US3925580A - Method of spraying a powder paint slurry - Google Patents

Method of spraying a powder paint slurry Download PDF

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Publication number
US3925580A
US3925580A US354374A US35437473A US3925580A US 3925580 A US3925580 A US 3925580A US 354374 A US354374 A US 354374A US 35437473 A US35437473 A US 35437473A US 3925580 A US3925580 A US 3925580A
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Prior art keywords
powder
water
slurry
paint
powder paint
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Expired - Lifetime
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US354374A
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English (en)
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George E F Brewer
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Grow Chemical Corp
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Grow Chemical Corp
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Priority to US354374A priority Critical patent/US3925580A/en
Priority to GB1770274A priority patent/GB1433286A/en
Priority to FR7414280A priority patent/FR2227139B1/fr
Priority to CA198,026A priority patent/CA1032029A/en
Priority to DE2420097A priority patent/DE2420097C2/de
Priority to BR3397/74A priority patent/BR7403397D0/pt
Priority to JP49047046A priority patent/JPS6038425B2/ja
Priority to BE143627A priority patent/BE814201A/xx
Priority to IT50643/74A priority patent/IT1008496B/it
Priority to AU68330/74A priority patent/AU485469B2/en
Application granted granted Critical
Publication of US3925580A publication Critical patent/US3925580A/en
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying

