US 12,378,420 B2
Process for making a powder for bonding to a substrate
Safraz Kahn, London (GB)
Assigned to AXALTA COATING SYSTEMS IP CO., LLC, Wilmington, DE (US)
Filed by AXALTA COATING SYSTEMS IP CO., LLC, Wilmington, DE (US)
Filed on Nov. 25, 2020, as Appl. No. 17/105,228.
Prior Publication US 2022/0162455 A1, May 26, 2022
Int. Cl. C09D 5/00 (2006.01); C08K 3/22 (2006.01); C09D 5/03 (2006.01); C09D 5/10 (2006.01); C09D 123/08 (2006.01); C09D 133/10 (2006.01); C09D 135/08 (2006.01)
CPC C09D 5/031 (2013.01) [C08K 3/22 (2013.01); C09D 5/106 (2013.01); C09D 123/0869 (2013.01); C09D 133/10 (2013.01); C09D 135/08 (2013.01); C08K 2003/2296 (2013.01)] 20 Claims
 
1. A process for making a powder for bonding to a substrate, the method comprising the steps of:
combining a copolymer and mono- or di-valent metal ions to form a mixture, wherein the copolymer has from about 70 to about 98 wt % of an alpha-olefin moiety and about 2 to about 30 wt % of a (meth)acrylate moiety, each based on a total weight of the copolymer;
reactively extruding the mixture to react the metal ions with the copolymer in the melt phase of the extrusion process to form in situ a neutralized copolymer having a melt flow index of from about 5 to about 1500 g/10 min, wherein the mixture is a dry mixture during extrusion, wherein during extrusion about 2 to about 50 wt % of the (meth)acrylate moiety is neutralized to form a mono- or di-valent metal salt present in an amount of from about 0.2 to about 20% based on the total (meth)acrylic acid content of the copolymer; and
grinding the neutralized copolymer to form the powder such that a temperature of grinding does not exceed a melting point of the neutralized copolymer,
wherein the process is free of utilizing a liquid.