IP Library › Granted Patent US 12,291,649
Granted Patent B2
US 12,291,649 · App. 17/400,607 · Granted May 6, 2025

Two-coat single cure powder coating

Inventors: Owen H. Decker (Smithville, MO); Thomas E. Reno (Kansas City, MO); Robert D. Breitzman (Liberty, MO); Carlos A. Concha (Kansas City, MO); Jeffrey D. Rogozinski (Kansas City, MO)
Assignee: The Sherwin-Williams Company
C09D5/03C23C24/10C23C30/00Y10T428/31678
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Quick Facts
Patent No.
US 12,291,649
App. No.
17/400,607
Granted
May 6, 2025
Kind
B2
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 (19)

1. A method, comprising:

providing a metal substrate;

applying a first coating comprising a first powder coating composition with flow of no more than about 40 mm;

applying a second coating comprising a second powder coating composition with flow greater than about 50 mm; and

heating the first coating and second coating in a single step to form a continuous cured coating, wherein the second coating in the cured coating covers the entire first coating.

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

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

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

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

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

7. The method of claim 1 , wherein the cured coating has 20-degree gloss of at least 50%.

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

9. The method of claim 1 , wherein the metal substrate is unprimed.

10. The method of claim 1 , wherein the metal substrate is clean blasted.

11. The method of claim 1 , wherein the metal substrate is pretreated.

12. The method of claim 1 , wherein the metal substrate is heated prior to applying the first coating composition.

13. 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.

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

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

Continuity (5)
Continuation 14019041 · Sep 5, 2013
Continuation In Part PCTUS2012070347 · Dec 18, 2012
Provisional Application 61642578 · May 4, 2012
Provisional Application 61613647 · Mar 21, 2012
Related Publication 20220033661A1 · Feb 3, 2022
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