein said neutralization agent is a mono-acid. 13. The cataphoretic electrodeposition process of Claim 1, wherein said neutralization agent is lactic acid or glycolic acid. 14. The cataphoretic electrodeposition process of Claim 1, wherein said emulsion comprises up to about 10 volume percent (vol%) thermoplastic resin, up to about 5 vol% ring opening agent, up to about 5 vol% neutralization agent, up to about 20 vol% solvent, up to about 20 vol% cosolvent, balance water. 15. The cataphoretic electrodeposition process of Claim 1, wherein said emulsion comprises about 3 vol% to about 8 vol% polyetherimide resin, about 0.2 vol% to about 3 vol% ring opening agent, about 0.3 vol% to about 3.5 vol% neutralization agent, about 8 vol% to about 15 vol% solvent, about 9 vol% to about 15 vol% cosolvent, balance water. 16. The cataphoretic electrodeposition process of Claim 1, wherein said emulsion comprises about 4 vol% to about 7 vol% polyetherimide resin, about 0.5 vol% to about 1.5 vol% ring opening agent, about 0.5 vol% to about 2 vol% neutralization agent, about 10 vol% to about 13 vol% solvent, about 10 vol% to about 12.5 vol% cosolvent, balance water. 17. The cataphoretic electrodeposition process of Claim 1, wherein said thermoplastic resin is polyetherimide and said polyetherimide resin comprises a copolymer made by condensation of 2,2-bis(2,3-dicarboxy phenoxy phenol)propane dianhydride with metaphenylene diamine and an aminopropyl-terminated D 0 polydimethylsiloxane. 18. The cataphoretic electrodeposition process of Claim 1, wherein said substrate comprises sheets, disks, cubes, and fibers. 19. The cataphoretic electrodeposition process of Claim 18, wherein said fiber preform comprises woven fabrics, non- woven fabrics, unidirectional tapes, and random fiber sheets. 20. The cataphoretic electrodeposition process of Claim 1, wherein said substrate comprises glass, carbon, aluminum, platinum, or mixtures thereof. 21. The cataphoretic electrodeposition process of Claim 19, wherein said substrate has a metal coating. 22. The cataphoretic electrodeposition process of Claim 21, wherein said metal coating is nickel, iron, steel, platinum, aluminum, titanium, or an alloy thereof. 23. The cataphoretic electrodeposition process of Claim 1, further comprising reacting about 50% to about 80% of said anhydride groups with said ring opening agent. 24. The cataphoretic electrodeposition process of Claim 1, further comprising reacting about 60% to about 75% of said anhydride groups with said ring opening agent. 25. The cataphoretic electrodeposition process of Claim 23, further comprising neutralizing about 42% to about 55% of said amine groups. 26. The cataphoretic electrodeposition process of Claim 1, wherein said thermoplastic resin is poly(amic acid), poly(urethane imide), poly(amide imide), polyetherimide, poly(thioether imide sulfone), or a combination thereof. 27. A method of making a thermoplastic emulsion for use in a cataphoretic electrodeposition process, comprising: dispersing thermoplastic resin in a solvent and a substantially water insoluble cosolvent, said thermoplastic resin having at least one imide linkage; reacting a ring opening agent with said imide linkage to form amine groups; neutralizing said amine groups with a neutralization agent to form a quaternized mixture; and mixing water into said quaternized mixture to form the emulsion. 28. The method of making a stable thermoplastic emulsion of Claim 27, wherein said thermoplastic resin is polyetherimide and said polyetherimide resin comprises structural units of the formula (I): wherein the divalent T moiety bridges the 3,3', 3,4', 4,3', or 4,4' positions of the aryl rings of the respective aryl imide moieties of formula (I); T is -O- or a group of the formula -O-Z-O- ; Z is a divalent radical selected from formulae (II): (II) wherein X is: ? " ' — c— , — s— — o— or -s— wherein y' is an integer from 1 to about 5, and q is 0 or 1; R is a divalent organic radical selected from: (a) aromatic hydrocarbon radicals having from 6 to about 20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals having from 2 to about 20 carbon atoms, (c) cycloalkylene radicals having from 3 to about 20 carbon atoms, and (d) divalent radicals of the general formula (IV): (IV) ϋ 0, where Q is: O O o where y' is an integer from about 1 to about 5. 