Dual-coated single-cure powder coating

Abstract

To provide an efficient powder coating of metal parts, where multiple cure cycles are eliminated and the coating demonstrates excellent performance characteristics, such as excellent corrosion protection, including at edges, and optimal surface smoothness.SOLUTION: Methods and systems for coating metal substrates are provided. The methods and systems include sequential application of low-flow and high-flow powder coatings and subsequent single-step simultaneous curing. The methods and systems include a marker that allows coating uniformity to be monitored and assessed during application. The described methods provide a coating with optimal surface smoothness and edge coverage.SELECTED DRAWING: None

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS)

[0001] This application claims priority to U.S. Provisional Patent Application Nos. 61 / 642,578, filed May 4, 2012, and 61 / 613,647, filed March 21, 2012. [Background technology]

[0002]

[0001] Powder coatings are solvent-free, 100% solids coating systems used as low-VOC, low-cost alternatives to traditional liquid coatings and paints.

[0003]

[0002] Powder coating of metal parts is common. However, coating certain parts of metal substrates, such as edges and corners, to achieve a uniform coating using typical powder coating processes can be challenging, and edge corrosion is a common problem. Typically, when applying powder coatings to metal parts, low-flow coatings are used, which provide good edge coverage. However, such coatings tend to cause orange peel, a waviness in the finished surface characterized by a surface with raised particles, i.e., a surface with low smoothness. On the other hand, increasing flow and smoothness can result in low edge coverage, potentially resulting in complete defects, and leaving the metal part susceptible to edge corrosion. Conventional systems that attempt to combine flow properties with increased surface smoothness typically require multiple curing steps, leading to process inefficiencies and delays. Summary of the Invention [Problem to be solved by the invention]

[0004]

[0003] From the foregoing, it can be seen that there is a need for an efficient powder coating for metal parts that eliminates multiple cure cycles and where the coating exhibits superior performance characteristics, such as excellent corrosion protection and optimal surface smoothness, including at the edges. [Means for solving the problem]

[0005]

[0004] The invention described herein includes a method for coating a metal substrate with one or more powder compositions. In one embodiment, the method includes providing a metal substrate and applying a first powder coating onto the substrate, the first powder coating having a flowability of about 40 mm or less. A second powder coating is then applied over the first powder coating, the second powder coating having a flowability of at least about 40 mm. The two coatings are then cured simultaneously to provide a coating with good corrosion resistance, including at the edges, and surface smoothness.

[0006]

[0005] In another embodiment, the present invention includes a coating system for a metal substrate, the system including a first powder composition having a flowability of about 40 mm or less and a second powder composition having a flowability of at least about 40 mm. When the first and second powder compositions are applied sequentially to a metal substrate and cured simultaneously, the resulting coating has optimal corrosion resistance and surface smoothness.

[0007]

[0006] In another embodiment, the invention comprises a method of coating a metal substrate comprising providing at least a first powder composition having a flowability of about 40 mm or less, and optionally providing at least a second powder composition having a flowability of at least about 40 mm. The method further comprises instructions for coating the metal substrate with at least the first composition, then coating with the second composition, and simultaneously curing the two compositions to form a cured coating.

[0008]

[0007] In yet another embodiment, the present invention comprises a method and system for coating a metal substrate, the method and system comprising providing a first powder composition comprising at least a marker, and optionally providing at least a second powder composition, the method or system including instructions for coating the metal substrate with at least a first coating, wherein the presence of the marker in the first powder composition allows for monitoring the application of the second powder composition.

[0009]

[0008] The details of one or more embodiments and aspects of the invention are set forth below. Other features, objects, and advantages of the invention will become apparent from the description and from the claims.

[0010]

[0009] Unless otherwise stated, the following terms used herein have the meanings provided below.

[0011]

[0010] The term "on," in reference to a coating applied on a surface or substrate, includes both a coating applied directly or indirectly to the surface or substrate. Thus, for example, a coating applied to a primer layer overlying a substrate constitutes a coating applied to the substrate. Furthermore, the term "metal substrate," as used herein, refers to untreated, unprimed, or blast-cleaned substrates, as well as to surfaces that have been primed, i.e., pretreated by various methods known to those skilled in the art.

