A system and method for coating a substrate, the system including integrated powder coating material preparation and deposition of powder coating material onto a substrate. The system includes a feed input that processes the powder coating materials for use in a filament extension atomizer. The filament extension atomizer stretches fluid filaments of the powder coating material to form droplets of powder coating material. The droplets of powder coating material are partially cooled to prevent agglomeration and to form a powder coating material suitable for electrostatic deposition. The cooled powder coating material is electrostatically charged and directed onto the substrate surface, where it is deposited due to the electrostatic potential between the substrate and cooled droplets. The deposited powder coating material is then cured to the substrate to form a cohesive film of coating material across the substrate.

A confluent system includes an internal venturi; an open hopper in gaseous communication with the internal venturi, the open hopper being configured to receive solid large particles; and a fluid bed in gaseous communication with the internal venturi. The method includes a set of coatings and composite structures formed from a portion of the solid large particles applied to workpieces by gas-supported transfer then fused together by heating that comprise large-scale variations in structure provided by the inclusion of particles that are larger in at least one dimension than conventional powder coating particles.

Control method and apparatus for a manual spray gun includes display that is disposed on the spray gun and that provides information to an operator about one or more coating operation parameters. An auxiliary trigger may be used that enables an operator to makes selections of one or more coating operation parameters. The display and auxiliary trigger together permit an operator to make selections without having to divert attention or field of view away from the spray gun or the coating area, especially during a coating operation.

Control method and apparatus for a manual spray gun may include a second manually actuated trigger disposed on the spray gun handle, with the second trigger being operational to select one or more coating operation parameters.

A system and method for coating a substrate, the system including integrated powder coating material preparation and deposition of powder coating material onto a substrate. The system includes a feed input that processes the powder coating materials for use in a filament extension atomizer. The filament extension atomizer stretches fluid filaments of the powder coating material to form droplets of powder coating material. The droplets of powder coating material are partially cooled to prevent agglomeration and to form a powder coating material suitable for electrostatic deposition. The cooled powder coating material is electrostatically charged and directed onto the substrate surface, where it is deposited due to the electrostatic potential between the substrate and cooled droplets. The deposited powder coating material is then cured to the substrate to form a cohesive film of coating material across the substrate.

A high dielectric contrast composition for particle formation that includes a high dielectric solvent, and a polymer dissolved into the high dielectric solvent. A method of forming particles including dissolving a polymer in a high dielectric solvent to form a high dielectric composition, and dielectrophoretically spinning the high dielectric composition in an electric field to form particles.

Control method and apparatus for a manual spray gun includes display that is disposed on the spray gun and that provides information to an operator about one or more coating operation parameters. An auxiliary trigger may be used that enables an operator to makes selections of one or more coating operation parameters. The display and auxiliary trigger together permit an operator to make selections without having to divert attention or field of view away from the spray gun or the coating area, especially during a coating operation.

A charged powder supply device is disclosed. A plurality of charged powder particles are disposed on an upper side of a carrier and at least an action source is positioned at a lower side of the carrier for acting on the carrier so as to vibrate the charged powder particles on the upper side of the carrier. As such, the vibrated charged powder particles are attached to objects to be coated, such as LEDs, under the effect of an electric field so as to form a powder layer, such as a phosphor layer. Since there are no other external forces that affect the moving direction of the charged powder particles, the powder layer can be uniformly formed on the objects.

The invention relates to a screen insert (70) for a powder container (24) of a powder supplying device, the screen insert (70) having a screen unit (71) for screening coating powder and an ultrasonic transducer (72) for generating ultrasonic vibrations. The screen unit (71) is connected to the ultrasonic transducer (72) in such a way that the ultrasonic vibrations generated by the ultrasonic transducer (72) can be transferred to the screen unit (71). To allow a particularly compact construction of the screen insert (70) to be achieved, according to the invention a screen carrier (73) which can be placed onto the powder container (24) is provided, for holding the ultrasonic transducer (72), with the screen unit (71) connected thereto, in such a way that the screen unit (71) is arranged below the screen carrier (73), so that the screen unit (71) is inside a powder chamber (22), formed by the powder container (24), when the screen carrier (73) has been placed onto the powder container (24).

A charged powder supply device is disclosed. A plurality of charged powder particles are disposed on an upper side of a carrier and at least an action source is positioned at a lower side of the carrier for acting on the carrier so as to vibrate the charged powder particles on the upper side of the carrier. As such, the vibrated charged powder particles are attached to objects to be coated, such as LEDs, under the effect of an electric field so as to form a powder layer, such as a phosphor layer. Since there are no other external forces that affect the moving direction of the charged powder particles, the powder layer can be uniformly formed on the objects.