WO2014150167A1 - Method for applying a powder coating - Google Patents
Method for applying a powder coating Download PDFInfo
- Publication number
- WO2014150167A1 WO2014150167A1 PCT/US2014/022459 US2014022459W WO2014150167A1 WO 2014150167 A1 WO2014150167 A1 WO 2014150167A1 US 2014022459 W US2014022459 W US 2014022459W WO 2014150167 A1 WO2014150167 A1 WO 2014150167A1
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- WO
- WIPO (PCT)
- Prior art keywords
- powder coating
- coating layer
- layer
- functionality
- group
- Prior art date
Links
- 239000000843 powder Substances 0.000 title claims abstract description 132
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000000576 coating method Methods 0.000 title claims description 37
- 239000011248 coating agent Substances 0.000 title claims description 29
- 239000011247 coating layer Substances 0.000 claims abstract description 94
- 239000010410 layer Substances 0.000 claims abstract description 73
- 229920005989 resin Polymers 0.000 claims abstract description 18
- 239000011347 resin Substances 0.000 claims abstract description 18
- 125000000524 functional group Chemical group 0.000 claims abstract description 12
- 239000000758 substrate Substances 0.000 claims abstract description 7
- 229920000728 polyester Polymers 0.000 claims description 23
- 239000004593 Epoxy Substances 0.000 claims description 10
- 239000012948 isocyanate Substances 0.000 claims description 9
- 150000002513 isocyanates Chemical class 0.000 claims description 9
- 230000005855 radiation Effects 0.000 claims description 7
- 150000001412 amines Chemical class 0.000 claims description 6
- 150000008064 anhydrides Chemical class 0.000 claims description 6
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 6
- 229920000642 polymer Polymers 0.000 claims description 4
- 150000001336 alkenes Chemical class 0.000 claims description 3
- 150000001408 amides Chemical class 0.000 claims description 3
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 claims description 3
- 150000002978 peroxides Chemical class 0.000 claims description 3
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 3
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims 9
- 125000004356 hydroxy functional group Chemical group O* 0.000 claims 8
- 150000002924 oxiranes Chemical class 0.000 claims 6
- OUPZKGBUJRBPGC-UHFFFAOYSA-N 1,3,5-tris(oxiran-2-ylmethyl)-1,3,5-triazinane-2,4,6-trione Chemical compound O=C1N(CC2OC2)C(=O)N(CC2OC2)C(=O)N1CC1CO1 OUPZKGBUJRBPGC-UHFFFAOYSA-N 0.000 claims 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims 3
- KXDHJXZQYSOELW-UHFFFAOYSA-N Carbamic acid Chemical compound NC(O)=O KXDHJXZQYSOELW-UHFFFAOYSA-N 0.000 claims 2
- 239000011230 binding agent Substances 0.000 description 5
- 239000002253 acid Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000000399 optical microscopy Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 150000003254 radicals Chemical class 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- 239000000499 gel Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 1
- 230000001427 coherent effect Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- GYZLOYUZLJXAJU-UHFFFAOYSA-N diglycidyl ether Chemical class C1OC1COCC1CO1 GYZLOYUZLJXAJU-UHFFFAOYSA-N 0.000 description 1
- 210000005069 ears Anatomy 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000001034 iron oxide pigment Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- -1 mereapto Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- 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
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/10—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by other chemical means
- B05D3/107—Post-treatment of applied coatings
- B05D3/108—Curing
-
- 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
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/52—Two layers
- B05D7/54—No clear coat specified
- B05D7/542—No clear coat specified the two layers being cured or baked together
-
- 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
- B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
- B05D1/06—Applying particulate materials
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/03—Powdery paints
Definitions
- Powder coatings are mixtures of thermosetting film-forming resins, usually one or more pigments and one or more other additives, which are mixed in the production process, extruded, ground, and generally applied by electrostatic spray process in which the powder coating particles are electrostatically charged and applied to a surface by a spray gun, or where a fluidized bed of powder is heated to melt and fuse the particles and cure the coating. Curing can take place by heat or by radiation, which melts, gels and cures the particles of the powder into a uniform film,
- powder coatings are applied as a single coat direct to metal or as a coating over another layer of powder primer which has been previously cured. These methods are referred to as a conventional powder coating application process. These conventional process steps are generally stepwise as follows:
- Step 1 Apply first layer
- Step 2 Cure first layer
- Step 3 Apply second layer
- Step 4 Cure second layer.