[0012]

[0011] As used herein, the term "flowability" refers to the relative flow of a powder composition upon heating. Flowability refers to the ability of a powder composition to flow. To measure flowability, a pressed pellet of the powder composition is placed on a preheated glass panel inclined at a 65° angle and allowed to flow and gel. The distance traveled by the composition across the plate is measured in mm and represents the flowability of the composition. Flowability can be measured according to the procedure described in ASTM Method D3451.

[0013]

[0012] The term "smoothness," as used herein, refers to the specular gloss, or light reflectance, of a powder-coated surface. Typically, it is obtained by comparing the specular reflectance of a coated sample to that of a black glass standard. As used herein, smoothness may be expressed by any means known to those skilled in the powder coating art, such as the visual standard developed by the Powder Coating Institute. This standard uses a visual scale of ten powder-coated panels ranging from a rating of 1 (highly rough / orange peel) to 10 (very smooth, high gloss finish). To determine relative smoothness, the powder-coated sample is visually compared to the standard panel and the relative smoothness is determined. A smoothness rating is assigned by assessing which reference panel most closely matches the sample. Alternatively, surface smoothness may be expressed as gloss at 20 or 60 degrees, measured using ASTM method D523. Additionally, smoothness may be assessed by observing distinctness of image (DOI), where a mirror image of the powder-coated sample is photographed on each of 10 PCI test panels and the velocity of light reflected from the surface is measured with a specialized instrument. A surface that perfectly reflects the image has a DOI value of 100, while a surface with little or no distinctness of image has a DOI value of 0. The method used to determine smoothness typically depends on the end use of the powder-coated substrate.

[0014]

[0013] As used herein, the term "edge coverage" refers to the degree to which a powder coating covers the edges or corners of a substrate. It is measured using the procedure described in ASTM Method D2967 and is expressed as the ratio of the coating thickness at the edge to the coating thickness on the surface of a square test bar. In the method described herein, the bar was typically coated to a thickness of about 75-100 micrometers (about 3-4 mils).

[0015]

[0014] The term "marker," as used herein, refers to any chemical or physical substance or component included in a powder coating composition that can be detected by physical or chemical means during application of the powder to a substrate. Physical detection means include observation with the naked eye under specific lighting conditions using specialized viewing equipment, i.e., glasses, etc. Chemical detection means include a chemical reaction between the marker and another component in the powder coating that can result in a visible or detectable change in the coating.

[0016]

[0015] Unless otherwise specified, the term "polymer" includes both photopolymers and copolymers (ie, polymers of two or more different monomers).

[0017]

[0016] The term "comprises" and variations thereof are used where such terms appear in the description and claims. Where they appear, they are not to be construed as limiting.

[0018]

[0017] The terms "preferred" and "preferably" refer to embodiments of the invention that may provide certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0019]

[0018] As used herein, "a," "an," "the," "at least one," and "one or more" are used interchangeably. Thus, for example, a coating composition containing "an" additive can be interpreted to mean that the coating composition contains "one or more" additives.

[0020]

[0019] Further herein, the recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.). Further, the disclosure of a range includes the disclosure of all subranges subsumed within that broader range (e.g., 1 to 5 discloses 1 to 4, 1.5 to 4.5, 1 to 2, etc.). DETAILED DESCRIPTION OF THE INVENTION

[0021]

[0020] Embodiments of the invention described herein include methods and systems for powder coating a metal substrate having an edge. The method includes applying at least a first powder composition to the substrate and applying at least a second powder composition over the first composition. The method further includes simultaneously curing the first and second powder compositions to obtain a coated article having optimal edge coverage and smoothness.

[0022]

[0021] Thus, in some embodiments, the present invention provides a method or system for coating substrates having edges with a process that uses a single curing step, thereby eliminating multiple curing cycles and resulting in a more efficient process. Moreover, the methods described herein provide optimal edge coverage of the substrate edges, eliminating the need for mechanical methods to round the edges prior to coating. As such, the methods described herein reduce the time, energy, and cost of powder coating substrates having edges without compromising the corrosion resistance or surface smoothness of the coating.