Definitions

  • ABSTRACT A method of painting with a composition of a pumpable, sprayable powder paint slurry comprising powder paint, water and a surfactant, having sufficient surfactant to reduce the surface tension of the aqueous portion to less than 35 dynes/cm, having a minimum concentration of water in excess of the interstitial volume of the powder, and having as a maximum concentration of water that necessary to produce, when sprayed onto a substrate, a film of powder and water in which the water is less than the interstitial volume of the powder.
  • Powder paint has been increasing in popularity as an industrial coating material at a rapid rate.
  • the reasons for the widespread acceptance of powder paint are: virtual absence of air pollution, recovery and reuse of powder lost by overspray, and improved quality of cured out paint films.
  • the application of a powder paint coating is essentially a two-step process involving first, applying a layer of powder, and second, treating the powder layer to cause it to coalesce, flow and cure into a desired paint film.
  • Previous powder paint coating technology has applied powder paint in a dry form using electrostatic spraying equipment or fluidized beds. Both methods employ specialized equipment to apply the powder which require large capital expenditures and which obsolete existing liquid paint spraying and dipping equipment.
  • Powder paint is, however, hydrophobic and does not wet when a slurry is formed. This difference in the physical properties of the powder paint and ceramic and enamel frits is evidenced by the problems involved in forming a slurry of powder paint which can be pumped and sprayed to produce a layer of powder and water.
  • an aqueous slurry of powder paint and water When an aqueous slurry of powder paint and water, without any additives, is pumped through conventional spray equipment, the pumps, guns and paint lines clog up after short periods of time and the equipment must be completely cleaned before spraying can be resumed.
  • an aqueous slurry of powder paint can be formed which is pumpable and sprayable without clogging and plugging the spray equipment and which will form a film of powder paint and water when sprayed.
  • a pumpable, sprayable, aqueous slurry of powder paint is prepared in which the aqueous portion has a surface tension of less than 35 dynes/cm, and preferably between 29 and 35 dynes/cm.
  • the minimum amount of the aqueous portion should be greater than the interstitial volume of the powder, and the maximum amount of the aqueous portion should not exceed that amount which, when the slurry is sprayed onto a substrate, will produce a film of powder and water in which the water portion is less than the interstitial volume of the powder.
  • there must be evaporated out of the slurry during the painting such an amount of water as will reduce the aqueous portion to below the interstitial volume of the powder portion.
  • FIG. 1 illustrates a slurry of powder paint and water having a volume of water less than the interstitial volume of the powder
  • FIG. 2 illustrates a slurry of powder paint and water having a volume of water greater than the interstitial volume of the powder
  • FIG. 3 illustrates a spraying apparatus for use in spraying a slurry of powder paint and water onto a substrate
  • FIG. 4 illustrates a method of determining the interstitial voiume of a powder
  • FIG. 5 is a graph of the effect of a surfactant on the surface tension of water, and a powder slurry.
  • the water acts as a vehicle in a conventional liquid paint. It functions as a carrier in which the film forming component, in this case powder paint, is dispersed and which is then applied to a substrate to form an adherent wet coating of water and powder. The liquid carrier is then evaporated to leave an adherent coating of powder on the substrate which can subsequently be treated to cause the powder to coalesce, flow and cure into a desired paint film.
  • the film forming component in this case powder paint
  • the slurry In painting with such an aqueous slurry there are several interrelated problems that can only be solved in relation to each other. They are: the slurry must be pumpable and sprayable from essentially conventional spray painting equipment without clogging or plugging the equipment; the applied slurry coating of powder and water must-adhere to the substrate sufficiently to produce a coating with substantially no sagging, running, or creeping; and the adherent slurry coating of powder and water must not contain any substances in such concentration that they would have a deleterious effect on the resulting cured paint film.
  • Pursuant to this invention it is possible to form a slurry of powder paint and water which can be sprayed onto a substrate to form an adherent film of powder and water, and which can be treated to remove the water and cause the powder paint to form a fixed and adherent paint film thereon.
  • One of the important properties of a free flowing slurry is the surface tension of the aqueous phase. I have found that a satisfactory sprayable and pumpable slurry of powder cannot be formed unless the surface tension of the aqueous portion is less than 35 dynes/cm and preferably between 29 and 35 dynes/cm. At a surface tension above 35 dynes/cm the powder slurry will clog and plug the paint spraying equipment.
  • Examples 1 and 2 illustrate the effect of surface tension on a powder slurry, and how when a slurry is formed with a surface tension of greater than 35 dynes/cm it will clog the paint spraying equipment, (Example I) and (in Example 2) when the surface tension of the slurry is reduced to less than 35 dynes/cm a free flowing pumpable, sprayable slurry is produced.
  • FIG. 5 illustrates the concentration of surfactant necessary to reduce the surface tension of water alone, and water and powder paint, to below 35 dynes/cm.
  • FIG. 5 the use of Aerosol OT as a surfactant is illustrated. It will be observed that the concentration of Aerosol OT necessary to sufficiently reduce the surface tension is less than 0.1 percent. It is desirable to use a surfactant which will reduce the surface tension below 35 dynes/cm at concentrations of less than one percent. Armeen S2 and Aerosol OT have been found to be satisfactory surfactants when used according to this invention.
  • Any commercially available surfactant would be satisfactory as long as it is capable of reducing the surface tension of the aqueous portion of the slurry to less than 35 dynes/cm, and has no deleterious effect on the powder particles or on the desired characteristics of the paint film to be formed.
  • FIG. I have illustrated in a simplified way the physical characteristics of a slurry which produces an adherent film, and in FIG. 2 a slurry which is free flowing or pumpable and sprayable.
  • FIG. 1 illustrates a slurry which has a paste-like appearance, resulting from mixing a large quantity of powder with water. If a spatula is used as an agitator and then withdrawn, the paste does not return to a smooth horizontal surface 8; and the paste forms an adherent film on the spatula which will not run off 6. Such a paste-like composition will clog up pumps, guns and other equipment after spraying for a short period of time. It will, however, when applied, form an adherent film of powder which does not run, sag or creep.
  • FIG. 4 schematically represents an interstitial volume determination.
  • a weighed amount of paint powder 36 is mixed with several times its weight of water 32, the surface tension of which has been reduced to below 35 dynes/cm through the addition of a small quantity of surfactant.
  • the powder is then allowed to settle, and the sedimentation volume 34 of the powder is determined.
  • the total volume confined by the upper miniscus 30 is read after any foaming has subsided or has been eliminated.
  • the total weight of the graduate, water and powder is determined.
  • the weight of the graduate is then subtracted giving the weight of water and powder in the graduate.
