Coating composition comprising a thermoset resin and a thermoplastic resin

1. A substrate coated on at least a portion thereof with a powder coating composition, the powder coating composition comprising:

a thermoset resin comprising an acid functional polyester material;

a thermoplastic resin; and

a crosslinker,

wherein the coating composition is substantially free of bisphenol A (BPA), bisphenol F (BPF), bisphenol A diglycidyl ether (BADGE) and bisphenol F diglycidyl ether (BFDGE).

2. The substrate of claim 1 , wherein the acid functional polyester material is formed from a polyacid comprising succinic acid, glutaric acid, adipic acid, heptanoic acid, dodecanedioic acid or combinations thereof.

3. The substrate of claim 1 , wherein the coating composition is substantially free of formaldehyde or sources thereof.

4. The substrate of claim 1 , wherein the thermoplastic resin comprises epoxy resin, polyester resin, polyolefin resin, polyamide resin, polyurethane resin, polysiloxane resin, acrylic resin, and/or hydrocarbon resin.

5. The substrate of claim 1 , wherein the crosslinker comprises a hydroxyalkylamide material, a hydroxyl functional alkyl polyurea material, and/or a carbodiimide resin.

6. The substrate of claim 1 , wherein the substrate comprises metal, plastic, and/or laminate.

7. The substrate of claim 1 , wherein the acid functional polyester material has an acid number of at least 25 mg KOH/g.

8. The substrate of claim 1 , wherein the acid functional polyester material has a Tg of 50° C. to 100° C.

9. The substrate of claim 1 , wherein the acid functional polyester material has a number average molecular weight of 1,000 to 20,000 Da.

10. The substrate of claim 1 , wherein the acid functional polyester material has a weight average molecular weight of 5,000 to 20,000 Da.

11. The substrate of claim 1 , wherein the acid functional polyester material has a melt viscosity at 200° C. of 10 to 50 Poise.

12. The substrate of claim 1 , wherein the thermoplastic resin has a Tg of 40° C. to 80° C.

13. The substrate of claim 1 , wherein the substrate forms at least a portion of a metal can, a plastic bottle, a plastic tube, a laminate, and/or flexible packaging.

14. The substrate of claim 1 , wherein the substrate forms at least a portion of a monobloc aerosol can and/or tube.

15. The substrate of claim 1 , wherein the substrate forms at least a portion of a food and/or beverage packaging.

16. The substrate of claim 1 , wherein the acid functional polyester material comprises the reaction product of a polyacid and a polyol.

17. The substrate of claim 16 , wherein the polyacid comprises at least 50 mol % terephthalic acid and/or isophthalic acid based on the total number of moles of polyacid.

18. The substrate of claim 16 , wherein the polyol comprises at least 10 mol % of neopentyl glycol based on the total number of moles of polyol.

19. The substrate of claim 16 , wherein the ratio of polyacid to polyol is from 20:1 to 1:20.

20. A packaging coated on at least a portion thereof with a powder coating composition, the powder coating composition comprising:

a thermoset resin comprising an acid functional polyester material;

a thermoplastic resin; and

a crosslinker,

wherein the coating composition is substantially free of bisphenol A (BPA), bisphenol F (BPF), bisphenol A diglycidyl ether (BADGE) and bisphenol F diglycidyl ether (BFDGE).

21. A method for producing a powder coating composition, the method comprising:

extruding a polymer mixture comprising a thermoset resin comprising an acid functional polyester material, a thermoplastic resin, and a crosslinker to form a thermoset powder; and

grinding the thermoset powder to an average particle size of 5 to 300 microns.

22. The method of claim 21 , further comprising dry blending the polymer mixture before extruding.