# US 2006/0150902 A1 · Powder coating apparatus and method of powder coating using an electromagnetic brush > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2006/0150902 A1 - Document ID: US20060150902A1 - Status: Published application - Kind: A1 - Application number: 11/371,653 - Filed: 2006-03-09 - Published: 2006-07-13 - Earliest claimed: 2004-03-09 - Assignees: Eastman Kodak Company - Inventors: Eric Stelter; Patrick Lambert; Joseph Guth; Laverne Lincoln; Michael Frauens - Web page: https://patentgrep.com/patent/US20060150902A1 ## CPC - G03G 15/0907: {with bias voltage (G03G15/065 takes precedence)} - G03G 5/144: {comprising inorganic material} - G03G 5/14704: {comprising inorganic material} - G03G 9/08793: {Crosslinked polymers} - G03G 9/08795: {characterised by their chemical properties, e.g. acidity, molecular weight, sensitivity to reactants} - G03G 9/08797: {characterised by their physical properties, e.g. viscosity, solubility, melting temperature, softening temperature, glass transition temperature} - G03G 9/09: Colouring agents for toner particles - G03G 9/0926: {characterised by physical or chemical properties} - G03G 9/09708: {Inorganic compounds} - B05D 1/06: Applying particulate materials - B05D 1/28: performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers - B05D 3/20: {by magnetic fields} - G03G: ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) ## Abstract Apparatus and methods for applying powder coatings to a substrate using a magnetic brush developer, including a method and apparatus for applying powder coatings to a substrate either directly or by intermediate transfer using a magnetic brush with a rotating magnetic field and for preparing the coating materials. The apparatus and method includes a supply of prepared powder coating material, a magnetic brush having a rotating magnetic field for applying the powder coating material to the substrate; and an electric field between the magnetic brush having a rotating magnetic field and the substrate. ## Claims ### Claim 1 An apparatus for applying powder coatings to a substrate comprising: a supply of prepared powder coating material; a magnetic brush having a rotating magnetic field for applying the powder coating material to the substrate; and an electric field between the magnetic brush having a rotating magnetic field and the substrate. ### Claim 2 (depends on 1) An apparatus in accordance with claim 1, wherein the substrate comprises a conductive material. ### Claim 3 (depends on 1) An apparatus in accordance with claim 1, wherein the substrate comprises a non-conductive material such as paper, wood, cloth and/or fibers. ### Claim 4 (depends on 3) An apparatus in accordance with claim 3, further comprising a charge applied to the front surface immediately adjacent the magnetic brush. ### Claim 5 (depends on 3) An apparatus in accordance with claim 3, further comprising a charge applied to the back surface. ### Claim 6 (depends on 3) An apparatus in accordance with claim 3, further comprising a conductive biased or grounded backing immediately adjacent the back surfaces. ### Claim 7 (depends on 1) An apparatus in accordance with claim 1, further comprising an intermediate transfer roller intermediate the brush and the substrate capable of transferring the supply of powder coating material to the substrate. ### Claim 8 (depends on 1) An apparatus in accordance with claim 1, the apparatus further comprising an applicator to apply the powder to a non-planar surface. ### Claim 9 (depends on 8) An apparatus in accordance with claim 8, the non-planar surface comprising wire, edges, perforation surfaces, wood, paper, cloth, fibers, screen and other non-uniform surfaces. ### Claim 10 (depends on 1) An apparatus in accordance with claim 1 the apparatus further comprising an electrostatic printer. ### Claim 11 (depends on 1) An apparatus in accordance with claim 1, the powder coating further comprising a multiple layer composite coating. ### Claim 12 (depends on 11) An apparatus in accordance with claim 11, the composite coating further comprising layers of toner. ### Claim 13 (depends on 11) An apparatus in accordance with claim 11, the composite coating further comprising mixtures of particles of different compositions. ### Claim 14 (depends on 1) An apparatus in accordance with claim 1, the material further comprising particles of the order of micron to nanometer diameter. ### Claim 15 (depends on 1) An apparatus in accordance with claim 1, the powder coating material further comprising surface treated toner. ### Claim 16 (depends on 15) An apparatus in accordance with claim 15, wherein the surface treated toner comprises binder having opposite charge from smaller particles dispersed in the powder coating material. ### Claim 17 (depends on 1) An apparatus in accordance with claim 1, the powder coating material further comprising surface treated magnetic carrier. ### Claim 18 (depends on 1) An apparatus in accordance with claim 1, the powder coating material further comprising binder having opposite charge from smaller particles applied as a surface treatment to the powder coating material. ### Claim 19 (depends on 1) An apparatus in accordance with claim 1, the powder coating material further comprising multiple components wherein one component of the powder coating material has an opposite charge from another component of the powder coating material. ### Claim 20 (depends on 1) An apparatus in accordance with claim 1, wherein the rotating magnetic field is provided by a rotating magnetic core. ### Claim 