  • a free flowing slurry is one which contains more fluid than the interstitial volume, as in FIG. 2, and a well adhering sprayed-on film contains less fluid than the interstitial volume, as in FIG. 2.
  • powder particles could be perfect spheres a sprayable slurry could be obtained when enough liquid is provided to cover the settled powder.
  • the other extreme is exemplified by powder particles which are flat square plates. These would tend to settle like bricks in a wall with a minimum of interstices. Yet to provide enough space for their random motion enough, liquid would have to be provided to allow for the rotation of their longest dimension, that is a spherical space of a diameter equal to the body diagonal of the square plate.
  • the liquid portion of the slurry contained 0.05% surfactant (5.2 ml of 1% Aerosol OT and 94.8 ml water).
  • the surfactant used was Aerosol OT, is described by the manufacturer, American Cyanamid Co., Process Chemicals Dept., Wayne, NJ. as 75 weights sodium dioctyl sulfo succinate, weight water, 5 weight of a lower alcohol to provide fluidity.
  • Interstitial volume X 100 Interstitial volume and weight of powder.
  • the maximum amount of water surfactant mixture which can be added to produce a free flowing pumpable slurry is that amount in excess of the interstitial volume, but in excess by less than the evaporative spray loss during spraying of the slurry onto a substrate to be coated.
  • the slurry pictured in FIG. 2 may be diluted with surfactant-water mixture to the extent that during the spraying of the slurry onto a substrate a sufficient amount of water can be evaporated to produce an adherent layer of powder paint and water with the characteristics of FIG. 1.
  • the volume of water contained in the sprayed on layer of powder and water must be less than the interstitial volume of the powder, for an adherent film to be formed which will not sag, run nor creep.
  • the volume of water added to produce a free flowing slurry can be increased above the interstitial volume to any amount necessary as long as during the spraying of the slurry onto a substrate a sufficient amount of water can be evaporated to produce a layer of powder paint and water having a volume of water less than the interstitial volume of the powder.
  • Another characteristic of a free flowing sprayable slurry is its behavior when not agitated. Slurries which settle hard as the painter calls it, will tend to clog up those parts of the spray equipment which lack agitation. Hard settling can be controlled by the addition of antisettling agents such as Ben-A-Gel EW. Any commercially available anti-settling agent can be used as long as it prevents hard settling of the powder paint in the slurry, and has no deleterious effect on the powder particles or on the desired characteristics of the paint film to be formed. Examples 4 and 5 illustrate the use of an antisettling agent with a powder which has hard settling characteristics. The addition of the anti-settling agent to the slurry increases the interstitial volume of the powder which requires a larger concentration of water to be provided to form a free flowing slurry.
  • EXAMPLE 1 The interstitial volume of 5 grams of Monsanto MA 1000 L58004 powder manufactured by Monsanto, Plastics Products and Resins Division, 190 Grochmal Avenue, Indian Orchard, Mass. was determined ac- To prepare a slurry in which the volume of water is equal to the interstitial volume for this powder will require a slurry containing 33.3% water and 66.7% powder.
  • a slurry was prepared as follows: 300.0 g Powder 0.13g Aerosol OT [0.l9g in water) 250.0 g Water (45.5% water) The liquid phase filtered from the slurry, showed a surface tension of 41.8 dynes/cm. The water concentration was 45.5% which is in excess of the critical concentration, or in excess of the interstitial volume.
  • the slurry was placed into spray equipment as in FIG.
  • the slurry is circulated from the pump to the gun and back to the paint pot at a rate of 1000 ml per minute when the slurry is not being sprayed.
  • the rate of circulation is reduced to 700 ml per minute.
  • EXAMPLE 2 Two slurries were prepared using the same powder as in Example 1, but with the addition of sufficient surfactant to lower the surface tension of the aqueous phase to less than 35 dynes/cm, as follows:
  • the liquid phase when filtered from the slurry, showed a surface tension of 30.7 dynes/cm.
  • the concentration of the water was 45.5% which was in excess of the critical concentration of 33.3%.
  • EXAMPLE 4 The interstitial volume of 5 grams of Grow GP-16-Dl powder manufactured by the Grow Chemical Corp., 14100 Stansbury, Detroit, Mich. was determined according to the procedure outlined above on two successive days, as follows.
  • Interstitial volume X 100 Interstitial volume and weight of powder both slurries produced good test panels through the third week.
  • the above test procedure is A.S.T.M. method D-2243 which is a general method to test the freezer-thaw stability of a sample.
  • Examples 1 and 2 illustrate that by lowering the surface tension of the aqueous portion of the slurry to less than 35 dynes/cm a sprayable, pumpable slurry was produced which did not clog the spray gun.
  • Example 2 Placed in the above equipment (Example 1) excellent pumping characteristics were observed. However, the gun clogged up. Without agitation, a hard, somewhat brittle sediment was found in the paint pot which would be characterized as hard settling by a paint sprayer.
  • EXAMPLE 5 Another slurry was prepared using the same powder as in Example 4, with the addition of an anti-settling agent to prevent hard settling.
  • a slurry was prepared as follows: 200.00g Powder 0.70g Armeen SZ 0.20g Ben-A-Gel EW 535.00g Water (75.2% of water).
  • Examples 2 and 3 illustrate that even when the surface tension of a slurry is reduced below 35 dynes/cm, there must be provided an amount ofliquid in excess of the interstitial volume of the powder to form a spraya-
  • the liquid portion of the slurry contained 13.1 ml of 1% Armeen 82 (see Example 4), 3.75 ml Ben-A-Gel EW (described by the manufacturer, National Lead Company, 111 Broadway, New York, NY. as a specially processed magnesium montmorillonite powder of The liquid phase, filtered from the slurry, showed a surface tension of 34.4 dynes/cm.
  • the slurry deposit on the test panels weighted 1.650 grams prior to heating to remove the water. After removal of the water a deposit of powder weighing 0.673 gram was obtained. The deposited coating of powder paint and water was thus 59.2% water, which is less than the interstitial volume of water as calculated above. During the spraying of the slurry containing 75.2% water, sufficient water had been evaporated to reduce the volume of water in the slurry deposit to less than 61.2%, the interstitial volume, and thus produce an adherent coating of powder and water.
  • the method of spray painting an aqueous slurry of powder paint comprising the steps of: preparing a slurry of the powder paint and water having a surface tension of the aqueous portion of less than 35 dynes/cm and having a minimum amount of water greater than the interstitial volume of the powder; spraying the powder slurry onto a substrate and evaporating from the slurry during the spraying of the slurry onto the substrate a sufficient amount of water to form a layer of powder paint and water on the substrate in which the amount of water is less than the interstitial volume of the powder.
  • the invention defined in claim 1 characterized by evaporating from the spray a sufficient amount of water to form a layer of powder paint and water on the substrate in which the amount of water is less than the interstitial volume of the powder.
  • the invention defined in claim 1 characterized by reducing the surface tension of the aqueous portion of the powder paint slurry to 29 35 dynes/cm by the addition of a surfactant.
  • the invention defined in claim 1 characterized by removing the water from the layer of powder paint and water on the substrate and causing the powder paint to coalesce and cure into a desired paint film.

