Morton International, Inc.

Rohm and Haas Company

Jeno Muthiah

Andrew T Daly

Richard P Haley

Joseph J Kozlowski

Paul R Horinka

Glenn D Correll

Eugene P Reinheimer

Carryll A Seelig

William E Wertz

Michael C Siminski

Catherine A Kleckner

Tina L Grubb

Owen H Decker

Edward G Nicholl

Navin B Shah

William George Ruth

Jacquelyn M Schlessman

Jeremiah J Teti

Matthew B Snyder

Karl R Wursthorn

Gordon L Tullos

David A Mountz

Paul H Radcliffe

E Susanne Deibert

Robert M Didrick

Andrea M Anderson

Veronica M Reichert

Jaquelyn Schelessman

Jeffrey B Farro

Andres T Daly

Richard P Haly

Corrosion- and chip-resistant coatings for high tensile steel components, such as automotive coil springs, are formed from a coating powder composition of 'toughened' epoxy resin. In a single coat embodiment, the entire coating is loaded with at least 75 phr zinc powder. In a dual coat embodiment, an inner coat is loaded with at least 75 phr zinc and an outer, zinc-free coating is reinforced by the addition of fibers and/or by a foaming agent which renders it porous.

Corrosion-and chip-resistant coatings for high tensile steel

A mixture of a self-curing epoxy resin having an equivalent weight of from about 100 to about 700, a melt viscosity of from about 200 to about 2000 centipoise at 150&#xb0; C. and a low temperature curing agent capable of maintaining its own domain during extrusion which is extruded as one component at a temperature below 220&#xb0; F. and the extrudate is cooled and pulverized to form a low temperature curable coating powder. The powder cures at a temperature of from about 225 to about 300&#xb0; F. and produces a coating having an exceptionally smooth surface with either a low or high gloss. The powder is particularly useful for coating heat sensitive substrates such as plastics, paper, cardboard and wood.

Coating powder of epoxy resin and low temperature curing agent

A mixture of a self-curing epoxy resin having an equivalent weight of from about 100 to about 700, a melt viscosity of from out 200 to about 3000 centipoise at 150&deg; C. and a low temperature curing agent is extruded or otherwise mixed in the molten state as one component at a temperature below 230&deg; F. and the extrudate is cooled and pulverized to form a low temperature curable coating powder. The powder cures at a temperature of from about 225 to about 300&deg; F. and produces a coating having an exceptionally smooth surface with either a low or high gloss. The powder is particulary useful for coating heat sensitive substrates such as plastic parts for automobiles, paper, cardboard and wood. Fiberboard having a pattern such as a simulated wood grain printed on its surface and a powder coating of this invention over said pattern has the appearance of natural wood.

One-component, low temperature curable coating powder

Corrosion- and chip-resistant coatings for high tensile steel components, such as automotive coil springs, are formed from a coating powder composition of &ldquo;toughened&rdquo; epoxy resin. In a single coat embodiment, the entire coating is loaded with at least 75 phr zinc powder. In a dual coat embodiment, an inner coat is loaded with at least 75 phr zinc and an outer, zinc-free coating is reinforced by the addition of fibers and/or by a foaming agent which renders it porous.

A mixture of a self-curing epoxy resin having an equivalent weight of from about 100 to about 700, a melt viscosity of from about 200 to about 2000 centipoise at 150&deg; C. and a low temperature curing agent is extruded as one component at a temperature below 220&deg; F. and the extrudate is cooled and pulverized to form a low temperature curable coating powder. The powder cures at a temperature of from about 225 to about 300&deg; F. and produces a coating having a smooth surface with either a low or high gloss. The powder is particulary useful for coating heat-sensitive substrates such as plastics, paper, cardboard and wood.

One-component powder coating of epoxy resin, epoxy-polyamine adduct and acid matting agent

A coating powder, based on glycidyl (meth)acrylate copolymer/carboxylic acid functional polyester chemistry, provides a smooth, weatherable, reduced gloss coating for use on heat sensitive substrates, such as wood. The glycidyl (meth)acrylate copolymer has an epoxy equivalent weight of 250 to 400 and the carboxylic acid functional polyester has a viscosity of 2500 cps or less at 200 C.