29. The method of making a thermoplastic emulsion of Claim 27, wherein said thermoplastic resin is polyetherimide and said polyetherimide resin comprises the reaction product formed by melt polymerization of 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride with metaphenylene diamine. 30. The method of making a thermoplastic emulsion of Claim 27, wherein said solvent and said cosolvent each have a solubility in water of less than about 5.5 g/1. 31. The method of making a thermoplastic emulsion of Claim 27, wherein said solvent is N-methyl pyrolidinone. 32. The method of making a thermoplastic emulsion of Claim 27, wherein said cosolvent is a ketone, phenol or ether solvent. 33. The method of making a thermoplastic emulsion of Claim 27, wherein said cosolvent is anisole. 34. The method of making a thermoplastic emulsion of Claim 27, wherein said ring opening agent is amine. 35. The method of making a thermoplastic emulsion of Claim 34, wherein said ring opening agent is a secondary or tertiary amine. 36. The method of making a thermoplastic emulsion of Claim 27, wherein said ring opening agent is N-methylpiperazine or 2- (piperaziny 1) ethanol . 37. The method of making a thermoplastic emulsion of Claim 27, wherein said neutralization agent has an acid strength, K a , of greater than about 10- 5 . 38. The method of making a thermoplastic emulsion of Claim 27, wherein said neutralization agent is a mono-acid. 39. The method of making a thermoplastic emulsion of Claim 27, wherein said neutralization agent is lactic acid or glycolic acid. 40. The method of making a thermoplastic emulsion of Claim 27, wherein said emulsion comprises up to about 10 volume percent (vol%) polyetherimide resin, up to about 5 vol% ring opening agent, up to about 5 vol% neutralization agent, up to about 20 vol% solvent, up to about 20 vol% cosolvent, balance water. 41. The method of making a thermoplastic emulsion of Claim 27, wherein said emulsion comprises about 3 vol% to about 8 vol% polyetherimide resin, about 0.2 vol% to about 3 vol% ring opening agent, about 0.3 vol% to about 3.5 vol% neutralization agent, about 8 vol% to about 15 vol% solvent, about 9 vol% to about 15 vol% cosolvent, balance water. 42. The method of making a thermoplastic emulsion of Claim 27, wherein said emulsion comprises about 4 vol% to about 7 vol% polyetherimide resin, about 0.5 vol% to about 1.5 vol% ring opening agent, about 0.5 vol% to about 2 vol% neutralization agent, about 10 vol% to about 13 vol% solvent, about 10 vol% to about 12.5 vol% cosolvent, balance water. 43. The method of making a thermoplastic emulsion of Claim 27, wherein said thermoplastic resin comprises polyetherimide and said polyetherimide resin comprises a copolymer made by condensation of 2,2- bis(2,3-dicarboxy phenoxy phenol)propane dianhydride with metaphenylene diamine and an aminopropyl-terminated Dio polydimethylsiloxane . 44. The method of making a thermoplastic emulsion of Claim 27, further comprising reacting about 50% to about 80% of said imide linkages with said ring opening agent. 45. The method of making a thermoplastic emulsion of Claim 27, further comprising reacting about 60% to about 75% of said imide linkages with said ring opening agent. 46. The method of making a thermoplastic emulsion of Claim 45, further comprising neutralizing about 42% to about 55% of said amine groups. 47. A cataphoretic electrodeposition process for forming a thermoplastic coating, comprising: forming a thermoplastic emulsion, comprising: dispersing a thermoplastic resin in a solvent and a substantially water insoluble cosolvent, said thermoplastic resin having at least one imide linkage; reacting a ring opening agent with said imide linkage to form amine groups; neutralizing said amine groups with a neutralization agent to form a quaternized mixture; forming the thermoplastic emulsion by adding water to said quaternized mixture; inserting at least one anode and at least one cathode electrode into said emulsion; applying an electrical current to said emulsion; forming a thermoplastic cation; and reacting said thermoplastic cation at said cathode to form an insoluble thermoplastic species which coats a substrate. 