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US354374A 1973-04-25 1973-04-25 Method of spraying a powder paint slurry Expired - Lifetime US3925580A (en)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US354374A US3925580A (en) 1973-04-25 1973-04-25 Method of spraying a powder paint slurry
GB1770274A GB1433286A (en) 1973-04-25 1974-04-23 Method of spray painting a substrate with an aqueous slurry of powder paint and a sprayable powder paint slurry
CA198,026A CA1032029A (en) 1973-04-25 1974-04-24 Method of spray painting using an aqueous slurry of powder paint
FR7414280A FR2227139B1 (Direct) 1973-04-25 1974-04-24
DE2420097A DE2420097C2 (de) 1973-04-25 1974-04-25 Verfahren zum Auftragen einer wäßrigen Pulverfarbenschlämme auf ein Substrat sowie Pulverfarbenschlämme
BR3397/74A BR7403397D0 (pt) 1973-04-25 1974-04-25 Processo para pintar por aspersao com uma suspensao aquosa de tinta em po, e suspensao de tinta em po dispersivel e bombeavel
JP49047046A JPS6038425B2 (ja) 1973-04-25 1974-04-25 粉末ペイントの水性スラリの吹付塗装法
BE143627A BE814201A (fr) 1973-04-25 1974-04-25 Procede de pistolage d'un substrat au moyen d'une suspension aqueuse de peinture en poudre
IT50643/74A IT1008496B (it) 1973-04-25 1974-04-26 Perfezionamento nelle composizioni liquide di vernici in polvere spruzzabili e procedimento di applicazione
AU68330/74A AU485469B2 (en) 1973-04-25 1974-04-26 Sprayable powder paint slurry and method

