Methods of coating substrates and coated substrates

Patent metadata

Field	Value
Publication number	US-2024385559-A1
Application number	US-202218290566-A
Country	US
Kind code	A1
Filing date	May 19, 2022
Priority date	May 19, 2021
Publication date	Nov 21, 2024
Grant date	—

Abstract

Methods of coating powder coating compositions, particularly substrate powder coating compositions, and methods of making a substrate container, a portion thereof, or a closure for a container, and powder coating systems.

First claim

1 - 82 . (canceled)

83 . A method of coating a substrate the method comprising:
directing multiple powder coating compositions to at least a portion of the substrate such that at least one powder coating composition is deposited on another powder coating composition; and providing conditions effective for the multiple powder coating compositions to form a hardened continuous adherent coating on at least a portion of the substrate, wherein each powder coating composition comprises powder polymer particles, and at least two of the multiple substrate powder coating compositions are different.

84 . The method of claim 83 , wherein the substrate is a coil of metal, preferably wherein the substrate comprises hot-rolled steel, cold-rolled steel, hot-dip galvanized steel, electrogalvanized steel, aluminum, tin plate, various grades of stainless steel, or aluminum-zinc alloy coated sheet steel.

85 . The method of claim 83 , wherein providing conditions effective comprises providing conditions effective for each of the powder coating compositions to form a hardened adherent coating between depositing layers of different powder coating compositions.

86 . The method of claim 83 , wherein the hardened adherent coating has an average total thickness of at least 1 micron, at least 2 microns, at least 3 microns, or at least 4 microns, and up to 50 microns, up to 25 microns, up to 20 microns, up to 15 microns, up to 10 microns, or up to 5 microns.

87 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise powder polymer particles comprising a polymer having a number average molecular weight of at least 2000 Daltons and up to 10,000,000 Daltons.

88 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise powder polymer particles having a particle size distribution having a D50 of less than 25 microns.

89 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise the powder polymer particles in an amount of at least 50 wt-%.

90 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise one or more charge control agents in contact with the powder polymer particles and/or magnetic carrier particles.

91 . The method of claim 83 , wherein the method comprises electrically grounding the substrate while directing at least one powder coating composition of the multiple powder coating compositions to the at least a portion of the substrate.

92 . The method of claim 91 , wherein the method comprises electrostatically adhering at least one powder coating of the multiple powder coating compositions to a transporter surface, imaging member, and/or intermediate transfer member, before directing each of the multiple powder coating compositions to at least a portion of the metal substrate; wherein electrostatically adhering the at least one powder coating composition comprises electrically biasing the transporter surface, imaging member, and/or intermediate transfer member to a non-zero voltage before electrostatically adhering the at least one powder coating composition to the transporter surface, imaging member, and/or intermediate transfer member.

93 . The method of claim 92 , wherein a first deposited powder coating composition is at a first polarity, and the method further includes changing the first polarity of the first deposited powder coating composition to a second polarity, and applying a second coating composition at a second polarity to the first deposited powder coating composition.

94 . The method of claim 83 , wherein directing each of the multiple powder coating compositions to at least a portion of the substrate comprises: feeding each of the multiple powder coating compositions to one or more transporters; and directing each of the multiple powder coating compositions from the one or more transporters to at least a portion of the substrate by means of an electric or electromagnetic field.

95 . The method of claim 83 , wherein transferring each of the multiple powder coating compositions from the one or more transfer members to at least a portion of the substrate comprises applying thermal energy, or electrical, electrostatic, or mechanical forces to effect the transfer.

96 . The method of claim 92 , wherein the one or more transporters comprises a magnetic roller, polymeric conductive roller, polymeric semiconductive roller, metallic belt, polymeric conductive belt, or polymeric semiconductive belt; and one or more of the multiple powder coating compositions comprise magnetic carrier particles.

97 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise powder polymer particles comprising a polymer having a melt flow index greater than 15 grams/10 minutes.

98 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise powder polymer particles comprising a polymer having a glass transition temperature (Tg) of at least 40° C. and up to 150° C.

99 . The method of claim 83 , wherein one or more of the multiple powder coating compositions comprise powder polymer particles comprising a polymer selected from a polyacrylic, polyether, polyolefin, polyester, polyurethane, polycarbonate, polystyrene, or a copolymer or mixture thereof.

101 . The method of claim 83 , wherein one or more of the multiple powder coating compositions are substantially free of all bisphenol compounds, except for TMBPF.

102 . The method of claim 83 , wherein one or more of the multiple powder coating compositions are substantially free of each of formaldehyde and formaldehyde-containing ingredients.

103 . A coated substrate having a surface at least partially coated with a coating prepared by the method of claim 83 .

Assignees

• Swimc Llc

Inventors

• Skillman Charles I
• Joslin Richard D
• Desousa Joseph
• Best Ted Robert
• Muns Jade Y
• Romagnoli Kevin M
• Stelter Eric Carl

Classifications

• B05D2451/00

  Type of carrier, type of coating (Multilayers) · CPC title

• B05D7/542

  the two layers being cured or baked together · CPC title

• G03G2215/0604

  solid type · CPC title

• G03G15/6594

  characterised by the format or the thickness, e.g. endless forms · CPC title

• G03G15/6591

  characterised by the recording material, e.g. plastic material, OHP, ceramics, tiles, textiles (details transferring the toner pattern onto particular materials G03G15/1625) · CPC title