Methods for forming composite coatings on substrates

A method for forming a composite coating comprising the steps of:

• (A) applying an aqueous primary coating composition to at least a portion of a surface of a substrate, the primary coating composition comprising:
• (1) at least one thermosettable dispersion comprising polymeric microparticles having functionality adapted to react with a crosslinking material, the microparticles comprising:
• (a) at least one acid functional reaction product of acrylic acid, styrene and at least one acrylate or methacrylate;
• and
• (b) at least one hydrophobic polymer selected from the group consisting of polyurethanes and polyesters and having a number average molecular weight of about 800 to about 3000 and an acid value of less than about 20;
• and
• (2) at least one aminoplast crosslinking material, to form a substantially uncured primary coating thereon;
• (B) applying a crosslinkable aqueous basecoat composition to at least a portion of the primary coating formed in step (A) in a wet-on-wet application without substantially curing the primary coating to form a substantially uncured secondary coating thereon;
• and
• (C) applying a clear coating composition to at least a portion of the secondary coating formed in step (B) in a wet-on-wet application without substantially curing the secondary coating to form a substantially uncured composite coating thereon.

A method for forming a composite coating comprising the steps of:

• (A) applying an aqueous primary coating composition to at least a portion of a surface of a substrate, the primary coating composition comprising:
• (1) at least one thermosettable dispersion comprising polymeric microparticles having functionality adapted to react with a crosslinking material, the microparticles comprising:
• (a) at least one acid functional reaction product of ethylenically unsaturated monomers;
• and
• (b) at least one hydrophobic polymer having a number average molecular weight of at least about 500;
• and
• (2) at least one crosslinking material, to form a substantially uncured primary coating thereon, the amount of the thermosettable dispersion in the primary coating composition ranging from about 30 to about 90 weight percent on a basis of total resin solids of the primary coating composition;
• (B) applying a secondary coating composition to at least a portion of the primary coating formed in step (A) without substantially curing the primary coating to form a substantially uncured secondary coating thereon;
• and
• (C) applying a clear coating composition to at least a portion of the secondary coating formed in step (B) without substantially curing the secondary coating to form a substantially uncured composite coating thereon.

A method for forming a composite coating comprising the steps of:

• (A) applying an aqueous primary coating composition to at least a portion of a surface of a substrate, the primary coating composition comprising:
• (1) at least one thermosettable dispersion comprising polymeric microparticles having functionality adapted to react with a crosslinking material, the microparticles comprising:
• (a) at least one acid functional reaction product of acrylic acid, styrene and at least one acrylate or methacrylate;
• and
• (b) at least one hydrophobic polymer selected from the group consisting of polyurethanes and polyesters and having a number average molecular weight of about 800 to about 3000;
• and
• (2) at least one aminoplast crosslinking material, to form a substantially uncured primary coating thereon, the amount of the thermosettable dispersion in the primary coating composition ranging from about 30 to about 90 weight percent on a basis of total resin solids of the primary coating composition;
• (B) applying a crosslinkable aqueous basecoat composition to at least a portion of the primary coating formed in step (A) in a wet-on-wet application without substantially curing the primary coating to form a substantially uncured secondary coating thereon;
• and
• (C) applying a clear coating composition to at least a portion of the secondary coating formed in step (B) in a wet-on-wet application without substantially curing the secondary coating to form a substantially uncured composite coating thereon.