Dip, spray, and flow coating process for forming coated articles
OwnerGerald A. Hutchinson, Robert A. Leeinventors
Life of this patent
Estimating the term…
Abstract
This invention relates to methods and apparatus for making coated articles with one or more layers by dip, spray or flow coating. In one aspect, this invention relates to an apparatus and method for making coated containers, preferably comprising polyethylene terephthalate, from coated preforms. In preferred embodiments, the apparatus and method permit the coated container or preform to be made in an energy-efficient manner that reduces the danger of coating damage and thus increases the efficacy of the final container.
Claims51
A process for making thermoplastic resin coated articles, the process comprising:
- applying an aqueous solution or dispersion of a first thermoplastic resin on the outer surface of an article substrate by dip, spray, or flow coating;
- withdrawing the article from the dip, spray, or flow coating at a rate so as to form a first coherent film;
- curing/drying the coated article until the first film is substantially dried so as to form a first coating;
- optionally applying an aqueous solution or dispersion of a second thermoplastic resin on the outer surface of an article substrate by dip, spray, or flow coating;
- withdrawing the article from the dip, spray, or flow coating at a rate so as to form a second coherent film;
- curing/drying the coated article until the second film is substantially dried so as to form a second coating;
- wherein at least one of the first and second thermoplastic resins comprises a thermoplastic epoxy resin.
An apparatus for making coated articles comprising:
- a conveyor that transports said articles through a flow coating system;
- and
- a flow coating system comprising:
- a first flow coating unit which comprises:
- a tank or vat containing an aqueous solution/dispersion coating material wherein said tank or vat is in fluid communication with a fluid guide;
- a fluid guide wherein said coating material flows off of said fluid guide forming a sheet or falling shower curtain;
- a coating material collector which receives unused coating material;
- a first curing/drying unit which comprises:
- an oven or chamber in which a curing/drying source is located;
- wherein said articles are moved through the oven or chamber by the article conveyor;
- a second flow coating unit which comprises:
- a tank or vat containing an aqueous solution/dispersion coating material wherein said tank or vat is in fluid communication with a fluid guide;
- a fluid guide wherein said coating material flows off of said fluid guide forming a sheet or falling shower curtain;
- a coating material collector which receives unused coating material;
- and
- a second curing/drying unit which comprises:
- an oven or chamber in which a curing/drying source is located;
- wherein said articles are moved through the oven or chamber by the article conveyor;
- wherein at least one of the aqueous solution/dispersion coating materials comprises a thermoplastic epoxy resin.
A multilayer article comprising:
- a substrate having at least one layer comprising thermoplastic epoxy resin coating material disposed on at least a portion of said substrate to form a coated article, wherein the coated article exhibits substantially no blushing or whitening when exposed to water.
A multilayer container preform or bottle having a body portion, end cap, and neck portion, said preform or bottle comprising:
- a first substrate comprising a thermoplastic material
- said thermoplastic material chosen from the chosen from the group consisting of polyesters, polyolefins, polycarbonates, polyamides and acrylics;
- one or more layers of thermoplastic resin coating material disposed on said substrate;
- wherein one or more layers contain one or more of the following characteristics:
- gas-barrier protection, UV protection, scuff resistance, blush resistance, chemical resistance;
- wherein the coating is disposed substantially only on the body portion of the preform;
- and
- wherein the finished product has substantially no distinction between layers.
Dependencies are inferred from the claim text.