- a first layer is applied and heated to create a "melt” and then a second layer is applied over the first layer "melt” thus requiring an additional process step of heating to create a melt.
- a powder coating topcoat and a powder coating primer coat that have reactive functionalities with each other can be electrostatically applied by spray (the first layer powder coating primer is applied to substrate followed by the application of a reactive topcoat or reactive subsequent topcoats) and heated and cured only once, thus eliminating at least one complete coating cure cycle.
- Step 2 Apply second layer (and subsequent layers) having functionalities reactive with the first (or previous) layer, and applying the second (and subsequent layers) before the previous layer cures;
- Step 3 Cure first layer and second (and subsequent layers) simultaneously.
- the present invention relates to a method for the application of at least two different powder coating layers to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer , without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer, wherein the first powder coating layer and the second powder coating layer each comprise at least one resin independently having at least one functional group in stoichiometric ratios sufficient to react or crosslink with the other layer at the interface of the two or more layers.
- the present invention also is a mult-coat, one-bake coating system, comprising a first powder coating layer followed by the application of a second (or subsequent) powder coating layer(s), without any substantial curing of the first powder coating layer prior to the application of the second (or subsequent) powder coating layer(s), followed by the simultaneous curing of the first powder coating layer and the second (or subsequent) powder coating layer(s), wherein the first powder coating layer and the second (or subsequent) powder coating layer(s) each comprise at least one resin independently having at least one functional group that is reactive or crosslinkable with the previously applied layer.
- the present invention is a coated article comprising a mult-coat, one-bake coating system, comprising a first powder coating layer followed by the application of a second (or subsequent) powder coating layer(s), without any substantial curing of the first powder coating layer prior to the application of the second (or subsequent) powder coating layer(s), followed by the simultaneous curing of the first powder coating layer and the second (or subsequent) powder coating layer(s), wherein the first powder coating layer and the second (or subsequent) powder coating layer(s) each comprise at least one resin independently having at least one functional group that is reactive or crosslinkable with the previously applied layer.
- Figure 1 is a cross-sectional photomicrograph of a powder coating system of this invention, showing the interface of co-reaction of the first layer powder coating and the second layer of a powder coating, by optical microscopy at 200x magnification.
- Figure 2 is a cross-sectional photomicrograph of a fused powder coating system where a second powder coating layer is applied over a first powder coating melt, by optical microscopy at 200x magnification.
- Figure 3 is a cross-sectional photomicrograph of a convention powder coating utilizing conventional process steps of applying a second powder coating layer over a cured first powder coating layer, by optical microscopy at 200x magnification.
- the function of coatings is to provide protection and/or an aesthetic appearance to a substrate. It was found that the process according to the present invention can be used to produce powder coatings films that have excellent intercoat adhesion and the increased barrier from co-reaction resulting in improved properties such as corrosion resistance.
- the film-forming resin and other ingredients are selected so as to provide the desired performa ce and appearance characteristics.
- coatings should generally be durable and exhibit good weatherabiiity, stain or dirt resistance, chemical or solvent resistance and/or corrosion resistance, as well as good mechanical properties, e.g. hardness, flexibility or resistance to mechanical impact; the precise characteristics required will depend on the intended use,
- the final composition must, of course, be capable of forming a coherent film on the substrate.
- any type of powder coating that has functional groups that are reactive or that ears crosslink with functional groups of a second and subsequent powder coating layers can be used for the first powder coating layer and the second powder coating layer, respectively.
- the film forming component in the first powder coating layer can be the same, or can be different as in the second or subsequent powder layers, so long as they have respective reactive functional groups or cross-linking moieties.
- at least two different powder coating layers, each having functional groups in stoichiometric ratios sufficient to react or crosslink with each other, are applied to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer, without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer.
- primer/topcoat powder coating layer combinations are possible in a dry-on-dry process in accordance with this invention.
- the primer layer is not heated or cured until after the application of the second powder coating layer, at which time the layers are cured simultaneously wherein the functional groups of the first powder layer and the second powder layer either co-react or cross-link with each other upon application of the second powder coating layer and upon application of heat.
- at least one layer comprises double bonds and/or other unsaturated moieties that will react with free radicals generated from peroxides or induced by radiation and incorporated into one or more of the layers of powder.
- any subsequent layers have functionality that reacts with the previously applied layer.
- the binder system of the first powder coating layer can be based on a polymeric binder system comprising polyepoxide film-forming resin.
