Advanced Powder Coating Technology

A novel powder coating manufacturing process has been developed based on the advanced supercritical fluid technology for material processing. The new process developed has several advantages over the conventional technology, viz.:

• no need for extrusion or melt processing for ingredient mixing (alleviating Pre-curing)
• no need for or alleviation of dusty and energy-intensive particle size classification
• better compatibilization between resin and ingredients
• single train possibility in manufacturing
• lower temperature blending, thus ensuring no precuring of materials
• better pigment dispersion, thus ensuring excellent color match, resulting in cost saving
• better control of molecular weight distribution of resins (ideal for powder coatings) by a proprietary polymer synthesis process: low polydispersity index (PDI =~2)
• excellent color match capability, resulting in elimination of guess work and trial-and-error
• small batch capability, especially beneficial for high value-added specialty coatings
• environmentally friendly with reduced risks and hazards
• applicable to a variety of polymeric resins as base resins including acrylics, polyester, epoxy, and hybrid, etc.
• producing higher quality coatings
• application to corrosion protective coatings

Key U.S. patents were issued:

•  S. Lee et al., “Polymerization, Compatibilized Blending, and Particle Size Control of Powder Coatings in a Supercritical Fluid”, U.S. Patent No. 6,340,722 (issued January 22, 2002).
•  S. Lee et al., “Polymerization, Compatibilized Blending, and Particle Size Control of Powder Coatings in a Supercritical Fluid”, U.S. Patent No. 6,849,678 (issued February 1, 2005).

Molecular weight distribution (MWD) of base polymeric resin, typically represented by its average Mw (e.g., acrylics Mw=~8000) and polydispersity index (PDI), is particularly important in determining the quality of the resultant powder coating.   The above patents fully describe the necessary details.  Additional information can be found in the Polymerization with MW Control section.

This process technology is available for licensing through the Temarex Corporation, a technology transfer company for the University of Akron.  If interested in further developing an enhanced and/or novel version of the advanced and powder coating processes and/or their specialty applications, please contact us.