Coating compositions and formulation methods

A method of preparing a multi-layer coated article with a high transfer efficiency applicator comprising a plurality of nozzles each being configured to apply a stream or droplets of a coating composition substantially without atomization, the method comprising:

• providing a substrate bearing a partially-dehydrated aqueous coating layer thereon;
• preparing a compatible coating composition by:
• providing a test layer of the partially-dehydrated aqueous coating layer on a test substrate,
• applying a plurality of candidate cosolvents to the test layer to give solvated portions thereof, each candidate cosolvent being allowed to contact the test layer for a dwell time of at least 3 seconds,
• identifying at least one compatible cosolvent from the candidate cosolvents based on the absence of a failure condition on the solvated portion of the test layer associated therewith, and
• formulating the compatible coating composition as a waterborne fluid suitable for overspray-free application comprising the at least one compatible cosolvent, a binder, a crosslinker, and a thickener;
• and
• applying the compatible coating composition to the substrate with the high transfer efficiency applicator via disposing a plurality of lines of the coating composition onto the partially-dehydrated aqueous coating layer of the substrate via the plurality of nozzles, thereby forming an overspray free coating layer thereon.