Low temperature curing powder coating for producing reduced gloss, weatherable coatings

Low gloss in a coating derived from a polyester/triglycidyl isocyanurate coating powder is achieved by including in the coating powder ethylene/acrylic acid copolymer plus a zinc salt of a fatty acid and/or a zinc salt of a beta diketone.

Low gloss polyester coating powder compositions

Corrosion- and chip-resistant coatings for high tensile steel

A process of forming coatings on substrates by applying a layer of curable materials in dry powder form and then melting and curing the material is improved by compressing the layer using a flexible confining membrane. Less material is required to provide equivalent barrier protection and surface finish. The process is particularly applicable to applying dry powder coatings on temperature sensitive substrates, such as medium density fiberboard, in press apparatus, such as a membrane press, which have not commercially used dry powder coating materials previously.

Powder coating involving compression of the coating during curing

Heat sensitive substrates, as well as others such as metal or glass, are electrostatically coated with a thermosetting coating powder comprising a melt-mixed, chilled, chipped, and powdered blend of an epoxy resin and a catalyst therefore, and a polyamine as a powdered low temperature curing agent along with a scavenger which will react secondarily with residual polyamine domains that do not contact the base epoxy resin during curing. The coating powder is deposited on the substrate and heated to fuse, flow and cure. The mixture of resin and catalyst does not cure within the extruder but it is made to cure at low temperatures on the desired substrate by the separate addition of the curing agent to the powdered melt-mixed blend.

Powder coating of epoxy resin, imidazole-epoxy resin catalyst or polyamine, polyamine powder and amine scavenger

In substrates, such as wood substrates, having sharp edges, corners and other surface discontinuities, in a front appearance surface, non-functional machining, such as formation of grooves, is performed on the rear non-appearance surface adjacent the surface discontinuities. Coating powder is applied, e.g., electrostatically, to the appearance surface of the substrate and the coating powder fused or fused and cured to form a continuous coating on the appearance surface of the substrate. The rear surface machining reduces cracking of the coating at the front surface discontinuities. In some cases, non-functional machining is distributed over the entire non-appearance surface of the work-piece to promote out-gassing of volatiles to the non-appearance surface, thereby eliminating out-gassing-caused defects in the coating formed on the appearance surface.

Method of powder coating a substrate

This invention provides a UV curable powder coating composition comprising a particulate blend of a non-crystalline unsaturated polyester base resin, a crystalline unsaturated crosslinker resin co-polymerizable with the base resin, and a photoinitiator, that exhibits reduced or eliminated hazing in the cured coating formed therefrom upon being cured at low temperatures demanded by certain heat sensitive substrates. This is accomplished by incorporating in the powder composition a recrystallization or haze inhibitor which is comprised of a crystalline epoxy resin. When this powder blend is melted for curing, the crystalline crosslinker resin visually appears to separate and recrystallize out of the molten powder less completely than it does in the absence of the recrystallization or haze inhibitor. This prevents a visible haze from developing on the surface of the coating upon curing with UV radiation.

Non-hazing UV curable powder coatings containing crystalline resins

Wood is electrostatically coated with a thermosetting powder coating system in which a mixture of a self-curing epoxy resin and a catalyst therefore is extruded and a low temperature curing agent are both pulverized and the powders are blended with conventional additives to make a coating powder which is deposited on a wooden substrate and heated to cure. The mixture of resin and catalyst does not cure within the extruder but it is made to cure at low temperatures by the separate addition of the curing agent. A small amount of the low temperature curing agent, insufficient to cause substantial curing during extrusion may be used in place of the catalyst.

Two component powder coating system and method for coating wood therewith

Low temperature curable unsaturated polyester powder coatings suited for heat sensitive substrates with improved surface cure through incorporation of active hydrogen groups into the unsaturated polyester molecule. The unsaturated polyesters containing active hydrogens are derived from ethylenically unsaturated polyfunctional carboxylic acids and active hydrogen containing polyols. Full cure on the surface is obtained without the need for polyethylene waxes or oxygen-reactive curative resins that are commonly employed in order to prevent atmospheric oxygen from inhibiting the free-radical induced cure at the surface of the coating.

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Wernersville, PA, United States of America

Jeno Muthiah