# US 10,370,542 B2 · Thermosetting powder coating material and coated product

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- Number: US 10,370,542 B2
- Document ID: US10370542B2
- Status: Granted
- Kind: B2
- Application number: 15/714,213
- Filed: 2017-09-25
- Published: 2018-09-27
- Granted: 2019-08-06
- Earliest claimed: 2017-03-21
- Assignees: Fuji Xerox Co., Ltd.
- Applicants: Fuji Xerox Co., Ltd.
- Inventors: Hirofumi Shiozaki; Susumu Yoshino
- Web page: https://patentgrep.com/patent/US10370542B2

## CPC

- C09D 5/031: {characterised by particle size or shape}
- C08G 18/4247: {derived from polyols containing at least one ether group and polycarboxylic acids}
- C08G 18/80: Masked polyisocyanates
- C08K 5/0025: {Crosslinking or vulcanising agents; including accelerators}
- C09D 5/033: {characterised by the additives}
- C09D 7/40: Additives
- C09D 133/08: Homopolymers or copolymers of acrylic acid esters
- C09D 133/10: Homopolymers or copolymers of methacrylic acid esters
- C09D 167/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C09D167/06 takes precedence)
- C09D 167/025: {containing polyether sequences}
- C09D 167/04: Polyesters derived from hydroxycarboxylic acids, e.g. lactones (C09D167/06 takes precedence)
- C09D 175/06: from polyesters
- B05D 2401/32: applied as powders
- B05D 2502/005: modified
- B05D 2518/00: Other type of polymers
- C08G 2150/20: Compositions for powder coatings
- C08J 5/18: Manufacture of films or sheets
- 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 (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

A thermosetting powder coating material includes powder particles containing a thermosetting resin, a thermosetting agent, and a surfactant. The amount of the surfactant is about 0.1 ppm or more and about 8.0 ppm or less on a mass basis.

## Claims

### Claim 1

A thermosetting powder coating material comprising:
powder particles containing a thermosetting resin, a thermosetting agent, and a surfactant,
wherein an amount of the surfactant is about 0.1 ppm or more and about 8.0 ppm or less on a mass basis.

### Claim 2 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein the thermosetting resin contains a thermosetting polyester resin.

### Claim 3 (depends on 2)

The thermosetting powder coating material according to claim 2, wherein a sum of an acid value and a hydroxyl value of the thermosetting polyester resin is about 10 mg KOH/g or more and about 250 mg KOH/g or less.

### Claim 4 (depends on 3)

The thermosetting powder coating material according to claim 3, wherein the thermosetting polyester resin has a number-average molecular weight of about 1,000 or more and about 100,000 or less.

### Claim 5 (depends on 2)

The thermosetting powder coating material according to claim 2, wherein the thermosetting polyester resin has a glass transition temperature (Tg) of about 60° C. or lower.

### Claim 6 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein the thermosetting resin contains a thermosetting (meth)acrylic resin.

### Claim 7 (depends on 6)

The thermosetting powder coating material according to claim 6, wherein the thermosetting (meth)acrylic resin has a number-average molecular weight of about 1,000 or more and about 20,000 or less.

### Claim 8 (depends on 6)

The thermosetting powder coating material according to claim 6, wherein the thermosetting (meth)acrylic resin has a glass transition temperature (Tg) of about 60° C. or lower.

### Claim 9 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein the surfactant contains at least one selected from the group consisting of anionic surfactants and nonionic surfactants.

### Claim 10 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein an amount of the thermosetting agent is about 1% by mass or more and about 30% by mass or less relative to an amount of the thermosetting resin.

### Claim 11 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein the thermosetting powder coating material is free of a colorant.

### Claim 12 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein the thermosetting powder coating material contains a metal element capable of having a valence of 2 or higher.

### Claim 13 (depends on 12)

The thermosetting powder coating material according to claim 12, wherein an amount of the metal element is about 0.002% by mass or more and about 0.2% by mass or less relative to a total amount of the thermosetting powder coating material.

### Claim 14 (depends on 1)

The thermosetting powder coating material according to claim 1, further comprising inorganic particles with hydrophobized surfaces.

### Claim 15 (depends on 14)

The thermosetting powder coating material according to claim 14, wherein the inorganic particles have a volume-average particle size of about 5 nm or more and about 40 nm or less.

### Claim 16 (depends on 14)

The thermosetting powder coating material according to claim 14, wherein an amount of the inorganic particles added is about 0.01% by mass or more and about 5% by mass or less relative to a total amount of the thermosetting powder coating material.

### Claim 17 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein a volume particle size distribution index GSDv is about less than 1.20.

### Claim 18 (depends on 1)

The thermosetting powder coating material according to claim 1, wherein an average circularity is about 0.96 or more.

### Claim 19 (depends on 1)

A coated product having a surface, comprising a coating film formed of the thermosetting powder coating material according to claim 1 on at least part of the surface.

### Claim 20 (depends on 19)

The coated product according to claim 19, wherein the coating film has a thickness of about 10 μm or more and about 120 μm or less.