Axalta Coating Systems IP Co LLC

Shih-Wa Wang

John R Moore

Michael R Koerner

Christian Jackson

Bradley A Jacobs

Matthew Irwin

Barry Snyder

Matthew Boland

Joanne Hardy

Daniel Naugle

Kevin J O'Connor

Petra Stoffel

Kevin O'Connor

Larry Eugene Steenhoek

Matthias Baltrusch

A method of preparing a coated article is disclosed. The method includes providing a substrate bearing a partially-dehydrated aqueous coating layer. The method further includes providing a coating composition to a high transfer efficiency applicator, the high transfer efficiency applicator comprising a plurality of nozzles each being configured to apply a stream of the coating composition to a substrate substantially without atomization. The coating composition is a waterborne fluid that exhibits a near-Newtonian viscosity profile, and comprises a binder, a crosslinker, and a thickener. The method further includes applying the coating composition to the substrate with the high transfer efficiency applicator via disposing a plurality of lines of the coating composition onto the partially-dehydrated aqueous coating layer of the substrate via the plurality of nozzles, thereby forming an overspray free coating layer thereon.

Coating compositions and related methods

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

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 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 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 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).

Method of forming a coating composition for application to a substrate utilizing a high transfer efficiency applicator

A system for applying a first coating composition and a second coating composition. 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 substrate defining a target area. The first high transfer efficiency applicator is configured to expel the first coating composition through the first nozzle orifice to the target area of the substrate to form a first coating layer. The second high transfer efficiency applicator is configured to expel the second coating composition through the second nozzle orifice to the first coating layer to form a second coating layer.

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Glen Mills, PA, United States of America

Shih-Wa Wang