Axalta Coating Systems IP Co LLC

E.i. Dupont De Nemours and Company

Other

Axalta Coating Systems Gmbh

John R Moore

Christian Jackson

Michael R Koerner

Bradley A Jacobs

Shih-Wa Wang

Matthew Irwin

Barry Snyder

Joanne Hardy

Daniel Naugle

Matthew Boland

Michael Stephen Wolfe

William K Moore

Kevin J O'Connor

Timothy S Moore

Larry Ray Marshall

Jack Eugene Armantrout

Tao Huang

Kevin O'Connor

Neal Pfeiffenberger

Carmen Flosbach

Larry Eugene Steenhoek

John Charles Larson

Robert R Matheson

Petra Stoffel

James Neal

Cameron Stevens

Shih-wa Wang

David A Fischer

Dennis M Dixon

A method includes applying a coating composition to a substrate through a high transfer efficiency applicator wherein the coating composition has a pH of greater than about 7 and comprises:

Method of applying a one-component waterborne coating composition to a substrate utilizing a high transfer efficiency applicator

Methods of coating a substrate are provided. In an exemplary embodiment, a coating composition is applied to the substrate with a high transfer efficiency applicator to produce a coating layer, where the high transfer efficiency applicator and the substrate remain spatially separate while the coating composition is applied. A droplet of the coating composition expelled from the high transfer efficiency applicator has a particle size of about 10 microns or greater. The coating composition has a viscosity of from about 1,000 to about 1,000,000 centipoise when the coating composition is subject to a shear rate of about 0.1 reciprocal seconds (s). However, the coating composition is non-Newtonian such that a coating composition viscosity decreases when the shear rate is increased to the coating composition. The coating layer is impinged with a gas such that a coating layer surface moves upon impingement with the gas.

Methods of coating a substrate

A nozzle plate defines at least one nozzle connected to the nozzle plate at a base, wherein the at least one nozzle has a height and a top having an inner width and an outer width, wherein a ratio of the height to the inner width is greater than 5, and wherein the nozzle plate comprises a borosilicate glass. The nozzle plate is formed via a method including providing a silicon wafer having a surface; providing a borosilicate glass wafer having a surface; etching the surface of the silicon wafer to form a plurality of trenches in the surface; anodically bonding the etched surface of the silicon wafer to the surface of the borosilicate glass wafer to form a two layer composite; heating the two layer composite at a temperature of at least about 750° C.; and releasing the silicon wafer from the borosilicate glass to form the nozzle plate.

Nozzle plate comprising borosilicate glass

A method of applying a coating composition to a substrate utilizing a high transfer efficiency applicator include the steps of providing the high transfer efficiency applicator comprising an array of nozzles wherein each nozzle defines a nozzle orifice having a diameter of from 0.00002 m to 0.0004, providing the coating composition, and applying the coating composition to the substrate through the nozzle orifice without atomization such that at least 99.9% of the applied coating composition contacts the substrate to form a coating layer having a wet thickness of at least 5 microns, wherein the coating composition includes a carrier, a binder, and a radar reflective pigment or a LiDAR reflective pigment. The coating composition has an Ohnesorge number (Oh) of from about 0.01 to about 12.6, a Reynolds number (Re) of from about 0.02 to about 6,200, and a Deborah number (De) of from greater than 0 to about 1730.

Coating compositions for application utilizing a high transfer efficiency applicator and methods and systems thereof

A system for applying a first, a second, and a third coating composition. The system includes a first high transfer efficiency applicator defining a first nozzle orifice. The system further includes a second high transfer efficiency applicator defining a second nozzle orifice. The system further includes a third high transfer efficiency applicator defining a third nozzle orifice. The system further includes a substrate defining a target area. The first, the second, and the third high transfer efficiency applicators are configured to expel the first coating composition through the first nozzle orifice to the target area of the substrate, through the second nozzle orifice to the target area of the substrate, and through the third nozzle orifice to the target area of the substrate.

A coating composition for application to a substrate utilizing a high transfer efficiency applicator. The coating composition includes a carrier, a binder, a corrosion inhibiting pigment. The coating composition has an Ohnesorge number (Oh) of from about 0.01 to about 12.6. The coating composition has a Reynolds number (Re) of from about 0.02 to about 6,200. The coating composition has a Deborah number (De) of from greater than 0 to about 1730.

Method of applying a coating composition to a substrate

A system for applying a coating composition is provided herein. The system includes a first high transfer efficiency applicator defining a first nozzle orifice and a second high transfer efficiency applicator defining a second nozzle orifice. The system further includes a reservoir. The system further includes a substrate defining a first target area and a second target area. The first high transfer efficiency applicator and the second high transfer efficiency applicator are configured to receive the coating composition from the reservoir and configured to expel the coating composition through the first nozzle orifice to the first target area of the substrate and to expel the coating composition through the second nozzle orifice to the second target area of the substrate.

