IP Library › Granted Patent US 12,734,549
Granted Patent B2
US 12,734,549 · App. 18/410,715 · Granted Sep 15, 2026

Two-coat single cure powder coating

Inventors: Owen H. Decker (Smithville, MO); Thomas E. Reno (Americus, GA); Robert D. Breitzman (Ramsey, MN); Carlos A. Concha (New Brighton, MN); Jeffrey D. Rogozinski (Blaine, MN); Keith M. Kirkwood (Apple Valley, MN)
Assignee: The Sherwin-Williams Company
B05D7/542B05D1/06B05D1/12B05D1/36B05D3/002B05D3/0218B05D3/0254B05D3/102B05D3/12B05D7/14C08K3/22C08K5/29C08K5/32C08K5/3445C09D5/03C09D5/035C09D163/00C23C24/00C23C26/00C23C28/00B05D2202/10B05D2451/00B32B7/02C08K2003/2241C09D167/00C09D167/02C09D167/03Y10T428/31529
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Quick Facts
Patent No.
US 12,734,549
App. No.
18/410,715
Granted
Sep 15, 2026
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 (28)

1 . A method of coating a substrate, comprising:

providing a substrate;

providing a first coating comprising a first powder composition, wherein the first powder composition has a flow of no more than about 40 mm;

providing a second coating comprising a second powder composition, wherein the second powder composition has a flow of at least about 50 mm, wherein the second coating is unpigmented; and

heating the first powder coating composition and second powder coating composition in a single step to form a cured coating,

wherein the first and/or second powder composition comprises a carboxyl-functional polyester resin cured with polymeric epoxy resins, hydroxyl-functional polyester resins cured with blocked isocyanates or uretdiones, epoxy resins cured with amines, or hydroxyl-functional acrylic resins cured with blocked isocyanates or uretdiones.

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

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

4 . The method of claim 1 , wherein the first coating is applied to the substrate at ambient temperature.

5 . The method of claim 1 , wherein the first coating and second coating are heated in a single step at a temperature of about 180° C. to 200° C.

6 . The method of claim 1 , wherein the metal substrate is unprimed, clean blasted, or pretreated.

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

8 . The method of claim 1 , wherein the second coating is applied at a film build of about 25 to 75 micron.

9 . A coated article, comprising:

a substrate;

a first coating comprising a first powder composition deposited on the substrate, wherein the first powder composition has a flow of no more than about 40 mm;

a second coating comprising a second powder composition deposited on the first powder composition, wherein the first powder composition has a flow of at least about 50 mm, wherein the second coating is unpigmented; and

wherein the first powder coating composition and second powder coating composition are heated in a single step to form a cured coating, and

wherein the first and/or second powder composition comprises a carboxyl-functional polyester resin cured with polymeric epoxy resins, hydroxyl-functional polyester resins cured with blocked isocyanates or uretdiones, epoxy resins cured with amines, or hydroxyl-functional acrylic resins cured with blocked isocyanates or uretdiones.

10 . The article of claim 9 , wherein the first powder composition has a flow of about 15 mm to 40 mm.

11 . The article of claim 9 , wherein the second powder composition has flow of greater than about 50 mm.

12 . The article of claim 9 , wherein the cured coating has 20-degree gloss of at least 50%.

13 . The article of claim 9 , wherein the cured coating has edge coverage equal to about 10% of the face coverage.

14 . The article of claim 9 , wherein the first powder composition is applied to the substrate at ambient temperature.

15 . The article of claim 9 , wherein the first powder composition and second coating composition are heated in a single step at a temperature of about 180° C. to 200° C.

16 . The article of claim 9 , wherein the first coating has a thickness of about 20 to 40 micron.

17 . The article of claim 9 , wherein the second coating has a thickness of about 25 to 75 micron.

18 . The article of claim 9 , wherein the first coating and the second coating are applied only to one or more edges of the substrate.

Continuity (7)
Continuation 15664511 · Jul 31, 2017
Division 14522143 · Oct 23, 2014
Continuation In Part 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 20240226959A1 · Jul 11, 2024
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