- the second powder coating layer can be based on a polymeric binder system comprising a carboxyl- functional polyester film forming resin.
- carboxyi-functional polyester systems can be commercial carboxyi-functional polyesters such as Crylcoat 4420-0, which have additional functionalities (residual hydroxyl functionality) for cross-linking.
- the poiyepoxide resins can be glycidyl ethers of bisphenoi A such as commercially available DER 672U commercially available from Dow.
- pigment and/or filler there are generally one or more additives that are mixed with the binder for performance characteristics.
- the invention is shown in the following example of a two layer system ( epoxy based powder coating primer and polyester powder coating topcoat ). These are intended to illustrate the invention but are not to be construed as limiting in any manner the scope thereof.
- first layer powder coating (“first layer”) and second layer powder coating (“second layer”) were electrostatically applied to four test panels of CRS-cold rolled stee at approximately 2,0-3,0 mils applied coating thickness each, as follows:
- Panel 1 Second layer only, then heated 10 min@205C.
- Panel 2 Second layer applied to first layer, prior to cure of first layer, then both layers cured simultaneously for 10 min@2Q5C (i.e., dry-on-dry according to this invention as shown in Figure 1),
- Panel 3 First layer applied and heated 1 min@205C to allow melt/gel, followed by application of the second layer, then both layers cured simultaneously for 10min@205C (i.e., fused primer as shown in Figure 2).
- Panel 4 First layer applied an fully cured for 10 mm@205C, followed by application of the second layer, then cured simultaneously 10 min@205C (i.e., fully cured layers of Figure 3).
- the panels are cured to ambient temperature and tested and compared for impact and cross-hatch adhesion.
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- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Wood Science & Technology (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Paints Or Removers (AREA)
Abstract
A method for the application of at least two different powder coating layers to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer, without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer, wherein the first powder coating layer and the second powder coating layer each comprise at least one resin independently having at least one functional group in stoichiometric ratios sufficient to react or crosslink with the other layer at the interface of the two or more layers.
Description
METHOD FOR APPLYING A POWDER COATING
BACKGROUND OF THE INVENTION
[0001] Powder coatings are mixtures of thermosetting film-forming resins, usually one or more pigments and one or more other additives, which are mixed in the production process, extruded, ground, and generally applied by electrostatic spray process in which the powder coating particles are electrostatically charged and applied to a surface by a spray gun, or where a fluidized bed of powder is heated to melt and fuse the particles and cure the coating. Curing can take place by heat or by radiation, which melts, gels and cures the particles of the powder into a uniform film,
[0002] Typically, powder coatings are applied as a single coat direct to metal or as a coating over another layer of powder primer which has been previously cured. These methods are referred to as a conventional powder coating application process. These conventional process steps are generally stepwise as follows:
Step 1 ; Apply first layer;
Step 2: Cure first layer;
Step 3 : Apply second layer; and
Step 4: Cure second layer.
[0003] In some processes of two-layer powder coating systems, a first layer is applied and heated to create a "melt" and then a second layer is applied over the first layer "melt" thus requiring an additional process step of heating to create a melt. According to this invention, a powder coating topcoat and a powder coating primer coat that have reactive functionalities with each other can be electrostatically applied by spray (the first layer powder coating primer is applied to substrate followed by the application of a reactive topcoat or reactive subsequent topcoats) and heated and cured only once, thus eliminating at least one complete coating cure cycle. These methods are referred to as dry-on-dry application process. These process steps are as follows:
Step 1 : Apply first layer;
Step 2: Apply second layer (and subsequent layers) having functionalities reactive with the first (or previous) layer, and applying the second (and subsequent layers) before the previous layer cures;
Step 3: Cure first layer and second (and subsequent layers) simultaneously.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a method for the application of at least two different powder coating layers to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer , without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer, wherein the first powder coating layer and the second powder coating layer each comprise at least one resin independently having at least one functional group in stoichiometric ratios sufficient to react or crosslink with the other layer at the interface of the two or more layers.
[0005] The present invention also is a mult-coat, one-bake coating system, comprising a first powder coating layer followed by the application of a second (or subsequent) powder coating layer(s), without any substantial curing of the first powder coating layer prior to the application of the second (or subsequent) powder coating layer(s), followed by the simultaneous curing of the first powder coating layer and the second (or subsequent) powder coating layer(s), wherein the first powder coating layer and the second (or subsequent) powder coating layer(s) each comprise at least one resin independently having at least one functional group that is reactive or crosslinkable with the previously applied layer.