[0023]

[0022] In some embodiments, the methods described herein include applying at least a first powder composition to a substrate, such as a substrate having a sharp edge. The first powder composition is a soluble composition that melts upon heating to form a coating film. For example, the powder is applied to a film thickness of about 10 to about 50 micrometers, preferably 20 to 40 micrometers, using methods known to those skilled in the art, such as electrostatic spraying. In some embodiments, the first powder composition is applied to either a cleaned (i.e., unprimed) or pretreated surface of a metal substrate. That is, the first powder composition may be applied to an unprimed, blast-cleaned metal surface or to a surface that has been pretreated by various methods known to those skilled in the art.

[0024]

[0023] In some embodiments, the methods described herein include applying at least a second powder composition to a substrate after applying at least a first powder composition. In some aspects, the second powder composition is a soluble composition that melts upon heating to form a coating film. The second powder composition may have the same chemical composition as the first composition, or a different chemical composition. The second powder composition is applied using methods known to those skilled in the art, such as electrostatic coating. The second powder composition is preferably applied to a coating of the first powder composition to a film build of 20 to 40 micrometers, preferably 25 to 35 micrometers, thereby achieving a low film build. The total thickness of the film formed by the first and second powder compositions may be about 60 to 100 micrometers, preferably 75 to 95 micrometers (about 3.0 to 3.7 mils). Without being limited by theory, it is believed that the layer of the first powder composition applied to the substrate forms a metal-to-metal interface. Upon curing, the particles of the first powder composition fuse into a low-flow liquid and remain where deposited, including on the edges of the substrate. Also, without being limited by theory, it is believed that the layer of the second powder composition deposited on the first composition forms an air interface. Upon curing, the particles of the second powder composition fuse into a highly flowable liquid that levels the surface of the substrate, resulting in a smooth coating.

[0025]

[0024] In some embodiments, the methods described herein include applying at least a first powder composition to a metal substrate, followed by applying at least a second powder composition to the substrate. In some embodiments, a uniform coating of the second powder composition covers substantially the entire first coating. That is, the first powder composition is preferably covered by the second powder composition so that there is little to no exposed portion of the first composition. Thus, in some embodiments, the first powder composition includes a visible marker during the application process, and the regularity or uniformity of the second powder coating can be assessed by monitoring the marker during application. For example, if the marker is a UV-sensitive component, a substrate already coated with the first powder can be illuminated with a black light. When the second powder coating is applied over the first coating, the illuminated marker identifies any portions of the first coating that remain exposed, thereby alerting the applicator that reapplication or reinforcement of the second powder coating is required.

[0026]

[0025] Without being limited by theory, it is believed that the corrosion resistance and smoothness of a coating, including its edges, are related to its flowability. Typically and preferably, edge coverage improves the corrosion resistance of the coated substrate, while low-flow coatings are believed to improve edge coverage, i.e., increased flow reduces edge coverage. Conversely, increased flow increases smoothness. When only one powder composition is applied to a substrate, a low-flow coating provides good edge coverage but poor surface smoothness. On the other hand, when a high-flow composition is used, high surface smoothness is achieved, but at the expense of edge coverage. Therefore, it is preferable to modify the flowability of the coating composition to coat a metal substrate and provide optimal edge coverage and smoothness.

[0027]

[0026] Thus, in one embodiment, the first powder composition and the second powder composition are selected based on their relative flowabilities. In one embodiment, the first powder composition is a low-flow composition, and the second powder composition is a relatively high-flow composition. The first powder composition has a flowability of about 40 mm or less, preferably about 10-30 mm, and more preferably about 15-25 mm. In another embodiment, the second powder composition has a flowability of at least about 40 mm, preferably greater than about 50 mm, and more preferably greater than about 70 mm.

[0028]

[0027] Conventionally, a substrate is first coated with a low-flow powder composition, and the coating is heated to melt and cure the composition. A second powder composition, typically a high-flow composition, is then applied over the first coating and melted and cured. While this results in a coating with good edge coverage and smoothness, the process requires two separate curing steps with corresponding increases in manufacturing line space, time, and energy costs.

