Granted Patent B2

US 12,539,525 · App. 18/066,639 · Granted Feb 3, 2026

Inventors: John R. Moore (Lansdale, PA); Michael Koerner (Media, PA); Christian Jackson (Wilmington, DE); Bradley A. Jacobs (Wilmington, NC); Shih-Wa Wang (Glen Mills, PA); Matthew Irwin (Philadelphia, PA)

Assignee: AXALTA COATING SYSTEMS IP CO., LLC

B05C5/027B05C11/1034C09D7/20C09D7/40B05C9/06

Abstract

Claims (40)

1 . A coating composition for application to a substrate utilizing a high transfer efficiency applicator comprising an array of nozzles wherein each nozzle defines a nozzle orifice having a diameter of from about 0.00002 m to about 0.0004 m and wherein the high transfer efficiency applicator is configured to apply the coating composition to a substrate through the nozzle orifice without atomization such that at least 99.9% of the applied coating composition contacts the substrate to form a coating layer,

wherein the coating composition has a solids content of from about 5 to about 70 weight % based on a total weight of the coating composition as measured in accordance with ASTM D2369 and comprises:

a carrier;

a binder present in an amount of from 5 to about 70 weight percent based on a total weight of the coating composition; and

a crosslinker present in an amount of from about 0.1 to about 25 weight percent based on a total weight of the coating composition;

wherein the solids content is chosen, and each of at least the carrier, binder, and crosslinker is independently present in an amount, such that the coating composition has:

(1) an Ohnesorge number (Oh) of from about 0.01 to about 12.6 as determined in accordance with equation I, as follows:

Oh=(η/√{square root over (ρσ D )})  (I),

wherein η represents viscosity of the coating composition in pascal-seconds (Pa*s), ρ represents density of the coating composition in kilograms per cubic meter (kg/m 3 ), σ represents surface tension of the coating composition in newtons per meter (N/m), and D is from about 0.00002 m to about 0.0004 m;

(2) a Reynolds number (Re) of from about 0.02 to about 6,200 as determined in accordance with equation II, as follows:

Re=(ρ vD /η)  (II)

wherein ρ represents density of the coating composition in kg/m 3 , v is about 1 to about 20 m/sec, D is from about 0.00002 m to about 0.0004 m, and η represents viscosity of the coating composition in Pa*s;

(3) a Deborah number (De) of from greater than 0 to about 0.01 as determined in accordance with equation III, as follows:

De=λ/ ρ D 3 /σ   (III)

wherein λ represents relaxation time of the coating composition in seconds(s), ρ represents density of the coating composition in kg/m 3 , D is from about 0.00002 m to about 0.0004 m, and σ represents surface tension of the coating composition in N/m;

(4) a viscosity of from about 0.002 Pa*s to about 0.2 Pa*s as measured according to ASTM 7867-13 with cone-and-plate or parallel plates at a shear rate of 1000 sec-1;

(5) a density of from about 838 kg/m 3 to about 1557 kg/m 3 ;

(6) a surface tension of from about 0.015 N/m to about 0.05 N/m; and

(7) a relaxation time of from about 0.00001 to about 1 s.

2 . The coating composition of claim 1 , wherein the Ohnesorge number (Oh) is from 0.01 to 12.6 and is defined based upon the following equations V and VI, in view of the Reynolds number (Re),

Oh is no greater than 10{circumflex over ( )}(−0.5006*log(Re)+1.2135)  (V), and

Oh is at least 10{circumflex over ( )}(−0.5435*log(Re)−1.0324)  (VI),

wherein the Reynolds number (Re) is from 0.02 to 6,200.

3 . The coating composition of claim 1 , wherein the coating composition has an Ohnesorge number (Oh) of from about 0.05 to about 1.8, and a Reynolds number (Re) of from about 0.3 to about 660.

4 . The coating composition of claim 3 , wherein the Ohnesorge number (Oh) is defined based upon the following equations VII and VIII, in view of the Reynolds number (Re),

Oh is no greater than 10{circumflex over ( )}(−0.5067*log(Re)+0.706)  (VII), and

Oh is at least 10{circumflex over ( )}(−0.5724*log(Re)−0.4876)  (VIII),

wherein the Reynolds number (Re) is from 0.3 to 660.

5 . The coating composition of claim 1 further comprising a primary pigment in an amount of from about 0.1 to about 20 weight % based on a total weight of the coating composition.

6 . The coating composition of claim 1 , wherein the coating composition is substantially free of a dye.

7 . The coating composition of claim 1 wherein the carrier is chosen from water, a non-aqueous solvent, and combinations thereof.

8 . The coating composition of claim 1 , wherein the coating composition has

a viscosity of from about 0.005 Pa*s to about 0.05 Pa*s as measured according to ASTM 7867-13 with cone-and-plate or parallel plates at a shear rate of 1000 sec-1,

a density of from about 958 kg/m 3 to about 1319 kg/m 3 , and

a surface tension of from about 0.02 N/m to about 0.032 N/m.

9 . The coating composition of claim 1 further comprising a primary or color giving pigment in an amount of from about 0.1 to about 20 weight % based on a total weight of the coating composition.

10 . The coating composition of claim 1 consisting essentially of the carrier, the binder, and the crosslinker.

11 . A system comprising:

the coating composition of claim 1 ; and

the high transfer efficiency applicator comprising the array of nozzles wherein each nozzle defines the nozzle orifice having the diameter of from 0.00002 m to 0.0004 m and wherein the high transfer efficiency applicator is configured to apply the coating composition to the substrate through the nozzle orifice without atomization such that at least 99.9% of the applied coating composition contacts the substrate to form the coating layer.

Assignments (1)

Continuity (5)

References Cited (267)