[0006] In another embodiment, the present invention is a coated article comprising a mult-coat, one-bake coating system, comprising a first powder coating layer followed by the application of a second (or subsequent) powder coating layer(s), without any substantial curing of the first powder coating layer prior to the application of the second
(or subsequent) powder coating layer(s), followed by the simultaneous curing of the first powder coating layer and the second (or subsequent) powder coating layer(s), wherein the first powder coating layer and the second (or subsequent) powder coating layer(s) each comprise at least one resin independently having at least one functional group that is reactive or crosslinkable with the previously applied layer.
DESCRIPTION OF THE DRAWINGS
[ 0007] Figure 1 is a cross-sectional photomicrograph of a powder coating system of this invention, showing the interface of co-reaction of the first layer powder coating and the second layer of a powder coating, by optical microscopy at 200x magnification.
[ΘΘ08] Figure 2 is a cross-sectional photomicrograph of a fused powder coating system where a second powder coating layer is applied over a first powder coating melt, by optical microscopy at 200x magnification.
[0009] Figure 3 is a cross-sectional photomicrograph of a convention powder coating utilizing conventional process steps of applying a second powder coating layer over a cured first powder coating layer, by optical microscopy at 200x magnification.
DETAILED DESCRIPTION OF THE INVENTION
|0010] The function of coatings is to provide protection and/or an aesthetic appearance to a substrate. It was found that the process according to the present invention can be used to produce powder coatings films that have excellent intercoat adhesion and the increased barrier from co-reaction resulting in improved properties such as corrosion resistance.
[0011] The film-forming resin and other ingredients are selected so as to provide the desired performa ce and appearance characteristics. In relation to performance, coatings should generally be durable and exhibit good weatherabiiity, stain or dirt resistance, chemical or solvent resistance and/or corrosion resistance, as well as good mechanical properties, e.g. hardness, flexibility or resistance to mechanical impact; the precise characteristics required will depend on the intended use, The final composition must, of course, be capable of forming a coherent film on the substrate.
[0012] In accordance with this invention, any type of powder coating that has functional groups that are reactive or that ears crosslink with functional groups of a second and subsequent powder coating layers can be used for the first powder coating layer and the second powder coating layer, respectively. The film forming component in the first powder coating layer can be the same, or can be different as in the second or subsequent powder layers, so long as they have respective reactive functional groups or cross-linking moieties. In accordance with this invention, at least two different powder coating layers, each having functional groups in stoichiometric ratios sufficient to react or crosslink with each other, are applied to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer, without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer.
[0013 J Various primer/topcoat powder coating layer combinations are possible in a dry-on-dry process in accordance with this invention. The primer layer is not heated or cured until after the application of the second powder coating layer, at which time the layers are cured simultaneously wherein the functional groups of the first powder layer and the second powder layer either co-react or cross-link with each other upon application of the second powder coating layer and upon application of heat. For example, the first powder layer can be selected from polymers having hydroxyl, phenol, amino, earboxylic acid, mereapto, epoxy, amine, anhydride, amide, isocyanate, vinyl (double bond for free radical cure), alkene (C=C double bond for free radical cure) or other primary or secondary functional or reactive groups; and the second and subsequent powder iayer(s) can have functional groups that can chemically react with the first layer or prior layer reactive groups. In one embodiment, at least one layer comprises double bonds and/or other unsaturated moieties that will react with free radicals generated from peroxides or induced by radiation and incorporated into one or more of the layers of powder.
According to this invention, any subsequent layers have functionality that reacts with the previously applied layer.
[0014] For example, the binder system of the first powder coating layer can be based on a polymeric binder system comprising polyepoxide film-forming resin. The second
powder coating layer can be based on a polymeric binder system comprising a carboxyl- functional polyester film forming resin. Such carboxyi-functional polyester systems can be commercial carboxyi-functional polyesters such as Crylcoat 4420-0, which have additional functionalities (residual hydroxyl functionality) for cross-linking. The poiyepoxide resins can be glycidyl ethers of bisphenoi A such as commercially available DER 672U commercially available from Dow.
[0015] Various combinations are listed in the following table based on the functionalities of the powder coating layers. These are intended to illustrate the invention but are not to be construed as limiting in any manner the scope thereof.
