Two-coat single cure powder coating

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.

TWO-COAT SINGLE CURE POWDER COATING

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. 1. A method , comprising:providing a metal substrate;applying a first coating comprising a powder coating composition with flow of no more than about 40 mm;applying a second coating comprising a powder coating composition with flow of at least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.2. A method , comprising:providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andproviding instructions for coating a metal substrate with at least the first composition, followed by coating with a second composition, and heating the two compositions in a single step to form a continuous coating.3. A coated article made by a process comprising:providing a substrate;providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.7. The method of claim 1 , wherein the first coating composition has a flow of about 15 mm to 40 mm.8. The method of claim 1 , wherein the first coating composition has a flow of about 20 to 35 mm.9. The method of claim 1 , wherein the second coating composition has flow of greater than about 50 mm.10. The method of claim 1 , wherein the second coating composition has flow of greater than about 70 mm.11. The method of claim 1 , wherein the second ...

HIGH-PERFORMANCE TEXTURED COATING

A coated article is described, including a substrate with a coating composition applied thereon to provide a coated article with a textured surface. In one aspect, the coated article is a steel rebar used to reinforce concrete. The textured surface provides optimal surface roughness and demonstrates superior pullout strength relative to an uncoated standard. 3. A method of coating a structural insert member , comprising:providing a structural insert member;heating the structural insert member to a temperature of about 150° C. to 300° C.; a binder resin component;', 'a texturizing additive; and', 'a functionalized filler; and, 'applying a powder coating composition to the heated insert member, wherein the powder coating composition comprisingcuring the applied powder coating composition.4. The article of claim 1 , wherein the textured surface is produced by including a texturizing additive in the powder coating composition.5. The article of claim 1 , wherein the textured surface is produced by forming a non-continuous cured film from the powder coating composition applied on the structural insert member.6. The method of claim 3 , wherein the binder resin component is selected from epoxy claim 3 , polyester claim 3 , polyurethane claim 3 , polyamide claim 3 , acrylic claim 3 , polyvinyl chloride claim 3 , nylon claim 3 , fluoropolymer claim 3 , silicone claim 3 , and mixtures or combinations thereof.7. The method of claim 3 , wherein the binder resin component is an epoxy-functional resin.8. The method of claim 3 , wherein the binder resin component is fusion-bonded epoxy resin.9. The article of claim 1 , wherein the structural insert member is an article made of material selected from metal claim 1 , glass claim 1 , polymeric materials claim 1 , ceramic claim 1 , and mixtures or combinations thereof.10. The article of claim 1 , wherein the structural insert member is an article selected from rebar claim 1 , dowel claim 1 , fiber claim 1 , mesh claim 1 , plate claim 1 ...

TWO-COAT SINGLE CURE POWDER COATING

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. 1. A method , comprising:providing a metal substrate;applying a first coating comprising a powder coating composition with flow of no more than about 40 mm;applying a second coating comprising a powder coating composition with flow of a least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.2. A method , comprising:providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andproviding instructions for coating a metal substrate with at least the first composition, followed by coating with a second composition, and heating the two compositions in a single step to form a continuous coating.3. A coated article made by a process comprising:providing a substrate;providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.46-. (canceled)7. The method of claim 1 , wherein the first coating composition has a flow of about 15 mm to 40 mm.8. The method of claim 1 , wherein the first coating composition has a flow of about 20 mm to 35 mm.9. The method of claim 1 , wherein the second coating composition has flow of greater than about 50 mm.10. The method of claim 1 , wherein the second coating composition has flow of greater than about 70 mm.11. The method of claim 1 , ...

Two-Coat Single Cure Powder Coating

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. 1. A method , comprising:providing a metal substrate;applying a first coating comprising a powder coating composition with flow of no more than about 40 mm;applying a second coating comprising a powder coating composition with flow of at least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.2. A method , comprising:providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andproviding instructions for coating a metal substrate with at least the first composition, followed by coating with a second composition, and heating the two compositions in a single step to form a continuous coating.3. A coated article made by a process comprising:providing a substrate;providing at least a first powder composition with flow of no more than about 40 mm;optionally, providing at least a second powder composition with flow of at least about 40 mm; andheating the first coating and second coating in a single step to form a continuous coating.5. The method of claim 1 , wherein the first coating composition has a flow of about 15 mm to 40 mm.6. The method of claim 1 , wherein the first coating composition has a flow of about 20 to 35 mm.7. The method of claim 1 , wherein the second coating composition has flow of greater than about 50 mm.8. The method of claim 1 , wherein the second coating composition has flow of greater than about 70 mm.9. The method of claim 1 , wherein the second ...

