Coating compositions for application utilizing a high transfer efficiency applicator and methods and systems thereof

A method of forming a coating composition for application to a substrate utilizing a high transfer efficiency applicator, wherein the method comprises:

• identifying at least one of an Ohnesorge number (Oh) for the coating composition, a Reynolds number (Re) for the coating composition, or a Deborah number (De) for the coating composition;
• obtaining at least one of a viscosity (η) of the coating composition, a surface tension (σ) of the coating composition, a density (ρ) of the coating composition, a relaxation time (λ) of the coating composition, a nozzle diameter (D) of the high transfer efficiency applicator, or an impact velocity (v) of the high transfer efficiency applicator,
• wherein at least one of the viscosity (η), the surface tension (σ), the density (ρ), or the nozzle diameter (D) is determined based upon the following equation I in view of the Ohnesorge number (Oh),
• Oh=(η/√{square root over (ρσD)}) (I),
• wherein at least one of the impact velocity (v), the density (ρ), the nozzle diameter D), or the viscosity (η) is determined based upon the following equation II in view of the Reynolds number (Re),
• Re=(ρvD/η) (II), and
• wherein at least one of the relaxation time (λ), the density (ρ), the nozzle diameter (D), or the surface tension (σ) is determined based upon the following equation III in view of the Deborah number (De),
• De=λ/√{square root over (ρD3/σ)} (III);
• and
• forming the coating composition having at least one of the viscosity (η), the surface tension (σ), or the density (ρ);
• identifying a drop contact value that relates to the tendency for a drop of the coating composition, upon contact with the substrate, to either remain as a single drop or separate into many droplets, by considering viscous and surface tension forces of the coating composition;
• identifying a flow pattern value that relates to the flow pattern of the coating composition extending between laminar flow and turbulent flow by considering viscous and inertial forces of the coating composition;
• and
• identifying a fluidity value that relates to the fluidity of the coating composition extending beyond Newtonian viscous flow and non-Newtonian viscous flow by considering relaxation time of the coating composition;
• wherein the coating composition is configured to be applied to the substrate utilizing the high transfer efficiency applicator having at least one of the nozzle diameter (D) or the impact velocity (v) and optionally based on at least one of the drop contact value, the flow pattern value, and fluidity value,
• wherein the coating composition has a solids content of from about 15 to about 70 weight % based on a total weight of the coating composition as measured in accordance with ASTM D2369 and comprises:
• a carrier;
• a binder present in an amount of from 15 to about 70 weight percent based on a total weight of the coating composition;
• and a crosslinker present in an amount of from about 0.1 to about 25 weight percent based on a total weight of the coating composition, and
• wherein the coating composition has a viscosity of from about 0.002 Pa*s to about 0.2 Pa*s as measured according to ASTM 7867-13 with cone-and-plate or parallel plates at a shear rate of 1000 sec-1.