TABLE 1
s
TAB
Tat sle 3
First Layer Functionality | Second Layer Functionality
Foiy socyanate i CO)
{* reacts with residual OH functionality of
(Examptes: Vesatgon B153Q, Vestagon 8F1540, Creian EF403, Creian NWS, Creian NI-2, Aicure
Polyester Hydroxyl 4470}
(Examples: Rucote
102, Rucote 104, {* reacts with residual Acid functionality of Albester 3020, polyester) Albester 3110, (Examples: DER 663U, NPES 903,617013, Lumiflcrs LF-71QF) GT70I4,
DER 672U}
i Tetrametho&vmeti l g!vcourii (T GU)
{Examples: Powderlink 1174, Acetomer 1174} Trig!ycidvl isocyanurate (TGiC)
I f* reacts with residua? Acid functionality of
(Examples: PT810, TEPIC G, Niuiang TGSC)
(Examples; Primd XL552, Primid SF45I0., Primid
QM1260)
[0016] Evidence of a co-reaction taking place at the interface of the first and second powder coating layers can be confirmed by accelerated testing (QIJV), which shows that, upon exposure to ultraviolet radiation, there is no reduction in the coating's resistance to the ultraviolet radiation. Without this co-reaction the polyepoxide component would migrate to the top layer and diminish the coatings resistance to ultra violet radiation.
[0017] In addition to film-forming binder resin and optional cross-Sinker, pigment and/or filler there are generally one or more additives that are mixed with the binder for performance characteristics.
[0018] The invention is shown in the following example of a two layer system ( epoxy based powder coating primer and polyester powder coating topcoat ). These are intended to illustrate the invention but are not to be construed as limiting in any manner the scope thereof.
EXAMPLES
The following standard powder coatings were used in these examples.
( 1 ) commercially available from DOW Chemical. [ 100.00 J
(2) commercially available frorn S CNT CO.,
LTD.
(3) commercially available from KS CNT CO,, LTD.
The above first layer powder coating ("first layer") and second layer powder coating ("second layer") were electrostatically applied to four test panels of CRS-cold rolled stee at approximately 2,0-3,0 mils applied coating thickness each, as follows:
Panel 1 : Second layer only, then heated 10 min@205C.
Panel 2: Second layer applied to first layer, prior to cure of first layer, then both layers cured simultaneously for 10 min@2Q5C (i.e., dry-on-dry according to this invention as shown in Figure 1),
Panel 3: First layer applied and heated 1 min@205C to allow melt/gel, followed by application of the second layer, then both layers cured simultaneously for 10min@205C (i.e., fused primer as shown in Figure 2).
Panel 4: First layer applied an fully cured for 10 mm@205C, followed by application of the second layer, then cured simultaneously 10 min@205C (i.e., fully cured layers of
Figure 3).
The panels are cured to ambient temperature and tested and compared for impact and cross-hatch adhesion.
[0019] Evidence of a co-reaction between a first poiyepoxide layer and a second layer without the required curative can be seen in the above examples when applied in a conventional process or melt process, as compared to a dry-on-dry process. In the case of the conventional process (Panel 4) and the fused process (Panel 3), the intercoat adhesion was very poor, indicating that no co-reaction of the first and second coating layer is taking place. In the case of the dry-on-dry process of Panel 2, adhesion was very good which indicates that a co-reaction had taken place between the first and second coating layer. Thus, the above comparative examples show that the method of Panel 2 (dry on dry) of the present, invention compare very favorably against the conventional and fused system powder coating methods,
[0020] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof, It is understood therefore, that this invention is not limited to the particular embodiments disclosed, but is intended to cover modifications that are within the spirit and scope of the invention, as defined by the claims.
Claims
We ..claim:
1 , A method for the application of at least two different powder coating layers to a substrate comprising the steps of application of a first powder coating layer followed by the application of a second powder coating layer, without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing at a temperature and time period sufficient to substantially cure the first powder coating layer and the second powder coating layer, wherein the first powder coating layer and the second powder coating layer each comprise at least one resin independently having at least one functional group in stoichiometric ratios sufficient to react or crosslink with the other layer.
2, The method of claim 1 , wherein the first powder coating layer has functionality selected from the group consisting of epoxy, polyester carboxyl and polyester hydroxyl.
