Powder layer composite, coating film, powder coating method, and powder coating apparatus

Patent metadata

Field	Value
Publication number	US-11878320-B2
Application number	US-202117396645-A
Country	US
Kind code	B2
Filing date	Aug 6, 2021
Priority date	Sep 16, 2020
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

A powder layer composite includes a base and a powder layer having a thickness of 100 μm or less and disposed on the base. An average of a total value of a number of powder aggregates having a long diameter of 500 μm or greater and a number of pinholes having a long diameter of 500 μm or greater, in any of a plurality of different regions of 20 mm×20 mm on a surface of the powder layer, is 0.2 pieces/cm2 or less.

First claim

What is claimed is:

1. A powder layer composite comprising:
a base; and
a powder layer consisting of at least one non-conducting material, and having a thickness of 100 μm or less and disposed on the base, wherein
an average of a total value of a number of powder aggregates having a long diameter of 500 μm or greater and a number of pinholes having a long diameter of 500 μm or greater, in any of a plurality of different regions of 20 mm×20 mm on a surface of the powder layer, is 0.2 pieces/cm 2 or less.

2. The powder layer composite of claim 1 , wherein
an average of a total value of the number of powder aggregates having a long diameter of 100 μm or greater and 500 μm or less and the number of pinholes having a long diameter of 100 μm or greater and 500 μm or less, in any of a plurality of different regions of 4.0 mm×6.0 mm on the surface of the powder layer, is 10 pieces/cm 2 or less.

3. The powder layer composite of claim 1 , wherein
an average of a total value of the number of powder aggregates having a long diameter of 50 μm or greater and 100 μm or less and the number of pinholes having a long diameter of 50 μm or greater and 100 μm or less, in any of a plurality of different regions of 0.4 mm×0.6 mm on the surface of the powder layer, is 10 pieces/cm 2 or less.

4. The powder layer composite of claim 1 , wherein
a concentration of a solvent contained in the powder layer is 50 ppm or less.

5. The powder layer composite of claim 1 , wherein
an average particle size of particles that form the powder layer is 10 μm or less.

6. The powder layer composite of claim 1 , wherein the at least one non-conducting material is selected from the group consisting of a resin and a ceramic.

7. The powder layer composite of claim 1 , wherein the at least one non-conducting material is selected from the group consisting of an alkyd resin and a ceramic.

8. The powder layer composite of claim 1 , wherein the at least one non-conducting material is selected from the group consisting of an alkyd resin, an acrylic resin, an amino resin, an epoxy resin, a phenol resin, an unsaturated polyester resin, a silicone resin, a polyphenylene ether, a polycarbonate, alumina, zirconia, barium titanate, silicon nitride, aluminum nitride and silicon carbide.

9. A powder layer composite comprising:
a base; and
a powder layer having a thickness of 23.5 μm or less and disposed on the base, wherein
an average of a total value of a number of powder aggregates having a long diameter of 500 μm or greater and a number of pinholes having a long diameter of 500 μm or greater, in any of a plurality of different regions of 20 mm×20 mm on a surface of the powder layer, is 0.2 pieces/cm 2 or less.

10. The powder layer composite of claim 9 , wherein
an average of a total value of the number of powder aggregates having a long diameter of 100 μm or greater and 500 μm or less and the number of pinholes having a long diameter of 100 μm or greater and 500 μm or less, in any of a plurality of different regions of 4.0 mm×6.0 mm on the surface of the powder layer, is 10 pieces/cm 2 or less.

11. The powder layer composite of claim 9 , wherein
an average of a total value of the number of powder aggregates having a long diameter of 50 μm or greater and 100 μm or less and the number of pinholes having a long diameter of 50 μm or greater and 100 μm or less, in any of a plurality of different regions of 0.4 mm×0.6 mm on the surface of the powder layer, is 10 pieces/cm 2 or less.

12. The powder layer composite of claim 9 , wherein
a concentration of a solvent contained in the powder layer is 50 ppm or less.

13. The powder layer composite of claim 9 , wherein
an average particle size of particles that form the powder layer is 10 μm or less.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Okochi Motohiro
• Horikawa Akihiro
• Kojima Toshiyuki

Classifications

• B05B7/144 Primary

  the means for supplying particulate material comprising moving mechanical means (B05B7/1422, B05B7/1459 take precedence) · CPC title

• B05B5/0255

  spraying and depositing by electrostatic forces only · CPC title

• B05B17/0607

  generated by electrical means, e.g. piezoelectric transducers · CPC title

• C08L33/08

  Homopolymers or copolymers of acrylic acid esters · CPC title

• B05B7/1445 Primary

  involving vibrations (B05B7/145 takes precedence) · CPC title