HIGH-PERFORMANCE TEXTURED COATING

A coated article is described, including a substrate with a coating composition applied thereon to provide a coated article with a textured surface. In one aspect, the coated article is a steel rebar used to reinforce concrete. The textured surface provides optimal surface roughness and demonstrates superior pullout strength relative to an uncoated standard. 3. A method of coating a structural insert member , comprising:providing a structural insert member;heating the structural insert member to a temperature of about 150° C. to 300° C.; a binder resin component;', 'a texturizing additive; and', 'a functionalized filler; and, 'applying a powder coating composition to the heated insert member, wherein the powder coating composition comprisingcuring the applied powder coating composition.4. The article of claim 1 , wherein the textured surface is produced by including a texturizing additive in the powder coating composition.5. The article of claim 1 , wherein the textured surface is produced by forming a non-continuous cured film from the powder coating composition applied on the structural insert member.6. The method of claim 3 , wherein the binder resin component is selected from epoxy claim 3 , polyester claim 3 , polyurethane claim 3 , polyamide claim 3 , acrylic claim 3 , polyvinyl chloride claim 3 , nylon claim 3 , fluoropolymer claim 3 , silicone claim 3 , and mixtures or combinations thereof.7. The method of claim 3 , wherein the binder resin component is an epoxy-functional resin.8. The method of claim 3 , wherein the binder resin component is fusion-bonded epoxy resin.9. The article of claim 1 , wherein the structural insert member is an article made of material selected from metal claim 1 , glass claim 1 , polymeric materials claim 1 , ceramic claim 1 , and mixtures or combinations thereof.10. The article of claim 1 , wherein the structural insert member is an article selected from rebar claim 1 , dowel claim 1 , fiber claim 1 , mesh claim 1 , plate claim 1 ...

TWO-COAT SINGLE CURE POWDER COATING

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. 120-. (canceled)21. A coated article made by a process comprising:providing a metal substrate;providing at least a first powder coating composition with flow of no more than about 40 mm to a surface of the metal substrate;providing at least a second powder coating composition with flow of at least about 40 mm; andheating the first powder coating and second powder coating composition in a single step to form a continuous cured coating on the metal substrate, thereby forming the coated article, wherein the cured coating is corrosion-resistant and having a surface smoothness on the Powder Coating Institute (PCI) scale of at least 4.22. The article of claim 21 , wherein the first powder coating composition has a flow of about 15 mm to 40 mm.23. The article of claim 21 , wherein the first powder coating composition has a flow of about 20 to 35 mm.24. The article of claim 21 , wherein the second powder coating composition has flow of greater than about 50 mm.25. The article of claim 21 , wherein the second powder coating composition has flow of greater than about 70 mm.26. The article of claim 21 , wherein the second powder coating composition has flow of greater than about 75 mm.27. The article of claim 21 , wherein the cured coating has edge coverage equal to at least 2% of face coverage.28. The article of claim 21 , wherein the cured coating has 20-degree gloss of at least 50%.29. The article of claim 21 , wherein the cured coating has edge coverage equal to about 10% of the face coverage.30. The article of claim 21 , wherein the metal ...