System for applying a coating composition

A system for applying a first coating composition and a second coating composition is provided herein. The system includes an atomizing applicator and a high transfer efficiency applicator defining a nozzle orifice. The system further includes a substrate assembly comprising a metal-containing substrate and a plastic-containing substrate. The metal-containing substrate is coupled to the plastic-containing substrate. The atomizing applicator is configured to apply the first coating composition to the metal-containing substrate. The high transfer efficiency applicator is configured to expel the second coating composition through the second nozzle orifice to the plastic-containing substrate.

A system for applying a first and a second coating composition is provided herein. The system includes a first high transfer efficiency applicator defining a first nozzle orifice and a second high transfer efficiency applicator defining a second nozzle orifice. The system further includes a first reservoir a second reservoir. The system further includes a substrate defining a first target area and a second target area. The first high transfer efficiency applicator is configured to receive the first coating composition from the first reservoir and configured to expel the first coating composition through the first nozzle orifice to the first target area of the substrate. The second high transfer efficiency applicator is configured to receive the second coating composition from the second reservoir and configured to expel the second coating composition through the second nozzle orifice to the second target area of the substrate.

A system for applying a coating composition to a substrate utilizing a high transfer efficiency applicator is provided herein. The system includes a high transfer efficiency applicator defining a nozzle orifice. The coating composition comprises a carrier and a binder. The coating composition has a viscosity of from about 0.002 Pa*s to about 0.2 Pa*s, a density of from about 838 kg/m3 to about 1557 kg/m3, a surface tension of from about 0.015 N/m to about 0.05 N/m, and a relaxation time of from about 0.0005 s to about 0.02 s. The high transfer efficiency applicator is configured to expel the coating composition through the nozzle orifice to the substrate to form a coating layer. At least 80% of the droplets of the coating composition expelled from the high transfer efficiency applicator contact the substrate.

A coating composition for application to a substrate utilizing a high transfer efficiency applicator. The coating composition includes a carrier and a binder comprising an elastomeric resin in an amount of at least 50 weight %, wherein the elastomeric resin has an Elongation to Break of at least 500% according to DIN 53 504. The coating composition has an Ohnesorge number (Oh) of from about 0.01 to about 12.6. The coating composition has a Reynolds number (Re) of from about 0.02 to about 6,200. The coating composition has a Deborah number (De) of from greater than 0 to about 1730.

A coating composition for application to a substrate utilizing a high transfer efficiency applicator is provided herein. The coating composition includes monomeric, oligomeric, or polymeric compounds having a number average molecular weight of from about 400 to about 20,000 and having a free-radically polymerizable double bond. The coating composition further includes a photo initiator. The coating composition has an Ohnesorge number (Oh) of from about 0.01 to about 12.6. The coating composition has a Reynolds number (Re) of from about 0.02 to about 6,200. The coating composition has a Deborah number (De) of from greater than 0 to about 1730.

A system for applying a coating composition to a substrate utilizing a high transfer efficiency applicator is provided herein. The system includes a storage device for storing instructions for performing a matching protocol, and one or more data processors configured to execute the instructions to, receive, by one or more data processors, target image data of a target coating, the target image data generated by an electronic imaging device, and apply the target image data to a matching protocol to generate application instructions. The system further includes a high transfer efficiency applicator defining a nozzle orifice. The high transfer efficiency applicator is configured to expel the coating composition through the nozzle orifice to the substrate to form a coating layer. The high transfer efficiency applicator is configured expel the coating composition based on the application instructions.

A method of forming a coating composition for application to a substrate utilizing a high efficiency transfer applicator. The method includes identifying at least one of an Ohnesorge number (Oh) for the coating composition, a Reynolds number (Re) for the coating composition, or a Deborah number (De) for the coating composition. The method includes obtaining at least one of a viscosity (&#x3b7;) of the coating composition, a surface tension (&#x3c3;) of the coating composition, a density (&#x3c1;) of the coating composition, a relaxation time (&#x3bb;) of the coating composition, a nozzle diameter (D) of the high efficiency transfer applicator, or an impact velocity (v) of the high efficiency transfer applicator. The method includes forming the coating composition having at least one of the viscosity (&#x3b7;), the surface tension (&#x3c3;), or the density (&#x3c1;). The coating composition is configured to be applied to the substrate utilizing the high efficiency transfer applicator having at least one of the nozzle diameter (D) or the impact velocity (v).

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Lansdale, PA, United States of America

John R Moore