48. The cataphoretic electrodeposition process of Claim 47, wherein said thermoplastic resin comprises polyetherimide, and said polyetherimide resin comprises structural units of the formula (I): wherein the divalent T moiety bridges the 3,3', 3,4', 4,3', or 4,4' positions of the aryl rings of the respective aryl imide moieties of formula (I); T is -O- or a group of the formula -O-Z-O- ; Z is a divalent radical selected from: 0>-^»-O - (II) wherein X is: _r ^ ϊ o wherein y' is an integer from 1 to about 5, and q is 0 or 1; R is a divalent organic radical selected from: (a) aromatic hydrocarbon radicals having from 6 to about 20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals having from 2 to about 20 carbon atoms, (c) cycloalkylene radicals having from 3 to about 20 carbon atoms, and (d) divalent radicals of the general formula (IV): where Q is: ? ? y' H 2y' — ' _ C_ ' "~ f — ' ~~ ° ~ or _S— O where y' is an integer from about 1 to about 5. 49. The cataphoretic electrodeposition process of Claim 47, wherein said polyetherimide resin comprises the reaction product formed by melt polymerization of 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride with metaphenylene diamine. 50. The cataphoretic electrodeposition process of Claim 47, wherein said solvent and said cosolvent each have a solubility in water of less than about 5.5 g/1. 51. The cataphoretic electrodeposition process of Claim 47, wherein said solvent is N-methyl pyrolidinone. 52. The cataphoretic electrodeposition process of Claim 47, wherein said cosolvent is a ketone, phenol or ether solvent. 53. The cataphoretic electrodeposition process of Claim 47, wherein said cosolvent is anisole. 54. The cataphoretic electrodeposition process of Claim 47, wherein said ring opening agent is amine. 55. The cataphoretic electrodeposition process of Claim 54, wherein said ring opening agent is a secondary or tertiary amine. 56. The cataphoretic electrodeposition process of Claim 47, wherein said ring opening agent is N-methylpiperazine or 2-(piperazinyl)ethanol. 57. The cataphoretic electrodeposition process of Claim 47, wherein said neutralization agent has an acid strength, K a , of greater than about 10- 5 . 58. The cataphoretic electrodeposition process of Claim 47, wherein said neutralization agent is a mono-acid. 59. The cataphoretic electrodeposition process of Claim 47, wherein said neutralization agent is lactic acid or glycolic acid. 60. The cataphoretic electrodeposition process of Claim 47, wherein said emulsion comprises up to about 10 volume percent (vol%) polyetherimide resin, up to about 5 vol% ring opening agent, up to about 5 vol% neutralization agent, up to about 20 vol% solvent, up to about 20 vol% cosolvent, balance water. 61. The cataphoretic electrodeposition process of Claim 47, wherein said emulsion comprises about 3 vol% to about 8 vol% polyetherimide resin, about 0.2 vol% to about 3 vol% ring opening agent, about 0.3 vol% to about 3.5 vol% neutralization agent, about 8 vol% to about 15 vol% solvent, about 9 vol% to about 15 vol% cosolvent, balance water. 62. The cataphoretic electrodeposition process of Claim 47, wherein said emulsion comprises about 4 vol% to about 7 vol% polyetherimide resin, about 0.5 vol% to about 1.5 vol% ring opening agent, about 0.5 vol% to about 2 vol% neutralization agent, about 10 vol% to about 13 vol% solvent, about 10 vol% to about 12.5 vol% cosolvent, balance water. 63. The cataphoretic electrodeposition process of Claim 47, wherein the polyetherimide resin comprises a copolymer made by condensation of 2,2- bis(2,3-dicarboxy phenoxy phenol)propane dianhydride with metaphenylene diamine and an aminopropyl-terminated Dio polydimethylsiloxane . 64. The cataphoretic electrodeposition process of Claim 47, further comprising reacting about 50% to about 80% of said imide linkages with said ring opening agent. 65. The cataphoretic electrodeposition process of Claim 47, further comprising reacting about 60% to about 75% of said imide linkages with said ring opening agent. 66. The cataphoretic electrodeposition process of Claim 65, further comprising neutralizing about 42% to about 55% of said amine groups. 67. The cataphoretic electrodeposition process of Claim 47, wherein said thermoplastic resin is poly(amic acid), poly(urethane imide), poly(amide imide), polyetherimide, poly(thioether imide sulfone), and combinations thereof. 68. A polyetherimide emulsion for use in a cataphoretic electrodeposition process, comprising: up to about 10 volume percent (vol%) polyetherimide resin, up to about 5 vol% ring opening agent, up to about 5 vol% neutralization agent, up to about 20 vol% solvent, up to about 20 vol% cosolvent, balance water. 