21 (depends on 1) An apparatus in accordance with claim 1, wherein the powder coating material is comprised of at least one of the following: resin; binder; flow aids; surface treatments; pigment; leveling aids; cross-linkers; catalysts; and charge agents. ### Claim 22 (depends on 1) An apparatus in accordance with claim 1, wherein the powder coating material is comprised of particles less than 50-micron volume mean diameter. ### Claim 23 (depends on 22) An apparatus in accordance with claim 22, wherein the powder coating material is prepared from a process for modifying a powder paint by regrinding electrostatic spray powder paint at low temperature. ### Claim 24 (depends on 1) An apparatus in accordance with claim 1, wherein the powder coating material is prepared by a process for modifying a powder paint by recompounding electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 25 (depends on 1) An apparatus in accordance with claim 1, wherein the powder coating material is prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 26 (depends on 25) An apparatus in accordance with claim 25, wherein the powder coating material is further prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity, where the surface treatment enhances properties other than transfer and charge. ### Claim 27 (depends on 25) An apparatus in accordance with claim 25, wherein the powder coating material is further prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity, where the surface treatment enhances properties such as toughness, color, tribocharge, florescence. ### Claim 28 (depends on 1) An apparatus in accordance with claim 1, wherein the powder coating material is carried in the magnetic brush by a hard magnetic carrier having permanent magnetism. ### Claim 29 (depends on 1) An apparatus in accordance with claim 1, further comprising an intermediate member having a conductive and a nonconductive portion on the same surface. ### Claim 30 (depends on 29) An apparatus in accordance with claim 29, wherein the conductive and nonconductive portions control material deposition. ### Claim 31 (depends on 1) An apparatus in accordance with claim 1, further comprising a controller with feedback to a toning station to correct banding and other variations. ### Claim 32 (depends on 31) An apparatus in accordance with claim 31, further comprising a controller with feedback to a second toning station to correct banding and other variations resulting from a first toning station. ### Claim 33 (depends on 1) An apparatus in accordance with claim 1, further comprising a controller with feedback based on changes in the quantity voltage V of the powder coating divided by current I of the toning station being proportional to changes in thickness. ### Claim 34 (depends on 1) An apparatus in accordance with claim 1, further comprising a controller with feedback based on changes in the quantity voltage V of the coating divided by current I of a device used for charging the coating being proportional to changes in thickness. ### Claim 35 (depends on 1) An apparatus in accordance with claim 1, further comprising a movable backing member adjacent the back of the substrate. ### Claim 36 (depends on 1) An apparatus in accordance with claim 1, further comprising a movable backing member adjacent the back of the substrate with additional movable rollers adjacent the substrate. ### Claim 37 (depends on 1) An apparatus in accordance with claim 1, further comprising a movable station shield. ### Claim 38 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush for applying the powder coating material to the substrate including the substrate portion from the reservoir; and an electric field between the magnetic brush having a rotating magnetic field and the substrate wherein the powder coating material is prepared from a process for modifying a powder paint by recompounding electrostatic spray powder paint at low temperature to incorporate addenda, regrinding, or surface treating while not substantially increasing viscosity. ### Claim 39 A method for applying powder coatings to a substrate comprising: providing powder-coating material in a reservoir; supplying an electric field between a magnetic brush having a rotating magnetic field and the substrate; and applying the powder coating material to the substrate, situated in the electric field, from the reservoir using the magnetic brush. ### Claim 40 (depends on 39) A method in accordance with claim 39, the method further including directly applying the powder coating with the magnetic brush. ### Claim 41 (depends on 39) A method in accordance with claim 39, the method further including applying the powder coating by intermediate transfer using an intermediate transfer roller. ### Claim 42 (depends on 39) An apparatus in accordance with claim 39, the apparatus further comprising applying the powder coating to a non-planar surface. ### Claim 43 (depends on 42) An apparatus in accordance with claim 42, the non-planar surface comprising wire, edges, perforation surfaces, wood, paper, cloth, fibers, screen and other non-uniform surfaces. ### Claim 44 (depends on 39) An apparatus in accordance with claim 39, the applying the powder coating material to the substrate material further comprising applying the powder coating as a composite coating. ### Claim 45 (depends on 44) An apparatus in accordance with claim 44, the composite further comprising layering a toner including the powder coating. ### Claim 46 (depends on 44) An apparatus in accordance with claim 44, the method further comprising