[0029]

[0028] Contrary to conventional methods and manufacturing biases, the methods described herein involve sequential application of a low-flow powder composition and a high-flow powder composition, but with a single curing step after application of the second composition. Surprisingly, the single-cure method results in good corrosion resistance, including edge, and surface smoothness. In some embodiments, the methods described herein result in edge coverage on the order of about 2%, preferably about 5%, and more preferably about 10% surface coverage.

[0030]

[0029] In certain embodiments, the methods described herein result in optimal surface smoothness. The methods described herein result in a surface smoothness of at least 4, preferably at least 5, on the PCI scale. As measured at 20° gloss, the methods described herein result in a surface smoothness of about 25-90%, preferably greater than 60%. Typically and preferably, the surface smoothness is determined by the desired end use of the powder-coated metal substrate.

[0031]

[0030] In some embodiments, the first or second powder composition comprises at least one polymeric binder. The powder composition may optionally include one or more pigments, opacifiers, or other additives.

[0032]

[0031] Suitable polymeric binders typically include a film-forming resin and, optionally, a curing agent for the resin. The binder may be selected from any resin or combination of resins that provides the desired film properties. Suitable examples of polymeric binders include thermosetting and / or thermoplastic materials, and may be made from epoxy, polyester, polyurethane, polyamide, acrylic, polyvinyl chloride, nylon, fluoropolymer, silicone, other resins, or combinations thereof. Thermosetting materials are preferred for use as polymeric binders in powder coating applications, with epoxy, polyester, and acrylic being particularly preferred. Elastomeric resins can be used for specific applications, if desired. In some embodiments, specific polymeric binders, i.e., resins, are included in the powder compositions described herein depending on the desired end use of the powder-coated substrate. For example, certain high molecular weight polyesters exhibit excellent corrosion resistance and are suitable for use on substrates used in interior and exterior applications.

[0033]

[0032] In some embodiments, the first and second powder compositions comprise the same polymeric binder. In other embodiments, the first and second powder compositions comprise different polymeric binders.

[0034]

[0033] Examples of suitable binders include carboxyl-functional polyester resins cured with epoxide-functional compounds (e.g., triglycidyl isocyanurate), carboxyl-functional polyester resins cured with polymeric epoxy resins, carboxyl-functional polyester resins cured with hydroxyalkylamides, hydroxyl-functional polyester resins cured with blocked isocyanates or uretdiones, epoxy resins cured with amines (e.g., dicyandiamide), epoxy resins cured with phenolic-functional resins, epoxy resins cured with carboxyl-functional curing agents, carboxyl-functional acrylic resins cured with polymeric epoxy resins, hydroxyl-functional acrylic resins cured with blocked isocyanates or uretdiones, unsaturated resins cured by free radical reactions, and silicone resins used as the sole binder or in combination with organic resins. Any curing reaction can be induced thermally or by exposure to radiation (e.g., UV, UV-visible, visible light, IR, near-IR, and e-beam).

[0035]

[0034] The first or second powder composition may optionally be colored with a dye or pigment. Various organic or inorganic color pigments may be used in the present invention. Suitable color pigments include titanium dioxide (TiO), carbon black, red iron oxide, iron yellow, raw umber, phthalocyanine blue, phthalocyanine green, naphthol red, toluidine red, various organic yellows, carbazole violet, and quinacridone. If desired, processed color pigments, such as pigments coated with polymeric materials, may be used. Suitable such pigments include SURPASS products from Sun Chemical.

[0036]

[0035] In a preferred embodiment, the first powder composition comprises a pigment that is a first color when applied and changes to a second (different) color upon curing. Suitable pigments of this type include those that undergo a large, permanent color change when exposed to typical curing temperatures for the powder compositions described herein, between about 130°C and 200°C, preferably between 150°C and 180°C. Examples of pigments include, but are not limited to, Hansa Red GG 12-5000 (Clariant), Novaperm Red HF35 70 (Clariant), etc. This type of pigment preferably functions as a marker component in the first powder composition.

