Polymeric coatings and methods of forming polymeric coatings are described. In a method of forming a polymeric coating a first layer is deposited on a substrate. The first layer includes at least one highly soluble diamine component. A second layer is formed on the substrate to contact the first layer. The second layer includes paraformaldehyde and an aromatic diamine including two primary amine groups. Once formed, the first and second layers are heated. Heating causes the components of the first and second layers to cure. For example, the paraformaldehyde from the second layer diffuses into the first layer and reacts via hemiaminal-type chemistry with the high soluble diamine component. The coatings may be substantially homogenous or comprise a compositional gradient in thickness or along the substrate plane depending on deposition methods and other processing parameters.

Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a nitrogen-containing salt of an inorganic acid, and an acidic compound. The acidic compound may be an organic acid, such as maleic acid or citric acid among others. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.

Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a nitrogen-containing salt of an inorganic acid, and an acidic compound. The acidic compound may be an organic acid, such as maleic acid or citric acid among others. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.

A coating for an article may be made by applying a powder of a polyhemiaminal (PHA) polymer material to the article in a particulate form and then converting the PHA polymer material to a polyhexahydrotriazine (PHT) polymer material and fusing the particles into a monolithic coating by applying heat to the particles. The method generally includes forming a dilute reaction mixture comprising a formaldehyde reactant, a solvent, a primary aromatic diamine, and heating the reaction mixture to a temperature of between about 20 C. and about 120 C. for a short time to form a polymer. A particulate solid is precipitated by adding an excess volume of a non-solvent to the mixture. The powder may be applied to an article and then heated to fuse the powder into a coating and convert the PHA to PHT.

A coating for an article may be made by applying a powder of a polyhemiaminal (PHA) polymer material to the article in a particulate form and then converting the PHA polymer material to a polyhexahydrotriazine (PHT) polymer material and fusing the particles into a monolithic coating by applying heat to the particles. The method generally includes forming a dilute reaction mixture comprising a formaldehyde reactant, a solvent, a primary aromatic diamine, and heating the reaction mixture to a temperature of between about 20 C. and about 120 C. for a short time to form a polymer. A particulate solid is precipitated by adding an excess volume of a non-solvent to the mixture. The powder may be applied to an article and then heated to fuse the powder into a coating and convert the PHA to PHT.

Polyhemiaminal (PHA) and polyhexahydrotriazine (PHT) materials are modified by 1,4 conjugate addition chemical reactions to produce a variety of molecular architectures comprising pendant groups and bridging segments. The materials are formed by a method that includes heating a mixture comprising solvent(s), paraformaldehyde, aromatic amine groups, aliphatic amine Michael donors, and Michael acceptors, such as acrylates. The reaction mixtures may be used to prepare polymer pre-impregnated materials and composites containing PHT matrix resin.

Polyhemiaminal (PHA) and polyhexahydrotriazine (PHT) materials are modified by 1,4 conjugate addition chemical reactions to produce a variety of molecular architectures comprising pendant groups and bridging segments. The materials are formed by a method that includes heating a mixture comprising solvent(s), paraformaldehyde, aromatic amine groups, aliphatic amine Michael donors, and Michael acceptors, such as acrylates. The reaction mixtures may be used to prepare polymer pre-impregnated materials and composites containing PHT matrix resin.

Polyhemiaminal (PHA) and polyhexahydrotriazine (PHT) materials are modified by 1,4 conjugate addition chemical reactions to produce a variety of molecular architectures comprising pendant groups and bridging segments. The materials are formed by a method that includes heating a mixture comprising solvent(s), paraformaldehyde, aromatic amine groups, aliphatic amine Michael donors, and Michael acceptors, such as acrylates. The reaction mixtures may be used to prepare polymer pre-impregnated materials and composites containing PHT matrix resin.

Polyhexahydrotriazine (PHT) and polyhemiaminal (PHA) materials incorporating divalent or trivalent bridging groups tend to form highly cross-linked polymers. While highly cross-linked polymers have certain advantageous with respect to stability and various physical characteristics, they are difficult to process once formed. PHA and PHT materials incorporating a plurality of trivalent PHA/PHT groups, a plurality of divalent bridging groups, and a plurality of monovalent end groups are disclosed. According to an embodiment, the cross-link density and molecular weight can be controlled by the inclusion of the end groups. Lower cross-link density and molecular weight give PHA and PHT materials improved characteristics with respect to film and fiber formation methods. A method of coating a component or substrate with a polymer is also disclosed. Embodiments of the method can be used to form either a PHA or PHT film on a substrate, such as microelectronic component.

Polyhexahydrotriazine (PHT) and polyhemiaminal (PHA) materials incorporating divalent or trivalent bridging groups tend to form highly cross-linked polymers. While highly cross-linked polymers have certain advantageous with respect to stability and various physical characteristics, they are difficult to process once formed. PHA and PHT materials incorporating a plurality of trivalent PHA/PHT groups, a plurality of divalent bridging groups, and a plurality of monovalent end groups are disclosed. According to an embodiment, the cross-link density and molecular weight can be controlled by the inclusion of the end groups. Lower cross-link density and molecular weight give PHA and PHT materials improved characteristics with respect to film and fiber formation methods. A method of coating a component or substrate with a polymer is also disclosed. Embodiments of the method can be used to form either a PHA or PHT film on a substrate, such as microelectronic component.