CPC B05D 7/542 (2013.01) [B05D 1/06 (2013.01); B05D 1/12 (2013.01); B05D 1/36 (2013.01); B05D 3/002 (2013.01); B05D 3/0218 (2013.01); B05D 3/0254 (2013.01); B05D 3/102 (2013.01); B05D 3/12 (2013.01); B05D 7/14 (2013.01); C08K 3/22 (2013.01); C08K 5/29 (2013.01); C08K 5/32 (2013.01); C08K 5/3445 (2013.01); C09D 5/03 (2013.01); C09D 5/035 (2013.01); C09D 163/00 (2013.01); C23C 24/00 (2013.01); C23C 26/00 (2013.01); C23C 28/00 (2013.01); B05D 2202/10 (2013.01); B05D 2451/00 (2013.01); B32B 7/02 (2013.01); C08K 2003/2241 (2013.01); C09D 167/00 (2013.01); C09D 167/02 (2013.01); C09D 167/03 (2013.01); Y10T 428/31529 (2015.04)] | 16 Claims |
1. A coated article made by a process comprising:
providing a metal substrate;
providing at least a first powder coating composition with flow of about 10 mm to 30 mm to a surface of the metal substrate at ambient temperature;
providing at least a second powder coating composition with flow of at least about 40 mm; and
heating 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 consisting of the first powder coating and second powder coating is corrosion-resistant and has a surface smoothness on the Powder Coating Institute (PCI) scale of at least 4 and wherein the cured coating has edge coverage equal to at least 2% of face coverage, and wherein the second powder coating in the cured coating covers the entire first powder coating.
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