3, The method of claim 1 , wherein the first powder coating layer has epoxy functionality and the second powder coating layer has functionality selected from the group consisting of polyester carboxyl, polyester hydroxyl, amine, phenolic, acrylic and anhydride,
4, The method of claim 1 , wherein the first powder coating layer has polyester carboxyl functionality and the second powder coating layer is selected from
tetramethoxymethyl glycouril, trlglycidyi isocyaniirate. hydroxyaikyiarnide, and resins having functionality selected from the group consisting of isocyanate and epoxide,
5, The method of claim 1 , wherein the first powder coating layer has polyester hydroxy! functionality and the second powder coating layer is selected from
tetramethoxymethy! giycouril, triglycidyl isocyanurate, hydroxyalkylamide. and resins having functionality selected from the group consisting of isocyanate and epoxide.
6. A multi-coat, one-bake coating system, comprising : a first powder coating layer followed by the application of a second powder coating layer, without any substantial curing of the first powder coating layer prior to the application of the second powder coating layer, followed by the simultaneous curing of the first powder coating layer and the second powder coating layer, wherein the first powder coating layer and the second powder coating layer each comprise at least one resin independently having at least one functional group that is reactive or crosslinkabie with the other layer.
7. The system of claim 6, wherein the first powder coating layer has functionality selected from the group consisting of epoxy, polyester carboxyl and polyester hydroxy!.
8. The system of claim 6, wherein the first powder coating layer has epoxy functionality and the second powder coating layer has functionality selected from the group consisting of polyester carboxyl, polyester hydroxy!, amine, phenolic, acrylic and anhydride.
9. The system of claim 6, wherein the first powder coating layer has polyester carboxyl functionality and the second powder coating layer is selected from
tetramethoxymethyl giyeouril, triglycidyl isocyanurate, hydroxyalkylamide, and resins having functionality selected from the group consisting of isocyanate and epoxide,
10. The system of claim 6, wherein the first powder coating layer has polyester hydroxy! functionality and the second powder coaling layer is selected from
tetramethoxymethyl giyeouril, triglycidyl isocyanurate, hydroxyalkylamide, and resins having functionality selected from the group consisting of isocyanate and epoxide.
1 1. The method of claim 1 , wherein the first powder layer is selected from polymers having functionalities selected from the group consisting of hydroxy!, phenol, amino, carboxylic acid, rnercapto, epoxy, amine, anhydride, amide, isocyanate, vinyl, alkene or other primary or secondary functional or reactive groups: and wherein the second and subsequent powder layer has groups that can chemically react with the first layer or prior layer reactive groups.
12. The system of claim 6, wherein the first powder layer is selected from polymers having functionalities selected from the group consisting of hydroxyl, phenol, amino, carboxylic acid, rnercapto, epoxy, amine, anhydride, amide, isocyanate, vinyl, alkene or other primary or secondary functional or reactive groups: and wherein the second and subsequent powder layer has groups that can chemically react with the first layer or prior layer reactive groups,
13. A coated article comprising the coating system of claim 6.
14. The coated article of claim 13, wherein the first powder coating layer has functionality selected from the group consisting of epoxy, polyester carboxyl and polyester hydroxy!,
15. The coated article of claim 13, wherein the first powder coating layer has epoxy functionality and the second powder coating layer has functionality selected from the group consisting of polyester carboxyl, polyester hydroxy!, amine, phenolic, acrylic and anhydride.
16. The coated article of claim 13, wherein the first powder coating layer has polyester carboxyl functionality and the second powder coating layer is selected from
teiramethoxymethyl glyeouril, iriglycidyl isocyanurate, hydroxyalkylamide, and resins having functionality selected from the group consisting of isocyanate and epoxide,
17. The coated article of claim 13, wherein the first powder coating layer has polyester hydroxy! functionality and the second powder coating layer is selected from tetramethoxymethyl glycouriL iriglycidyl isocyanurate, hydroxyalkylamide, and resins having functionality selected from the group consisting of isocyanate and epoxide,
18. The system of claim 6 wherein at least one layer comprises double bonds or other unsaturated moieties that will react with free radicals generated from peroxides or induced by radiation and incorporated into one or more of the layers of powder.
19. The system of Claim 6 where the polymers contain both a chemically reactive group and unsaturated double bonds that can react with free radicals generated from peroxides or induced by radiation and incorporated into one or more of the layers of powder.
