Decorative and durable coating having a homogeneous hue, methods for their preparation, and articles coated therewith
Disclosed are powder coating compositions suitable for producing a decorative and durable coating having a homogeneous hue, articles comprising a decorative and durable coating having a homogeneous hue deposited thereon, methods for preparing a decorative and durable coating having a homogeneous hue, kits capable of producing a decorative and durable coating having a homogeneous hue, and methods for color matching using powder coating compositions.
1. A method for preparing a decorative and durable coating having a homogeneous hue comprising:
(a) dry-blend mixing a first powder coating composition having a first hue and a second powder coating composition having a second hue different than the first hue to form a heterogeneous association of the first powder coating composition and the second powder coating composition; and
(b) directly applying the heterogeneous association of the first powder coating composition and the second powder coating composition to at least a portion of a substrate,
wherein the first powder coating composition and/or the second powder coating composition comprises a particulate film-forming resin and polymer-enclosed color-imparting nanoparticles, the color-imparting nanoparticles having average particle size of 300 nanometers or less,
wherein the particulate film-forming resin comprises an epoxy functional resin,
wherein the polymer-enclosed color-imparting nanoparticles are enclosed by a polymer different from the particulate film-forming resin,
wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising the reaction product of (i) an ethylenically unsaturated water-dispersible polymerizable dispersant, and (ii) an ethylenically unsaturated monomer, and
wherein the water-dispersible polymerizable dispersant comprises a polymer selected from the group consisting of polyurethane polymers, polyester polymers, polyether polymers, silicon-based polymers, co-polymers thereof, and mixtures thereof.
2. The method of claim 1 , wherein the first powder coating composition and the second powder coating composition are both an extrusion product of an extruder feed comprising both the particulate film-forming resin and the polymer-enclosed color-imparting nanoparticles.
3. The method of claim 2 , wherein the extruder feed comprises an aqueous dispersion of the polymer-enclosed color-imparting nanoparticles.
4. The method of claim 2 , wherein the first powder coating composition and the second powder coating composition comprise the same particulate film-forming resin.
5. The method of claim 1 , wherein the polymer-enclosed color-imparting nanoparticles comprise nanoparticles having an average particle size of 100 nanometers or less.
6. The method of claim 1 , wherein the nanoparticles comprise organic nanoparticles.
7. The method of claim 1 , wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising a free-radical polymerization reaction product of (i) the ethylenically unsaturated polymerizable polyester polyurethane, and (ii) the ethylenically unsaturated monomer.
8. The method of claim 7 , wherein the polymerizable polyester polyurethane comprises a polyester polyurethane having terminal ethylenic unsaturation.
9. The method of claim 8 , wherein the polyester polyurethane having terminal ethylenic unsaturation is prepared from reactants comprising:
(a) a polyisocyanate;
(b) a polyester polyol; and
(c) a material comprising an ethylenically unsaturated group and an active hydrogen group.
10. The method of claim 1 , wherein the coating is a non-hiding coating.
11. The method of claim 1 , wherein the particulate film-forming resin comprises a carboxylic acid functional resin.
12. A method for color matching using a powder coating composition comprising dry-blend mixing a first powder coating composition having a first hue and a second powder coating composition having a second hue different than the first hue to form a heterogeneous association of the first powder coating composition and the second powder coating composition in a proportion that results in a coating having a desired homogeneous hue when the heterogeneous association of the first powder coating composition and the second powder coating composition is directly applied to at least a portion of a substrate and cured,
wherein the first powder coating composition and/or the second powder coating composition comprises a particulate film-forming resin and polymer-enclosed color-imparting nanoparticles, the color-imparting nanoparticles having average particle size of 300 nanometers or less,
wherein the particulate film-forming resin comprises an epoxy functional resin,
wherein the polymer-enclosed color-imparting nanoparticles are enclosed by a polymer different from the particulate film-forming resin,
wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising the reaction product of (i) an ethylenically unsaturated water-dispersible polymerizable dispersant, and (ii) an ethylenically unsaturated monomer, and
wherein the water-dispersible polymerizable dispersant comprises a polymer selected from the group consisting of polyurethane polymers, polyester polymers, polyether polymers, silicon-based polymers, co-polymers thereof, and mixtures thereof.
13. The method of claim 12 , wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising a free-radical polymerization reaction product of (i) the ethylenically unsaturated polymerizable polyester polyurethane, and (ii) the ethylenically unsaturated monomer.
14. The method of claim 13 , wherein the polymerizable polyester polyurethane comprises a polyester polyurethane having terminal ethylenic unsaturation.
15. The method of claim 14 , wherein the polyester polyurethane having terminal ethylenic unsaturation is prepared from reactants comprising:
(a) a polyisocyanate;
(b) a polyester polyol; and
(c) a material comprising an ethylenically unsaturated group and an active hydrogen group.
16. A method for preparing a decorative and durable coating having a homogeneous hue comprising:
(a) dry-blend mixing a first powder coating composition having a first hue and a second powder coating composition having a second hue different than the first hue to form a heterogeneous association of the first powder coating composition and the second powder coating composition; and
(b) directly applying the heterogeneous association of the first powder coating composition and the second powder coating composition to at least a portion of a substrate,
wherein the first powder coating composition and/or the second powder coating composition comprises a particulate film-forming resin and color-imparting nanoparticles having average particle size of 300 nanometers or less,
wherein the particulate film-forming resin comprises an epoxy functional resin,
wherein the polymer-enclosed color-imparting nanoparticles are enclosed by an acrylic polymer different from the particulate film-forming resin,
wherein the first powder coating composition and/or the second powder coating composition comprises 50 to 90 percent by weight of a particulate film-forming resin comprising a carboxylic acid functional resin,
wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising the reaction product of (i) an ethylenically unsaturated water-dispersible polymerizable dispersant, and (ii) an ethylenically unsaturated monomer, and
wherein the water-dispersible polymerizable dispersant comprises a polymer selected from the group consisting of polyurethane polymers, polyester polymers, polyether polymers, silicon-based polymers, co-polymers thereof, and mixtures thereof.
17. The method of claim 16 , wherein the first powder coating composition and/or the second powder coating composition comprises an extrusion product of an extruder feed comprising both the particulate film-forming resin and the polymer-enclosed color-imparting nanoparticles.
18. The method of claim 17 , wherein the first powder coating composition and the second powder coating composition are both the extrusion product of an extruder feed comprising both the particulate film-forming resin and the polymer-enclosed color-imparting nanoparticles.
19. The method of claim 17 , wherein the extruder feed comprises an aqueous dispersion of the polymer-enclosed color-imparting nanoparticles.
20. The method of claim 16 , wherein the nanoparticles comprise organic nanoparticles.
21. The method of claim 16 , wherein the coating is a non-hiding coating.
22. The method of claim 16 , wherein the polymer-enclosed color-imparting nanoparticles comprise a polymer comprising a free-radical polymerization reaction product of (i) the ethylenically unsaturated polymerizable polyester polyurethane, and (ii) the ethylenically unsaturated monomer.
23. The method of claim 22 , wherein the polymerizable polyester polyurethane comprises a polyester polyurethane having terminal ethylenic unsaturation.
24. The method of claim 23 , wherein the polyester polyurethane having terminal ethylenic unsaturation is prepared from reactants comprising:
(a) a polyisocyanate;
(b) a polyester polyol; and
(c) a material comprising an ethylenically unsaturated group and an active hydrogen group.