dispersing particles of different compositions in the toner comprising the powder coating. ### Claim 47 (depends on 39) An apparatus in accordance with claim 39, the method further comprising applying particles of the order of micron to nanometer diameter. ### Claim 48 (depends on 39) An apparatus in accordance with claim 39, the method further comprising applying a surface treatment to the powered material to create a composite material. ### Claim 49 (depends on 48) An apparatus in accordance with claim 48, wherein the surface treated toner comprises applying an opposite charge to a binder portion of the powder coating material than the surface treatment. ### Claim 50 (depends on 39) An apparatus in accordance with claim 39, the powder coating material further comprising surface treated magnetic carrier. ### Claim 51 (depends on 50) An apparatus in accordance with claim 50, the powder coating material further comprising dispersed catalysts. ### Claim 52 (depends on 38) A method in accordance with claim 38, wherein the powder coating material is prepared from a process for modifying a powder paint by recompounding electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 53 A method for applying powder coatings to a substrate comprising: providing powder-coating material in a reservoir; supplying an electric field between a magnetic brush having a rotating magnetic field and the substrate; and applying a first powder coating material to the substrate, situated in the electric field, from the reservoir using the magnetic brush; applying a second powder coating proximate the first powder coating. ### Claim 54 A method for applying powder coatings to a substrate comprising: providing powder-coating material in a reservoir; supplying an electric field between a magnetic brush having a rotating magnetic field and the substrate; and applying a first powder coating material to the substrate, situated in the electric field, from the reservoir using the magnetic brush; applying a second powder coating proximate the first powder coating; curing the first and second coating after the application of the second powder coating. ### Claim 55 A method for applying powder coatings to a substrate comprising: providing powder coating material in a reservoir by a process that modifies a powder paint by recompounding an electrostatic spray powder paint at low temperature; and incorporating additional additives to the powder coating material while not substantially increasing viscosity. supplying an electric field between a magnetic brush having a rotating magnetic field and the substrate; and applying the powder coating material to the substrate, situated in the electric field, from the reservoir using the magnetic brush. ### Claim 56 A powder coating apparatus comprising: a reservoir of charged powder particles in the presence of hard carrier particles; a movable receiver for receiving charged powder particles from the reservoir of charged powder particles; a shell to feed the charged powder particles with carrier particles from the reservoir to a position proximate the movable receiver and to deposit the charged powder particles on the receiver; the deposition device comprising a rotatable shell, a rotatable magnetic core, and an electric field between the rotatable shell and the movable receiver; a magnetic brush having a rotating magnetic field for applying the charged powder particles to the movable receiver. ### Claim 57 (depends on 56) A powder coating apparatus according to claim 56, wherein the receiver is an intermediate transfer drum, the apparatus further comprising a movable substrate, the intermediate transfer drum adapted to transfer particles to the movable substrate. ### Claim 58 (depends on 56) A powder coating apparatus according to claim 56, further comprising a plurality of deposition devices positioned along the receiver, each of the plurality of deposition devices adapted to deposit powder particles onto the receiver. ### Claim 59 (depends on 56) A powder coating apparatus according to claim 56, further comprising a plurality of deposition devices positioned along opposite sides of the receiver, at least two of the plurality of deposition devices adapted to deposit powder particles onto the opposite sides of the receiver. ### Claim 60 (depends on 56) A powder coating process according to claim 56, wherein the powder particles comprise a clear overcoat. ### Claim 61 (depends on 56) An apparatus in accordance with claim 56, wherein the powder coating material is comprised of at least on of the following: resin; binder; flow aids; surface treatments; pigment; leveling aids; cross-linkers; catalysts; and charge agents. ### Claim 62 (depends on 56) An apparatus in accordance with claim 56, wherein the powder coating material is comprised of particles less than 50 microns volume mean diameter. ### Claim 63 (depends on 56) An apparatus in accordance with claim 56, wherein the powder coating material is prepared from a process for modifying a powder paint by recompounding electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 64 (depends on 56) An apparatus in accordance with claim 56, wherein the carrier is coated with at least one of the following: resins; and polymeric materials. ### Claim 65 An apparatus for applying powder coatings to a conductive substrate comprising: a supply of powder coating material; and a magnetic brush having a rotating magnetic field for applying the powder coating material to the substrate, including the conductive substrate, from the reservoir. ### Claim 