US 11,925,957 B2
Two-coat single cure powder coating
Owen H. Decker, Smithville, MO (US); Thomas E. Reno, Kansas City, MO (US); Robert D. Breitzman, Liberty, MO (US); Carlos A. Concha, Kansas City, MO (US); and Jeffrey D. Rogozinski, Kansas City, MO (US)
Assigned to The Sherwin-Williams Company, Cleveland, OH (US)
Filed by The Sherwin-Williams Company, Cleveland, OH (US)
Filed on Jan. 14, 2021, as Appl. No. 17/148,622.
Application 15/664,511 is a division of application No. 14/522,143, filed on Oct. 23, 2014, granted, now 9,751,107, issued on Sep. 5, 2017.
Application 17/148,622 is a continuation of application No. 15/950,699, filed on Apr. 11, 2018, granted, now 10,940,505.
Application 15/950,699 is a continuation of application No. 15/664,511, filed on Jul. 31, 2017.
Application 14/522,143 is a continuation in part of application No. 14/019,041, filed on Sep. 5, 2013, granted, now 11,098,202.
Application 14/019,041 is a continuation of application No. PCT/US2012/070347, filed on Dec. 18, 2012.
Claims priority of provisional application 61/642,578, filed on May 4, 2012.
Claims priority of provisional application 61/613,647, filed on Mar. 21, 2012.
Prior Publication US 2021/0237118 A1, Aug. 5, 2021
Int. Cl. B05D 3/02 (2006.01); B05D 1/06 (2006.01); B05D 1/12 (2006.01); B05D 1/34 (2006.01); B05D 1/36 (2006.01); B05D 3/00 (2006.01); B05D 3/10 (2006.01); B05D 3/12 (2006.01); B05D 5/02 (2006.01); B05D 7/00 (2006.01); B05D 7/14 (2006.01); C08K 3/22 (2006.01); C08K 5/29 (2006.01); C08K 5/32 (2006.01); C08K 5/3445 (2006.01); C09D 5/03 (2006.01); C09D 163/00 (2006.01); C23C 24/00 (2006.01); C23C 26/00 (2006.01); C23C 28/00 (2006.01); B32B 7/02 (2019.01); C09D 167/00 (2006.01); C09D 167/02 (2006.01); C09D 167/03 (2006.01)
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.