# US 11,999,869 B2 · Coating compositions and methods for application utilizing a high transfer efficiency applicator > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,999,869 B2 - Document ID: US11999869B2 - Status: Granted - Kind: B2 - Application number: 17/804,311 - Filed: 2022-05-27 - Published: 2022-12-08 - Granted: 2024-06-04 - Earliest claimed: 2021-05-27 - Assignees: Axalta Coating Systems IP Co., LLC - Applicants: Axalta Coating Systems IP Co., LLC - Inventors: Shih-Wa Wang; Mei Wen; Michael Wolfe - Web page: https://patentgrep.com/patent/US11999869B2 ## CPC - B05D 1/26: performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface - C09D 4/06: {Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond} in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00 - B05D 3/067: {Curing or cross-linking the coating} - C09D 5/00: Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced {(electrically insulating plastics, resins or waxes H01B3/30)}; Filling pastes - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - 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) ## Abstract Methods and coating compositions for application to a substrate utilizing a high transfer efficiency applicator are provided. An exemplary method includes providing the coating composition to the high transfer efficiency applicator; applying the coating composition onto the substrate utilizing a high transfer efficiency applicator to form an applied layer, wherein a loss of volatiles after application through the high transfer efficiency applicator is less than about 1 weight percent based on a total weight of the coating composition; performing a partial polymerization via radiation of the applied layer; and after performing the partial polymerization of the applied layer, thermally curing and drying the applied layer. An exemplary coating composition has a pre-application viscosity, at a shear rate of 1000 s−1, of less than about 100 centipoise (cP), and a post-radiation-exposure viscosity at a shear rate of 0.1 s−1 of from about 500 cP to about 150,000 cP. ## Claims ### Claim 1 A method of applying a coating composition to a substrate utilizing an applicator to form a coating layer disposed on the substrate, said method comprising the steps of: providing the coating composition to the applicator; applying the coating composition onto the substrate utilizing the applicator to form an applied layer with an application efficiency greater than 80%, wherein a loss of volatiles after application through the applicator is less than about 1 weight percent based on a total weight of the coating composition; performing a partial polymerization via radiation of the applied layer; and after performing the partial polymerization of the applied layer, thermally curing and drying the applied layer; wherein the coating composition comprises: a thermal binder; a radiation-polymerizable binder; optionally, a photo-initiator; optionally, a thermal-initiator; optionally, a pigment; and a liquid carrier; wherein the coating composition has a pre-application viscosity, at a shear rate of 1000 s−1, of less than about 100 centipoise (cP); wherein the coating composition has a post-radiation-exposure viscosity, at a shear rate of 0.1 s−1, of from about 500 cP to about 150,000 cP; wherein the thermal binder is a polymer or resin with crosslinkable groups selected from the group consisting of hydroxyl, acetoacetoxy, carboxyl, primary amine, secondary amine, epoxy and a combination thereof and crosslinking components selected from the group consisting of polyisocyanate, blocked polyisocyanate, polyamine, ketimine, melamine, epoxy, polyacid and a combination thereof. ### Claim 2 (depends on 1) The method of claim 1 wherein the post-radiation-exposure viscosity, at a shear rate of 0.1 s−1, is from about 1000 cP to about 150,000 cP, from about 2000 cP to about 150,000 cP, or from about 5000 cP to about 150,000 cP. ### Claim 3 (depends on 1) The method of claim 1 wherein the coating composition comprises a desired amount of the radiation-polymerizable binder based on total resin solid, wherein the desired amount is selected from about 0.5 to about 60 wt %, from about 1 to about 40 wt %, and from about 2 to about 30 wt %. ### Claim 4 (depends on 3) The method of claim 3 wherein the radiation sources can be attached onto the high efficiency applicator head or mounted to a separate robot arm or mount in the booth or mount in the oven or combination so the radiation can be used at desired timing after the coating layer applied to the substrate and before the final thermal cure to achieve desired surface appearance and sag resistance. ### Claim 5 (depends on 1) The method of claim 1 wherein the coating composition further comprises a desired amount of photo-initiator, based on the total weight of the composition, wherein the desired amount is selected from about 0.01 to about 10 wt %, from about 0.05 to about 8 wt %, and from about 0.08 to about 6 wt %. ### Claim 6 (depends on 1) The method of claim 1 wherein the radiation-polymerizable binder contains functional groups other than acrylate or vinyl double bonds that can react with other functional groups in remaining binder during a post-radiation bake process. ### Claim 7 (depends on 1) The method of claim 1 wherein the liquid carrier can be water, organic solvents or a combinations thereof. ### Claim 8 (depends on 1) The method of claim 1 wherein the radiation sources can be attached onto the high efficiency applicator head or mount to a separate robot arm or mount in the booth or mount in the oven or combination so the radiation can be used at desired timing after the coating layer applied to the substrate and before the final thermal cure to achieve desired surface appearance and sag resistance. ### Claim 9 A method for forming a layer of a coating composition on a substrate, the method comprising: applying the coating composition onto the substrate utilizing an applicator to form an applied layer with an application efficiency greater than 80%, wherein a loss of volatiles after application through the applicator is less than about 1 weight percent based on a total weight of the coating composition; after leveling of the applied layer, performing a partial polymerization via radiation of the applied layer; and after performing the partial polymerization of the applied layer, thermally curing and drying the applied layer, wherein before applying the coating composition onto the substrate, the coating composition has a pre-application viscosity at a shear rate of 1000 s−1 of less than about 100 centipoise (cP); and wherein after performing the partial polymerization of the applied layer, the coating composition has a post-radiation-exposure viscosity at a shear rate of 0.1 s−1 selected from at least 500 cP, at least 1000 cP, at least 2000 cP, and at least 5000 cP. ### Claim 10 (depends on 9) The method of claim 9 wherein the coating composition includes a radiation polymerizable binder, and wherein performing the partial polymerization of the applied layer comprises exposing the applied layer to radiation. ### Claim 11 (depends on 9) The method of claim 9 wherein the coating composition includes a photo-initiator and a radiation-polymerizable binder, and wherein performing the partial polymerization of the applied layer comprises exposing the applied layer to radiation. ### Claim 12 (depends on 9) The method of claim 9 wherein: after performing the partial polymerization of the applied layer, the coating composition has a post-radiation-exposure viscosity at a shear rate of 0.1 s−1 of at least 5000 cP. ### Claim 13 (depends on 9) The method of claim 9 wherein the coating composition includes a photo-initiator and a polymerizable binder, and wherein performing the partial polymerization of the applied layer comprises exposing the applied layer to radiation generated by an LED lamp. ### Claim 14 (depends on 9) The method of claim 9 wherein the coating composition includes a photo-initiator and a visible light polymerizable binder, and wherein performing the partial polymerization of the applied layer comprises exposing the applied layer to visible light.