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AssigneeMorton International, Inc.
InventorsJeno Muthiah, Andrew T. Daly, Richard P. Haley, Paul R. Horinka, Joseph J. Kozlowski, Glenn D. Correll
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Thermosetting powder coating compositions adapted to form a grainy textured finish on heat sensitive substrates, especially wood products, such as particle board, conductive particle board, and medium density fiber board, without damaging the substrates comprise an epoxy resin, particularly bisphenol A type epoxy resins having low viscosities, either a catalytic curing agent comprising an imidazole, a substituted imidazole, or adduct of an imidazole or substituted imidazole and an epoxy resin, or a curing agent comprising an adduct of a polyamine and an epoxy resin, or a combination of the catalytic curing agent and curing agent, a texturing agent, a flow control agent, optional extender, and optional pigment. The thermosetting powder coatings have a cure time/temperature ranging from about 30 seconds at about 350.degree. F. peak substrate temperature down to about 20 minutes at about 225.degree. F. peak substrate temperature which provides for either a rapid cure or low bake temperature to prevent excessive heat exposure to the heat sensitive substrate, resulting in substantially no physical or chemical degradation of the heat sensitive substrate during baking. The powder coatings are applied to heat sensitive substrates, especially wood products, through electrostatic spraying onto the substrate followed by heating to cure the textured finish uniformly on the surfaces and edges of the substrate. Electrostatic spraying is performed with a triboelectric or corona spray gun and heat curing is performed with a high intensity infrared oven, a convection oven, or combination. Coated heat sensitive substrates having continuous grainy textured finishes that are excellent for hiding substrate surface defects and later appearing scratches are obtained.
A thermosetting powder coating composition for forming a grainy textured finish, which is a composition in particulate blend form consisting essentially of effective film-forming amounts of an epoxy resin, a catalytic curing agent which is selected from an imidazole and an adduct of an imidazole and epoxy resin, and a texturing agent.
A thermosetting powder coating composition for forming a grainy textured finish, which is a composition in particulate blend form consisting essentially of effective film-forming amounts of an epoxy resin, a curing agent which comprises an adduct of a polyamine and an epoxy resin, and a texturing agent.
A thermosetting powder coating composition for forming a grainy textured finish suitable for heat sensitive substrates, which is a film-forming composition in particulate blend form consisting essentially of a film-forming bisphenol A type epoxy resin, between about 1 and 8 phr of a catalytic curing agent selected from an imidazole or an adduct of an imidazole and a bisphenol A type epoxy resin, between about 1 and 30 phr of a texturing agent selected from organophilic clays, crosslinked rubber particles and thermoplastic polymer particles, between about 1 and 5 phr of a flow control agent, up to about 120 phr of an extender, and up to about 100 phr of a pigment.
A thermosetting powder coating composition for forming a grainy textured finish suitable for heat sensitive substrates, which is a film-forming composition in particulate blend form consisting essentially of a film-forming bisphenol A type epoxy resin, between about 1 and 8 phr of a catalytic curing agent selected from an imidazole, between about 1 and 30 phr of a texturing agent selected from organophilic clays, crosslinked rubber particles, and thermoplastic polymer particles, between about 1 and 5 phr of a flow control agent, up to about 120 phr of an extender, and up to about 100 phr of a pigment.
A thermosetting powder coating composition for forming a grainy textured finish suitable for heat sensitive substrates, which is a film-forming composition in particulate blend form consisting essentially of a film-forming bisphenol A type epoxy resin, between about 5 and 40 phr of a curing agent selected from an adduct of a polyamine and a bisphenol A type epoxy resin, between about 1 and 30 phr of a texturing agent selected from organophilic clays, crosslinked rubber particles, and thermoplastic polymer particles, between about 1 and 5 phr of a flow control agent, up to about 120 phr of an extender, and up to about 100 phr of a pigment.
A method of coating a heat sensitive material with a thermosetting powder coating composition adapted to provide a grainy textured dry film finish without damaging the substrate, which comprises:
A method of coating a heat sensitive material with a thermosetting powder coating composition adapted to provide a grainy textured dry film finish without damaging the substrate, which comprises:
Dependencies are inferred from the claim text.