66 An apparatus for applying powder coatings to a nonconductive substrate comprising: a supply of powder coating material; and a magnetic brush having a rotating magnetic field for applying the powder coating material to the substrate, including the nonconductive substrate, from the reservoir. ### Claim 67 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush for applying the powder coating material to the substrate, the magnetic brush comprising nonconductive or semiconductive magnetic carrier particles; and an electric field between the magnetic brush and the substrate. ### Claim 68 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush for applying the powder coating material to the substrate, the magnetic brush comprising magnetic carrier particles; an intermediate transfer member intermediate the brush and the substrate including a nonconductive coating capable of transferring the supply of powder coating material to the substrate; an electric field between the magnetic brush and the intermediate; and an electric field between the intermediate and the substrate. ### Claim 69 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a rotating magnetic brush for applying the powder coating material to the substrate, the magnetic brush comprising magnetic carrier particles; an imaging member such as a photoconductor, electrographic master, or ionographic member intermediate the brush and the substrate; an electric field between the magnetic brush and the imaging member; and an electric field between the imaging member and the substrate. ### Claim 70 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a rotating magnetic brush for applying the powder coating material to the substrate, the magnetic brush comprising magnetic carrier particles; an imaging member such as a photoconductor, electrographic master, or ionographic member intermediate the brush and the substrate; an intermediate transfer member intermediate the imaging member and the substrate including a nonconductive coating capable of transferring the supply of powder coating material to the substrate; an electric field between the magnetic brush and the imaging member; an electric field between the imaging member and the intermediate and an electric field between the intermediate and the substrate. ### Claim 71 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush for applying the powder coating material to the substrate; and an electric field between the magnetic brush and the substrate. ### Claim 72 (depends on 71) An apparatus in accordance with claim 71, wherein the powder coating material is prepared from a process for modifying a powder paint by regrinding electrostatic spray powder paint at a low temperature. ### Claim 73 (depends on 71) An apparatus in accordance with claim 71, wherein the powder coating material is prepared by a process for modifying a powder paint by recompounding electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 74 (depends on 71) An apparatus in accordance with claim 71, wherein the powder coating material is prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity. ### Claim 75 (depends on 74) An apparatus in accordance with claim 74, wherein the powder coating material is further prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity, where the surface treatment enhances properties other than transfer and charge. ### Claim 76 (depends on 74) An apparatus in accordance with claim 74, wherein the powder coating material is further prepared by a process for modifying a powder paint by surface treating electrostatic spray powder paint at low temperature to incorporate addenda while not substantially increasing viscosity, where the surface treatment enhances properties such as toughness, color, tribocharge, florescence. ### Claim 77 (depends on 71) An apparatus in accordance with claim 71, further comprising a controller with feedback based on changes in the quantity of voltage V of the powder coating divided by current I of the toning station being proportional to changes in thickness. ### Claim 78 (depends on 71) An apparatus in accordance with claim 71, further comprising a controller with feedback based on changes in the quantity of voltage V of the coating divided by current I of a device used for charging the coating being proportional to changes in thickness. ### Claim 79 (depends on 71) An apparatus in accordance with claim 71, further comprising a movable backing member adjacent the back of the substrate. ### Claim 80 (depends on 71) An apparatus in accordance with claim 71, further comprising a movable backing member adjacent the back of the substrate with additional movable rollers adjacent the substrate. ### Claim 81 (depends on 71) An apparatus in accordance with claim 71, further comprising a movable station shield. ### Claim 82 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush for applying the powder coating material to the substrate; and an electric field between the magnetic brush having a rotating magnetic field and the substrate. the magnetic brush comprising a conductive shell with an insulative coating ### Claim 83 An apparatus for applying powder coatings to a substrate comprising: a supply of powder coating material; a magnetic brush having a rotating magnetic field for applying the powder coating material to the substrate; and an electric field between the magnetic brush having a rotating magnetic field and the substrate. the magnetic brush comprising a shell that rotates cocurrent with the substrate at a speed less than 10% of the substrate speed.