Continuous processing of powder coating compositions
First Claim
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1. In a method for producing a powder coating, the step of:
- contacting a powder coating precursor stream comprising powder coating ingredients including at least one resin and at least one additional powder coating ingredient in a continuous extruder with a process media fluid effective to reduce the viscosity of the powder coating precursor stream to allow continuous extrusion of the powder coating precursor stream at a lower temperature, said process media fluid comprising a process media material in the form of a fluid selected from the group consisting of supercritical fluids and liquified gases.
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Abstract
Systems, apparatus combinations and methods for producing a powder coating are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.
136 Citations
33 Claims
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1. In a method for producing a powder coating, the step of:
contacting a powder coating precursor stream comprising powder coating ingredients including at least one resin and at least one additional powder coating ingredient in a continuous extruder with a process media fluid effective to reduce the viscosity of the powder coating precursor stream to allow continuous extrusion of the powder coating precursor stream at a lower temperature, said process media fluid comprising a process media material in the form of a fluid selected from the group consisting of supercritical fluids and liquified gases. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. In a method for producing a powder coating wherein powder coating raw materials including at least one resin and at least one additional powder coating ingredient are fed to and processed in a continuous extruder to disperse the at least one additional ingredient with the at least one resin to form an extrudate product, the step of:
adding a process media fluid comprising a process media material in the form of a fluid selected from the group consisting of supercritical fluids and liquified gases to a process stream of at least one of the following; a.) the raw materials fed to the continuous extruder; b.) the raw materials processed in the continuous extruder; and c.) the extrudate product of the continuous extruder, said addition being effective to reduce the viscosity of the selected process stream to allow processing of the process stream at a lower temperature. - View Dependent Claims (21, 22, 23, 24, 25, 32)
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26. A method for producing a powder coating, said method comprising the steps of:
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extruding a premixed blend of powder coating raw materials including at least one thermosettable resin and at least one curing agent for the at least one thermosettable resin to form an extrudate product; feeding a stream of the extrudate product through a melt pump to form a stream of extrudate product at increased pressure; and spray drying the stream of extrudate product at increased pressure to form the powder coating, wherein at least one of the blend of powder coating raw materials undergoing extrusion and the stream of extrudate product at increased pressure is contacted with a process media fluid selected from the group consisting of supercritical fluids and liquified gases, the process media being effective to reduce the viscosity of the materials of the selected process stream to allow processing at a lower temperature. - View Dependent Claims (27, 28, 29, 30, 31, 33)
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Specification