TWO-COAT SINGLE CURE POWDER COATING

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. 1. A method , comprising:providing a metal substrate;applying a primer coating comprising a first powder coating composition including a polymeric binding resin, wherein the first powder coating composition has flow of no more than about 40 mm;applying a topcoat comprising a second powder coating composition with flow of at least about 40 mm; andheating the metal substrate with the primer coating and topcoat applied thereon in a single step, without multiple heating cycles, to form a corrosion-resistant coating having a surface smoothness on the Powder Coating Institute (PCI) scale of at least 4.2. The method of claim 1 , wherein the polymeric binding resin includes a carboxyl-functional polyester binding resin.3. The method of claim 1 , wherein the first coating composition has a flow of about 15 mm to 40 mm.4. The method of claim 1 , wherein the first coating composition has a flow of about 20 to 35 mm.5. The method of claim 1 , wherein the second coating composition has flow of greater than about 50 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 polymeric binder is made with epoxy claim 1 , polyester claim 1 , polyurethane claim 1 , polyamide claim 1 , acrylic claim 1 , polyvinylchloride claim 1 , nylon claim 1 , fluoropolymer claim 1 , silicone claim 1 , or combinations thereof.8. The method of claim 1 , wherein the first coating composition and second coating composition are heated in a single step at a temperature of about 180 degree ...

TWO-COAT SINGLE CURE POWDER COATING

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. 1. A method , comprising:providing a metal substrate;applying a primer coating comprising a first powder coating composition including a polymeric binding resin, wherein the first powder coating composition has flow of no more than about 40 mm;applying a topcoat comprising a second powder coating composition with flow of at least about 40 mm; andheating the metal substrate with the primer coating and topcoat applied thereon in a single step, without multiple heating cycles, to form a corrosion-resistant coating having a surface smoothness on the Powder Coating Institute (PCI) scale of at least 4.2. The method of claim 1 , wherein the polymeric binding resin includes a carboxyl-functional polyester binding resin.3. The method of claim 1 , wherein the first coating composition has a flow of about 15 mm to 40 mm.4. The method of claim 1 , wherein the first coating composition has a flow of about 20 to 35 mm.5. The method of claim 1 , wherein the second coating composition has flow of greater than about 50 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 polymeric binder is made with epoxy claim 1 , polyester claim 1 , polyurethane claim 1 , polyamide claim 1 , acrylic claim 1 , polyvinylchloride claim 1 , nylon claim 1 , fluoropolymer claim 1 , silicone claim 1 , or combinations thereof.8. The method of claim 1 , wherein the first coating composition and second coating composition are heated in a single step at a temperature of about 180 degree ...

Two-Coat Single Cure Powder Coating

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.

High-performance textured coating

High-performance textured coating

A coated article is described, including a substrate with a coating composition applied thereon to provide a coated article with a textured surface. In one aspect, the coated article is a steel rebar used to reinforce concrete. The textured surface provides optimal surface roughness and demonstrates superior pullout strength relative to an uncoated standard.

Two-coat single cure powder coating

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.

Two-coat single cure powder coating

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.

Two-coat single cure powder coating

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.

Two-coat single cure powder coating

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.

High-performance textured coating

Wysokowydajna powłoka teksturowana

High-performance textured coating

A coated article is described, including a substrate with a coating composition applied thereon to provide a coated article with a textured surface. In one aspect, the coated article is a steel rebar used to reinforce concrete. The textured surface provides optimal surface roughness and demonstrates superior pullout strength relative to an uncoated standard.

Two-coat single cure powder coating

A representative sample of a primer and topcoat formulation (as shown in Table 5, for example) were each examined to compare their rheological behavior, with a blend of the topcoat and primer formulation (85% topcoat, 15% primer) used for comparison. The time and temperature dependence of the viscosity was measured on a strain-controlled rheometer using parallel plate geometry in dynamic mode, with an applied strain of 1% and 1 Hz frequency of oscillation. The data is represented as complex viscosity (Pa-s). For the primer and topcoat formulations, sample discs were prepared by compressing 0.3 g of the powder composition in a 13-mm plug mold at 1000 ram force for 15 seconds. Pressing was done at room temperature to avoid premature curing of the powder. The rheometer was set at 70° C. for sample loading. The gap was then set to 0.05 mm below the thickness of the pressed pellet to ensure contact with parallel plates. The temperature of the sample and fixtures were equilibrated for 10 minutes before measurements were taken. The sample temperature was ramped at 5° C./min from 70° C. to 245° C. to examine the rheological behavior as a function of temperature. The resultant curve of complex viscosity versus temperature and is examined to compare the flow behavior of the powder compositions.