20. A multi-layered coating system obtainable from the method of claim 1.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP14721575.0A EP2969261A1 (en) | 2013-03-14 | 2014-03-10 | Method for applying a powder coating |
| MX2015012762A MX2015012762A (en) | 2013-03-14 | 2014-03-10 | Method for applying a powder coating. |
| CA2905749A CA2905749A1 (en) | 2013-03-14 | 2014-03-10 | Method for applying a powder coating |
| CN201480023285.9A CN105142802A (en) | 2013-03-14 | 2014-03-10 | Method for applying a powder coating |
| BR112015022862A BR112015022862A2 (en) | 2013-03-14 | 2014-03-10 | method for applying a powder coating |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201313827005A | 2013-03-14 | 2013-03-14 | |
| US13/827,005 | 2013-03-14 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2014150167A1 true WO2014150167A1 (en) | 2014-09-25 |
Family
ID=50639906
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2014/022459 WO2014150167A1 (en) | 2013-03-14 | 2014-03-10 | Method for applying a powder coating |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US11007550B2 (en) |
| EP (1) | EP2969261A1 (en) |
| CN (1) | CN105142802A (en) |
| BR (1) | BR112015022862A2 (en) |
| CA (1) | CA2905749A1 (en) |
| MX (1) | MX2015012762A (en) |
| WO (1) | WO2014150167A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3626786A1 (en) | 2018-09-19 | 2020-03-25 | Emil Frei GmbH & Co. KG | Powder coating system for coating, particularly a metallic substrate, its use on a metallic substrate and method for applying such a powder coating system to metallic substrate |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106311103A (en) * | 2016-09-27 | 2017-01-11 | 天津傲卓菲科技有限公司 | Strawberry-shaped super-hydrophobic composite microsphere and application thereof |
| KR102394180B1 (en) * | 2017-04-07 | 2022-05-03 | 피피지 인더스트리즈 오하이오 인코포레이티드 | Coating compositions, dielectric coatings formed therefrom, and methods of making dielectric coatings |
| US11892117B1 (en) | 2019-10-30 | 2024-02-06 | Watts Regulator Co. | Method for coating a valve assembly with a two layer antimicrobial anticorrosion coating |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060110601A1 (en) * | 2004-11-19 | 2006-05-25 | Hennessey Craig K | Process for applying fluoropolymer powder coating as a primer layer and an overcoat |
| EP2060328A2 (en) * | 2007-11-15 | 2009-05-20 | General Electric Company | Methods of forming composite powder coatings and articles thereof |
| WO2011134986A1 (en) * | 2010-04-29 | 2011-11-03 | Akzo Nobel Coatings International B.V. | Method for applying a powder coating |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7507440B2 (en) * | 2005-02-23 | 2009-03-24 | Ppg Industries Ohio, Inc. | Methods of forming composite coatings |
-
2014
- 2014-03-10 BR BR112015022862A patent/BR112015022862A2/en not_active Application Discontinuation
- 2014-03-10 EP EP14721575.0A patent/EP2969261A1/en not_active Withdrawn
- 2014-03-10 CN CN201480023285.9A patent/CN105142802A/en active Pending
- 2014-03-10 MX MX2015012762A patent/MX2015012762A/en unknown
- 2014-03-10 WO PCT/US2014/022459 patent/WO2014150167A1/en active Application Filing
- 2014-03-10 CA CA2905749A patent/CA2905749A1/en not_active Abandoned
-
2018
- 2018-05-14 US US15/978,689 patent/US11007550B2/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060110601A1 (en) * | 2004-11-19 | 2006-05-25 | Hennessey Craig K | Process for applying fluoropolymer powder coating as a primer layer and an overcoat |
| EP2060328A2 (en) * | 2007-11-15 | 2009-05-20 | General Electric Company | Methods of forming composite powder coatings and articles thereof |
| WO2011134986A1 (en) * | 2010-04-29 | 2011-11-03 | Akzo Nobel Coatings International B.V. | Method for applying a powder coating |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3626786A1 (en) | 2018-09-19 | 2020-03-25 | Emil Frei GmbH & Co. KG | Powder coating system for coating, particularly a metallic substrate, its use on a metallic substrate and method for applying such a powder coating system to metallic substrate |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2905749A1 (en) | 2014-09-25 |
| US20180361429A1 (en) | 2018-12-20 |
| EP2969261A1 (en) | 2016-01-20 |
| CN105142802A (en) | 2015-12-09 |
| BR112015022862A2 (en) | 2017-07-18 |
| MX2015012762A (en) | 2016-09-07 |
| US11007550B2 (en) | 2021-05-18 |
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