[0037]

[0036] The first or second powder composition may optionally contain other additives. These other additives can improve the application of the powder coating, the melting and / or curing of the coating, or the performance or appearance of the final coating. Examples of optional additives that may be useful in the powder include curing catalysts, antioxidants, color stabilizers, slip and mar additives, UV absorbers, hindered amine light stabilizers, photoinitiators, conductive additives, triboelectric additives, anticorrosion additives, fillers, texturing agents, degassing additives, flow modifiers, thixotropic agents, and edge coating additives.

[0038]

[0037] The polymeric binder, along with any optional additives, is dry mixed and then typically melt blended by passing through an extruder. The resulting extrudate is solidified by cooling and then crushed or pulverized to form a powder. Other methods may also be used. For example, one alternative method uses a binder that is soluble in liquid carbon dioxide. In this method, the dry ingredients are mixed into liquid carbon dioxide and sprayed to form powder particles. If necessary, the powder may be screened, i.e., sieved, to obtain the desired particle size and / or particle size distribution.

[0039]

[0038] The resulting powder is of a size that can be efficiently used by the coating process. In fact, particles less than 10 micrometers in size are difficult to apply effectively using conventional electrostatic coating methods. Thus, powders having a median particle size of less than about 25 micrometers typically have a majority of small particles and are therefore difficult to apply electrostatically. Preferably, the milling is controlled (or sieving, i.e., classification is performed) to obtain a powder having a median particle size of about 25 to 150 micrometers, more preferably 30 to 70 micrometers, and most preferably 30 to 50 micrometers.

[0040]

[0039] Optionally, other additives may be used in the present invention. As noted above, these optional additives may be added before extrusion as part of the base powder, or may be added after extrusion. Additives suitable for adding after extrusion include materials that would not perform well if added before extrusion, or that would cause additional wear to the extrusion equipment or other additives.

[0041]

[0040] Further optional additives include materials that can be added during the extrusion process, but can also be added later. Additives can be added alone or in combination with other additives to provide a desired effect on the final powder, i.e., the powder composition. These other additives can improve the spreadability, meltability, and / or curability of the powder, or the final performance or appearance. Examples of optional additives that may be useful include curing catalysts, antioxidants, color stabilizers, slip and scratch additives, UV absorbers, hindered amine light stabilizers, photoinitiators, conductive additives, triboelectric charging additives, anticorrosion additives, fillers, texturing agents, degassing additives, flow modifiers, thixotropic agents, and edge coating additives.

[0042]

[0041] In a preferred embodiment, the compositions described herein are used as static coatings for powder coating compositions. The composition may further include additives that improve electrodeposition. Suitable additives of this type include, for example, extrudable coating additives, fumed metal oxides, combinations thereof, etc. In some embodiments, the coating additives may be added to the raw materials prior to extrusion, and other additives, such as metal oxides, may be added later, for example, during milling or pulverization of the composition.

[0043]

[0042] Other preferred additives include performance enhancing additives such as rubberizing agents, friction reducers, and microcapsules. Additionally, additives can be abrasives, heat sensitive catalysts, agents that promote the formation of a porous final coating, or agents that improve the wetting of the powder.

[0044]

[0043] Techniques for preparing low-flow and high-flow powder compositions are known to those skilled in the art. Mixing can be performed by any available mechanical mixer or by hand mixing. Some examples of possible mixers include Henschel mixers (e.g., available from Henschel Mixing Technology, Green Bay, WI), Mixaco mixers (e.g., available from Triad Sales, Greer, SC, or Dr. Herfeld GmbH, Neuenrade, Germany), Marion mixers (e.g., available from Marion Mixers, Inc., 3575 3rd Avenue, Marion, IA), inverted mixers, Littleford mixers (Littleford Day, Inc.), horizontal mixers, and ball mills. Preferred mixers would be those that are most easily cleaned.

[0045]

[0044] Powder coatings are typically manufactured in a multi-step process. Various ingredients, which may include resins, curing agents, pigments, additives, and fillers, are dry-blended to form a premix. This premix is ​​then fed into an extruder, which uses a combination of heat, pressure, and shear to melt the soluble components and thoroughly mix all components. The extrudate is cooled to a brittle solid and then ground into a powder. Depending on the desired coating end use, grinding conditions are typically adjusted to obtain a powder with a median particle size of approximately 25 to 150 micrometers.

