Abradable powder coating manufactured with solvent-free liquid polymer resin base coat
OwnerAndrew W. Sumaninventor
Life of this patent
Estimating the term…
Abstract
An abradable coating is formed on a mechanical part from a polymer resin-containing powder deposited over a polymer resin-containing liquid that is substantially free of volatile organic hydrocarbons. The liquid and the powder are then cured together to form an abradable coating. The polymer resin-containing powder may include a first thermosetting resin and a filler having a melting point above a cure temperature of the first thermosetting resin. The interactions of the powder and the liquid result in a durable abradable coating. Because the liquid is substantially free of volatile organic hydrocarbons, overspray may be recovered and used to coat other parts.
Claims20
A process of forming an abradable coating, comprising:
- applying a liquid base coat to a first mechanical part;
- applying a powder of particles over the liquid base coat while the liquid base coat is liquid;
- and
- curing the liquid base coat and the powder to form an abradable coating on the first mechanical part;
- wherein the abradable coating comprises a first layer formed from the liquid base coat below a second layer formed from the powder;
- the particles comprise a first thermosetting resin and a filler having a melting point above a cure temperature of the first thermosetting resin;
- and
- the liquid base coat comprises a second thermosetting resin and is substantially free of volatile organic hydrocarbons.
A coated part, comprising:
- a part surface;
- a first layer comprising a first polymer adjacent the part surface;
- a second layer comprising a structure of particles adhered to one-another, the particles comprising a second polymer;
- and
- an interfacial area where the second layer is joined to the first layer;
- wherein the structure of particles comprises particles that are within the interfacial area and particles that are above the interfacial area;
- and
- the particles that are within the interfacial area have a same size distribution as the particles that are above the interfacial area.
Dependencies are inferred from the claim text.