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JP (1) JPS6038425B2 (Direct)
BE (1) BE814201A (Direct)
BR (1) BR7403397D0 (Direct)
CA (1) CA1032029A (Direct)
DE (1) DE2420097C2 (Direct)
FR (1) FR2227139B1 (Direct)
GB (1) GB1433286A (Direct)
IT (1) IT1008496B (Direct)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4795094A (en) * 1985-09-04 1989-01-03 Sames S.A. Apparatus for spraying a powder coating with enclosure surrounding a vibrating hose
US4800107A (en) * 1987-10-15 1989-01-24 The Glidden Company Dry fog sprayable latex paint
US5064696A (en) * 1988-09-08 1991-11-12 Kabushiki Kaisha Toshiba Pigment containing film coating method utilizing a colliding of two flow streams
US5379947A (en) * 1993-11-09 1995-01-10 Basf Corporation Process for producing a powder coating composition
DE19910405C1 (de) * 1999-01-28 2000-06-15 Hkr Systembau Gmbh Verfahren zur Beschichtung von nichtleitenden Substraten und Anwendung des Verfahrens
US6150465A (en) * 1998-10-01 2000-11-21 Basf Corporation Powder slurry compositions with solid particulate carbamate resin component dispersed in liquid aminoplast resin carrier
US20180154381A1 (en) * 2016-12-02 2018-06-07 General Electric Company Coating system and method
US20220205709A1 (en) * 2020-12-30 2022-06-30 Whirlpool Corporation Insulation materials for a vacuum insulated structure and methods of forming
US11739695B2 (en) 2016-12-06 2023-08-29 General Electric Company Gas turbine engine maintenance tool

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5258731A (en) * 1975-11-10 1977-05-14 Osame Kogyo Kk Method of preparing thermosetting coatings
JPS52107033A (en) * 1976-03-05 1977-09-08 Nippon Paint Co Ltd Method of manufacturing slurry-type water dispersed paint
EP0080790A3 (en) * 1981-08-10 1985-09-11 Tokyo Copal Chemical Company Limited Method and apparatus for forming an extremely thin film on the surface of an object
EP0113537A1 (en) * 1982-12-13 1984-07-18 Willett International Limited Method of applying an adhesive composition

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US2972553A (en) * 1957-04-01 1961-02-21 Gen Plastics Corp Nylon coating method
US3089783A (en) * 1960-01-06 1963-05-14 Pfaudler Permutit Inc Corrosion resistant coating and method of applying the same
US3287157A (en) * 1962-10-10 1966-11-22 Prismo Safety Corp Method of plating metal article with metal
US3437072A (en) * 1965-04-15 1969-04-08 Monsanto Graphic Syst Apparatus for fusing an electroscopic powder particle image
US3446652A (en) * 1964-05-11 1969-05-27 Lester W Smith Chlorinated oxetane polymer coating
US3502493A (en) * 1966-01-24 1970-03-24 Forestek Plating & Mfg Co Deposition of micron-sized particles into porous surfaces
US3687885A (en) * 1970-04-15 1972-08-29 Du Pont Water base paints having an improved balance of anti-drip and leveling qualities
US3713872A (en) * 1971-02-01 1973-01-30 Ppg Industries Inc Method of spraying thermoplastic paint compositions
US3770482A (en) * 1971-01-18 1973-11-06 Beatrice Foods Co Electrostatic coating method of applying multilayer coating
US3787230A (en) * 1971-10-06 1974-01-22 Grow Chemical Corp Method of applying powder paint