[0046]

[0045] The final powder may then be applied to an article by various means, such as using a fluidized bed and a spray applicator. Most commonly, an electrostatic coating process is used, in which the powder particles are electrostatically charged and sprayed onto the primed article so that they are attracted to and adhere to the article. After coating, the article is heated. This heating step causes the powder particles to melt and flow together, coating the article. Optionally, continued or additional heating may be used to cure the coating. Other alternatives, such as UV curing of the coating, may be used.

[0047]

[0046] The coating is optionally cured, and such curing can occur by continued heating, subsequent heating, or residual heat in the substrate. In another embodiment of the present invention, if a radiation-curable powder coating base is selected, the powder can be melted by a relatively short or low-temperature heating cycle and then exposed to radiation to initiate the curing process. An example of this embodiment is a UV-curable powder. Other examples of radiation curing include the use of UV-visible, visible light, near-IR, IR, and e-beam.

[0048]

[0047] The compositions and methods described herein can be used with a variety of substrates. Typically and preferably, the powder coating compositions described herein are used to prime substrates. Metal substrates are coated, including, but not limited to, bare metal, blast-cleaned metal, and pre-treated metal, such as plated substrates and electrodeposited metal substrates. Typical pre-treatments of metal substrates include, for example, treatment with iron phosphate, zinc phosphate, etc. Metal substrates can be cleaned and pre-treated using a variety of standard processes known in the art. Examples include, but are not limited to, iron phosphate treatment, zinc phosphate treatment, nanoceramic treatment, various ambient temperature pre-treatments, zirconium-containing pre-treatments, pickling, or any other method known in the art that results in a clean, contaminant-free surface on the substrate.

[0049]

[0048] The coating compositions and methods described herein are not limited to conversion coatings, i.e., parts or surfaces that have been treated with a conversion coating. Moreover, the coating compositions described herein can be applied to pre-coated substrates by a variety of processes known to those skilled in the art, including, for example, electrodeposition, plating, etc. It is not intended that the substrates coated with the compositions described herein always be untreated, i.e., unprimed, metal substrates.

[0050]

[0049] Preferably, the coated substrate has desirable physical and mechanical properties, such as optimum sharp edge coverage and surface smoothness. Typically, the final film coating will have a thickness of 25 to 200 micrometers, preferably 50 to 150 micrometers, and more preferably 75 to 125 micrometers.

[0051]

[0050] The following examples are provided to aid in the understanding of the present invention and are not to be construed as limiting the scope thereof. Unless otherwise stated, all parts and percentages are by weight. [Example]

[0052]

[0051] Unless otherwise stated, the following test methods were used in the examples below. Melt flow measurement

[0052] The melt flowability of the powder composition is tested using ASTM D3451 (Standard Guide for Testing Coating Powders and Powder Coatings).

[0053] Edge coverage

[0053] The edge coverage of powder coatings is tested using the method described in ASTM D2967 (Standard Test Method for Corner Coverage of Powder Coatings).

[0054] Smoothness

[0054] The surface smoothness of the coating is measured as 20 degree gloss using the procedure described in ASTM D523 (Standard Test Method for Specular Gloss).

[0055] Example 1 Comparison of coating types

[0055] Powder compositions were prepared as shown in Table 1 and applied to 0.05 cm (0.020 in) thick cold-rolled steel panels. The total coating thickness (whether single or dual layer) for each coating in Table 1 was approximately 75-90 micrometers (3.0-3.6 mils). The flow, edge coverage, and smoothness of each coating type were then measured.

[0056] [Table 1]

[0057] Example 2 Edge coverage and smoothness depending on flowability

[0056] Panels were prepared as described in Example 1, except that only a single powder composition was applied (the composition selected by its flowability as shown in Table 2). Edge coverage and smoothness were then measured for each panel.

