# US 9,751,107 B2 · Two-coat single cure powder coating

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- Number: US 9,751,107 B2
- Document ID: US9751107B2
- Status: Granted
- Kind: B2
- Application number: 14/522,143
- Filed: 2014-10-23
- Published: 2015-02-12
- Granted: 2017-09-05
- Earliest claimed: 2012-03-21
- Assignees: Valspar Sourcing, Inc.
- Applicants: Valspar Sourcing, Inc.
- Inventors: Owen H. Decker; Thomas E. Reno; Robert D. Breitzman; Carlos A Concha; Jeffrey D. Rogozinski; Keith M. Kirkwood
- Web page: https://patentgrep.com/patent/US9751107B2

## CPC

- B05D 7/542: {the two layers being cured or baked together}
- B05D 1/06: Applying particulate materials
- B05D 1/12: Applying particulate materials (B05D1/06, B05D1/10 take precedence)
- B05D 1/36: Successively applying liquids or other fluent materials, e.g. without intermediate treatment
- B05D 3/002: {Pretreatement}
- B05D 3/0218: {Pretreatment, e.g. heating the substrate}
- B05D 3/0254: {After-treatment}
- B05D 3/102: {Pretreatment of metallic substrates (C23C takes precedence)}
- B05D 3/12: by mechanical means
- B05D 7/14: to metal, e.g. car bodies (involving a chemical reaction between the metal and the coating C23)
- C08K 3/22: of metals
- C08K 5/29: Compounds containing {one or more} carbon-to-nitrogen double bonds
- C08K 5/32: Compounds containing nitrogen bound to oxygen
- C08K 5/3445: Five-membered rings
- C09D 5/03: Powdery paints
- C09D 5/035: {Coloring agents, e.g. pigments (C09D5/032 takes precedence)}
- C09D 163/00: Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
- C23C 24/00: Coating starting from inorganic powder (spraying of the coating material in molten state C23C4/00; solid state diffusion C23C8/00 - C23C12/00)
- C23C 26/00: Coating not provided for in groups C23C2/00 - C23C24/00
- C23C 28/00: Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- B05D 2202/10: based on Fe
- B05D 2451/00: Type of carrier, type of coating (Multilayers)
- B32B 7/02: Physical, chemical or physicochemical properties
- C08K 2003/2241: {Titanium dioxide}
- C09D 167/00: Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain (based on polyester-amides C09D177/12; based on polyester-imides C09D179/08); Coating compositions based on derivatives of such polymers
- C09D 167/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C09D167/06 takes precedence)
- C09D 167/03: the dicarboxylic acids and dihydroxy compounds having the carboxyl - and the hydroxy groups directly linked to aromatic rings
- Y10T 428/31529: Next to metal
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Methods and systems for coating metal substrates are provided. The methods and systems include sequential application of low flow and high flow powder coatings followed by a single heating step to provide a cured coating. The methods and systems include a marker that allows coating uniformity to be monitored and assessed during application. The described methods provide coatings with optimal surface smoothness and edge coverage.

## Claims

### Claim 1

A method, comprising:
providing a metal substrate;
applying a primer coating comprising a first powder coating composition including a carboxyl-functional polyester binding resin, wherein the first powder coating composition has flow of no more than about 40 mm;
applying a topcoat comprising a second powder coating composition with flow of at least about 40 mm; and
heating the metal substrate with the primer coating and topcoat applied thereon in a single step, without multiple heating cycles, to form a continuous corrosion-resistant coating with 20-degree gloss of at least 50%.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first coating composition has a flow of about 15 mm to 40 mm.

### Claim 3 (depends on 1)

The method of claim 1, wherein the first coating composition has a flow of about 20 to 35 mm.

### Claim 4 (depends on 1)

The method of claim 1, wherein the second coating composition has flow of greater than about 50 mm.

### Claim 5 (depends on 1)

The method of claim 1, wherein the second coating composition has flow of greater than about 70 mm.

### Claim 6 (depends on 1)

The method of claim 1, wherein the second coating composition has flow of greater than about 75 mm.

### Claim 7 (depends on 1)

The method of claim 1, wherein the cured coating has edge coverage equal to at least 2% of face coverage.

### Claim 8 (depends on 1)

The method of claim 1, wherein the cured coating has edge coverage equal to about 10% of the face coverage.

### Claim 9 (depends on 1)

The method of claim 1, wherein the metal substrate is unprimed, clean blasted, or pretreated.

### Claim 10 (depends on 1)

The method of claim 1, wherein the first coating composition and second coating composition are heated in a single step at a temperature of about 180° C. to 200° C.

### Claim 11 (depends on 1)

The method of claim 1, wherein the first coating composition and second coating composition are heated in a single step at a temperature of about 140° C. to 170° C.

### Claim 12 (depends on 1)

The method of claim 1, wherein the first coating composition and second coating composition are heated in a single step at a temperature of about 120° C. to 135° C.

### Claim 13 (depends on 1)

The method of claim 1, wherein the first coating composition is applied only to one or more edges of the substrate.

### Claim 14 (depends on 1)

The method of any claim 1, wherein the second coating composition is applied only to one or more edges of the substrate.

### Claim 15 (depends on 1)

The method of claim 1, wherein the first coating composition and the second coating composition are applied only to one or more edges of the substrate.

### Claim 16 (depends on 1)

The method of claim 1, wherein the first coating composition is applied at a film build of about 20 to 40 micron.

### Claim 17 (depends on 1)

The method of claim 1, wherein the second coating composition is applied at a film build of about 25 to 35 micron.