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1302271B (Direct) *

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2972553A (en) * 1957-04-01 1961-02-21 Gen Plastics Corp Nylon coating method
US3089783A (en) * 1960-01-06 1963-05-14 Pfaudler Permutit Inc Corrosion resistant coating and method of applying the same
US3287157A (en) * 1962-10-10 1966-11-22 Prismo Safety Corp Method of plating metal article with metal
US3446652A (en) * 1964-05-11 1969-05-27 Lester W Smith Chlorinated oxetane polymer coating
US3437072A (en) * 1965-04-15 1969-04-08 Monsanto Graphic Syst Apparatus for fusing an electroscopic powder particle image
US3502493A (en) * 1966-01-24 1970-03-24 Forestek Plating & Mfg Co Deposition of micron-sized particles into porous surfaces
US3687885A (en) * 1970-04-15 1972-08-29 Du Pont Water base paints having an improved balance of anti-drip and leveling qualities
US3770482A (en) * 1971-01-18 1973-11-06 Beatrice Foods Co Electrostatic coating method of applying multilayer coating
US3713872A (en) * 1971-02-01 1973-01-30 Ppg Industries Inc Method of spraying thermoplastic paint compositions
US3787230A (en) * 1971-10-06 1974-01-22 Grow Chemical Corp Method of applying powder paint

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4795094A (en) * 1985-09-04 1989-01-03 Sames S.A. Apparatus for spraying a powder coating with enclosure surrounding a vibrating hose
US4800107A (en) * 1987-10-15 1989-01-24 The Glidden Company Dry fog sprayable latex paint
US5064696A (en) * 1988-09-08 1991-11-12 Kabushiki Kaisha Toshiba Pigment containing film coating method utilizing a colliding of two flow streams
US5379947A (en) * 1993-11-09 1995-01-10 Basf Corporation Process for producing a powder coating composition
US6391969B1 (en) 1998-10-01 2002-05-21 Basf Corporation Powder slurry compositions with solid particulate carbamate resin component dispersed in liquid aminoplast resin carrier
US6150465A (en) * 1998-10-01 2000-11-21 Basf Corporation Powder slurry compositions with solid particulate carbamate resin component dispersed in liquid aminoplast resin carrier
DE19910405C1 (de) * 1999-01-28 2000-06-15 Hkr Systembau Gmbh Verfahren zur Beschichtung von nichtleitenden Substraten und Anwendung des Verfahrens
US20180154381A1 (en) * 2016-12-02 2018-06-07 General Electric Company Coating system and method
US10589300B2 (en) * 2016-12-02 2020-03-17 General Electric Company Coating system and method
US11358171B2 (en) * 2016-12-02 2022-06-14 General Electric Company Coating system and method
US11739695B2 (en) 2016-12-06 2023-08-29 General Electric Company Gas turbine engine maintenance tool
US20220205709A1 (en) * 2020-12-30 2022-06-30 Whirlpool Corporation Insulation materials for a vacuum insulated structure and methods of forming
US12072140B2 (en) * 2020-12-30 2024-08-27 Whirlpool Corporation Insulation materials for a heat and sound insulated structure and methods of forming with a mold that is gas and liquid permeable

Also Published As

Publication number Publication date
GB1433286A (en) 1976-04-22
IT1008496B (it) 1976-11-10
FR2227139A1 (Direct) 1974-11-22
AU6833074A (en) 1975-10-30
JPS5030945A (Direct) 1975-03-27
DE2420097C2 (de) 1983-07-21
JPS6038425B2 (ja) 1985-08-31
CA1032029A (en) 1978-05-30
BE814201A (fr) 1974-08-16
BR7403397D0 (pt) 1974-11-19
FR2227139B1 (Direct) 1977-10-28
DE2420097A1 (de) 1974-11-14

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