[0058] [Table 2]

[0059] As can be seen from Table 2, coatings with a flowability of less than about 40 are acceptable. Coatings with a flowability greater than about 40 provide optimal surface smoothness while providing good edge coverage. [1] Providing a metal substrate; applying a first coating comprising a powder coating composition having a flowability of about 40 mm or less; applying a second coating comprising a powder coating composition having a flowability of at least about 40 mm; simultaneously curing the first coating and the second coating to form a cured coating; A method comprising: [2] providing at least a first powder composition having a flowability of about 40 mm or less; optionally, providing at least a second powder composition having a flowability of at least about 40 mm; providing instructions for coating a metal substrate with at least a first composition, then coating with a second composition, and simultaneously curing the two compositions to form a cured coating; A method comprising: [3] providing at least a first powder composition having a flowability of about 40 mm or less; optionally, providing at least a second powder composition having a flowability of at least about 40 mm; providing instructions for coating a metal substrate with at least a first composition, then coating with a second composition, and simultaneously curing the two compositions to form a cured coating; A coating system comprising a process including: [4] a first coating composition comprising a powder composition having a flowability of about 40 mm or less; and a second coating composition comprising a powder composition having a flowability of at least about 40 mm, wherein the first and second coating compositions are applied sequentially and cured together to coat the metal substrate. [5] Providing a metal substrate; applying a first coating comprising a first coating composition and a marker; applying a second coating over the first coating, the second coating comprising a second coating composition; wherein the uniformity of the second coating is assessed by monitoring a marker in the first coating. [6] 6. The method or system according to any one of 1 to 5 above, wherein the first coating composition has a fluidity of about 15 mm to 40 mm. [7] 7. The method or system according to any one of 1 to 6 above, wherein the first coating composition has a fluidity of about 20 mm to 35 mm. [8] 8. The method or system according to any one of claims 1 to 7, wherein the second coating composition has a flowability of greater than about 50 mm. [9] 9. The method or system according to any one of 1 to 8, wherein the second coating composition has a flowability of greater than about 70 mm.

[10] 10. The method or system according to any one of claims 1 to 9, wherein the second coating composition has a flowability of greater than about 75 mm.

[11] 11. The method or system of any one of claims 1 to 10, wherein the cured coating has an edge coverage equal to at least 2% of the surface coverage.

[12] 12. The method or system of any one of claims 1 to 11, wherein the cured coating has a 20 degree gloss that is at least 50%.

[13] 13. The method or system of any one of claims 1 to 12, wherein the cured coating has an edge coverage equal to about 10% of the surface coverage.

[14] 14. The method or system according to any one of 1 to 13, wherein the metal substrate is not coated with a primer.

[15] 15. The method or system according to any one of 1 to 14, wherein the metal substrate has been blast cleaned.

[16] 16. The method or system according to any one of 1 to 15, wherein the metal substrate is pretreated.

[17] 17. The method or system according to any one of 1 to 16, wherein the metal substrate may be heated before application of the first coating composition.

[18] 18. The method or system according to any one of claims 1 to 17, wherein the first coating composition is applied to the metal substrate at ambient temperature.

[19] 19. The method or system according to any one of 1 to 18, wherein the marker is an ultraviolet-sensitive pigment or an ultraviolet-sensitive dye.

[20] 20. The method or system according to any one of 1 to 19, wherein the marker is a pigment that undergoes a color change upon hardening. [twenty one] 21. The method or system according to any one of 1 to 20, wherein the marker is a detectable moiety that is visible under black light.

Claims

1. Providing a metal substrate; applying a first coating comprising a first powder coating composition containing a polymeric binder resin; applying a second coating comprising a second powder coating composition containing a polymeric binder resin; heating the metal substrate having the first and second coatings applied thereto in one step at a temperature of 130°C to 200°C, rather than multiple heating steps, to form a hardened corrosion-resistant coating; A method comprising: The above method, wherein the first powder coating composition has a flowability of 40 mm or less and the second powder coating has a flowability of greater than 50 mm, the cured coating has an edge coverage of surface coverage of 2% or greater, and the 20 degree gloss of the cured coating is 50% or greater.

2. 10. The method of claim 1, wherein the cured coating has a surface smoothness of 5 or greater on the PCI scale.

3. 10. The method of claim 1, wherein the cured coating has a 20 degree gloss of greater than 60%.

Images