69. The polyetherimide emulsion of Claim 68, wherein said emulsion comprises about 3 vol% to about 8 vol% polyetherimide resin, about 0.2 vol% to about 3 vol% ring opening agent, about 0.3 vol% to about 3.5 vol% neutralization agent, about 8 vol% to about 15 vol% solvent, about 9 vol% to about 15 vol% cosolvent, balance water. 70. The polyetherimide emulsion of Claim 69, wherein said emulsion comprises about 4 vol% to about 7 vol% of said polyetherimide resin, about 0.5 vol% to about 1.5 vol% of said ring opening agent, about 0.5 vol% to about 2 vol% of said neutralization agent, about 10 vol% to about 13 vol% of said solvent, about 10 vol% to about 12.5 vol% of said cosolvent, said balance water. 71. The polyetherimide emulsion of Claim 68, wherein said polyetherimide resin comprises structural units of the formula (I): wherein the divalent T moiety bridges the 3,3', 3,4', 4,3', or 4,4' positions of the aryl rings of the respective aryl imide moieties of formula (I); T is -O- or a group of the formula -O-Z-O- ; Z is a divalent radical selected from formulae (II): -^Q-^-^ f - (II) wherein X is: wherein y' is an integer from 1 to about 5, and q is 0 or 1; R is a divalent organic radical selected from: (a) aromatic hydrocarbon radicals having from 6 to about 20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals having from 2 to about 20 carbon atoms, (c) cycloalkylene radicals having from 3 to about 20 carbon atoms, and (d) divalent radicals of the general formula (IV): where Q is: ~" C y' 2y ~ ' — C~ • ~" f _ ■ — °— ° r — s~ ° where y' is an integer from about 1 to about 5. 72. The polyetherimide emulsion of Claim 68, wherein said polyetherimide resin comprises the reaction product formed by melt polymerization of 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride with metaphenylene diamine. 73. The polyetherimide emulsion of Claim 68, wherein said solvent and said cosolvent each have a solubility in water of less than about 5.5 g/i. 74. The polyetherimide emulsion of Claim 68, wherein said solvent is N-methyl pyrolidinone. 75. The polyetherimide emulsion of Claim 68, wherein said cosolvent is a ketone, phenol or ether solvent. 76. The polyetherimide emulsion of Claim 68, wherein said cosolvent is anisole. 77. The polyetherimide emulsion of Claim 68, wherein said opening agent is amine. -D J- 78. The polyetherimide emulsion of Claim 68, wherein said opening agent is a secondary or tertiary amine. 79. The polyetherimide emulsion of Claim 68, wherein said opening agent is N-methylpiperazine or 2-(piperazinyl)ethanol. 80. The polyetherimide emulsion of Claim 68, wherein said neutralization agent has an acid strength, K a , of greater than about 10 -5 . 81. The polyetherimide emulsion of Claim 68, wherein said neutralization agent is a mono-acid. 82. The polyetherimide emulsion of Claim 68, wherein said neutralization agent is lactic acid or glycolic acid. 83. The polyetherimide emulsion of Claim 68, wherein the polyetherimide resin comprises a copolymer made by condensation of 2,2- bis(2,3-dicarboxy phenoxy phenol) propane dianhydride with metaphenylene diamine and an aminopropyl-terminated Dio polydimethylsiloxane . 84. The polyetherimide emulsion of Claim 68, further comprising reacting about 50% to about 80% of said imide linkages with said ring opening agent. 85. The polyetherimide emulsion of Claim 68, further comprising reacting about 60% to about 75% of said imide linkages with said ring opening agent. -oi- 86. The polyetherimide emulsion of Claim 85, further comprising neutralizing about 42% to about 55% of said amine groups.

Inventors: BAILLY CHRISTIAN MARIA EMILE, DE WIT GERRIT, LENSVELT KEES, PUYENBROEK ROBERT, QARIOUH EL HOUSSAIN, SCHUE FRANCOIS GUY-MARIE, SCHUE ROSSITZA, WASCHER UWE SIEGFRIED, BAILLY, CHRISTIAN, MARIA, EMILE, DE WIT, GERRIT, LENSVELT, KEES, PUYENBROEK, ROBERT, QARIOUH, EL HOUSSAIN, SCHUE, FRANCOIS, GUY-MARIE, SCHUE, ROSSITZA, WASCHER, UWE, SIEGFRIED
Applicants: BAILLY CHRISTIAN MARIA EMILE, GEN ELECTRIC, LENSVELT KEES, PUYENBROEK ROBERT, QARIOUH EL HOUSSAIN, SCHUE FRANCOIS GUY MARIE, SCHUE ROSSITZA, WASCHER UWE SIEGFRIED, WIT GERRIT DE, BAILLY, CHRISTIAN, MARIA, EMILE, DE WIT, GERRIT, GENERAL ELECTRIC COMPANY, LENSVELT, KEES, PUYENBROEK, ROBERT, QARIOUH, EL HOUSSAIN, SCHUE, FRANCOIS, GUY-MARIE, SCHUE, ROSSITZA, WASCHER, UWE, SIEGFRIED
Application year: 1999
Main classification: C08G73
IPC codes: C08J3, C09D5, C09D179