DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES

1 . A process for making thermoplastic resin coated containers having neck portions and body portions, the process comprising:

applying an aqueous solution or dispersion of a thermoplastic epoxy resin substantially on only the outer surface of a body portion of a container by dip, spray, or flow coating;

withdrawing the container from the dip, spray, or flow coating at a rate so as to form a first coherent film; and

irradiating the container until the first film is substantially dried so as to form a first coating.

2 . The process of claim 1 , further comprising:

applying an aqueous solution or dispersion of a thermoplastic resin on the outer surface of the container by dip, spray, or flow coating;

withdrawing the container from the dip, spray, or flow coating at a rate so as to form a second coherent film; and

curing/drying the container until the second film is substantially dried so as to form a second coating.

3 . The process of claim 1 , wherein the step of irradiating is performed so as to form an article that exhibits substantially no blushing or whitening when exposed to water.

4 . The process if claim 1 , wherein the step of irradiating is performed as to at least partially crosslink the thermoplastic epoxy resin.

5 . The process of claim 1 further comprising applying one or more additional coating layers to said article.

6 . The process of claim 1 , further comprising:

applying a layer of a polyester or an acrylic on the first coating; and

crosslinking at least part of the polyester or the acrylic.

7 . The process of claim 1 , wherein the step of irradiating comprises drying the first coherent film with an IR source.

8 . The process of claim 1 , wherein the step of irradiating comprises drying the first coherent film with an electron beam processing source.

9 . The process of claim 1 , wherein the step of irradiating occurs for about 5 to 60 seconds until the first film is substantially dried so as to form a first coating.

10 . The process of claim 1 , wherein the first coating comprises about 0.05 to about 0.75 grams of the thermoplastic epoxy resin.

11 . The process of claim 1 , wherein the first coating comprises about 0.05 g to about 0.55 g of the thermoplastic epoxy resin.

12 . The process of claim 1 , wherein the first coating comprises about 0.06 g to about 0.2 g of the thermoplastic epoxy resin.

13 . The process of claim 1 , wherein the container is a preform.

14 . A process for making thermoplastic resin coated containers, the process comprising:

applying an aqueous solution or dispersion of a thermoplastic epoxy resin on outer surfaces of a plurality of containers by advancing and rotating the plurality of preforms through a flow coating, and

irradiating the plurality of coated containers for about 5 to 60 seconds to form a substantially dry coating layer on each container.

15 . The process of claim 14 , wherein the coating layer comprises about 0.05 to about 0.75 grams of the thermoplastic epoxy resin.

16 . The process of claim 14 , wherein the coating layer comprises about 0.05 g to about 0.55 g of the thermoplastic epoxy resin.

17 . The process of claim 14 , wherein the coating layer comprises about 0.06 g to about 0.2 g of the thermoplastic epoxy resin.

18 . The process of claim 14 , wherein the coating layer comprises an acid salt of the thermoplastic epoxy resin.

19 . The process of claim 14 , further comprising:

applying a layer of a polyester or an acrylic on the coating layer, and crosslinking at least part of the polyester or the acrylic.

20 . The process of claim 14 , further comprising removing excess aqueous solution or dispersion from the plurality of containers.

21 . A process for making thermoplastic resin coated preforms having neck portions and body portions, the process comprising:

advancing a plurality of preforms on a conveying system;

applying an aqueous solution or dispersion of a thermoplastic barrier coating material substantially on only the outer surface of a body portion of each preform of the plurality of preforms by dip, spray, or flow coating while rotating the preforms in the aqueous solution or dispersion, the outer surface of the preform comprising polyethylene terephthalate;

withdrawing the plurality of preforms from the dip, spray, or flow coating at a rate so as to form a first coherent film on each preform;

removing excess aqueous solution or dispersion from the plurality of preforms;

irradiating the plurality of preforms for about 5 to 60 second with an IR source until the first film is substantially dried so as to form a first coating comprising about 0.05 to about 0.75 g of the thermoplastic barrier coating material; and

cooling the plurality of preforms for about 5 to 40 seconds.

22 . The process of claim 21 , further comprising:

applying an aqueous solution or dispersion of a thermoplastic resin on the first coating of the preform by dip, spray, or flow coating;

withdrawing the preform from the dip, spray, or flow coating at a rate so as to form a second coherent film; and

curing/drying the container until the second film is substantially dried so as to form a second coating.

23 . The process of claim 21 , wherein the first coating comprises about 0.05 g to about 0.55 g of the thermoplastic barrier coating material.

24 . The process of claim 21 , wherein the first coating comprises about 0.06 g to about 0.2 g of the thermoplastic barrier coating material.

25 . The process of claim 22 , wherein at least one of the thermoplastic barrier coating material or the thermoplastic resin comprises a thermoplastic epoxy polymer.

26 . The process of claim 22 , further comprising crosslinking at least part of the thermoplastic resin, the thermoplastic resin being selected from a polyester, an acrylic, or a thermoplastic epoxy.