Methods and systems for coating metal substrates are provided. The methods and systems include sequential application of low flow and high flow powder coatings followed by a single heating step to provide a cured coating. The methods and systems include a marker that allows coating uniformity to be monitored and assessed during application. The described methods provide coatings with optimal surface smoothness and edge coverage.

The invention relates to a powder coating composition comprising a curing system comprising a curable resin and one or more curing additives for curing the curable resin, wherein the powder coating composition comprises: —two or more powder coating components with different contents of curable resin and/or at least one of the one or more curing additives; —in the range of from 0.1 to 25 wt % of a dry-blended inorganic particulate additive C consisting of inorganic components i), ii), and iii), wherein component i) is non-coated aluminium oxide or non-coated silica, component ii) is aluminium hydroxide and/or aluminium oxyhydroxide, and component iii) is silica; and —optionally up to 35 wt % of a further dry-blended inorganic particulate additive D, wherein the total wt % of dry-blended inorganic particulate additives C and D is at most 40 wt %, wherein powder coating components A and B and any further powder coating component have a particle size distribution with a D.sub.v90 of at most 50 μm and a D.sub.v50 of at most 30 μm, and wherein for any combination of two powder coating components the ratio of the D.sub.v50 of one of the powder components to the D.sub.v50 of the other one of the powder coating components is in the range of from 0.8 to 1.2.

A system for producing a homogenous extrudate powder coating composition having predetermined properties, the system comprising a color library database that is configured to store one or more input formulation data objects capable of use in controlling the inputs and operation of an electronically controlled homogenous extrudate mixer.

A coating layer application device (200) for applying a coating layer, which is located on a transfer element, to a substrate, the coating layer (206) being formed from a coating material, in particular a thermosetting coating material, the coating layer (206) being curable and comprising an amorphous material, the coating layer application device comprising: a heating device (214, 220) being configured so as to (i) maintain the temperature of the coating layer (206) within a temperature range before removal of N the transfer element (204) from the coating layer (206), wherein within the temperature range the uncured coating material is in its supercooled liquid state; and/or (ii) partially cure the coating layer (206) during a contact of the coating layer (206) and the substrate (210) and before removal of the transfer element (204) from the coating layer, in particular by increasing the temperature of the coating layer (206) to a temperature at or above a curing temperature of the coating layer (206).

A powder coating composition can include: a polyester polymer having carboxylic acid functional groups; a first crosslinker reactive with the carboxylic acid functional groups of the polyester polymer; and a fluoropolymer unreactive with the polyester polymer and first crosslinker. A weight ratio of the polyester polymer to the fluoropolymer is from 80:20 to 60:40. When cured, the powder coating composition forms a single coating layer including the polyester polymer and the fluoropolymer.

The coating quality prediction device includes: a learned model that has learned a relationship between characteristics of a paint, conditions at a time of applying the paint, and a smoothness of a surface of a coating film obtained by applying the paint under the conditions; and a calculation unit that uses the learned model to calculate the smoothness of the surface of the coating film from the characteristics of the paint and the conditions at the time of applying the paint.

The present document describes a composition for the pretreatment of surfaces, which comprises plasticizers, degassers, pH adjusting agents, pigments, a phenol formaldehyde resin based adhesive, process of making the same and method of using the same.

An improved drywall finishing system is comprised of a container, a powdered compound and an applicator, and several methods of applying the compound to a drywall surface via the applicator. The first method of the system involves applying the compound to a drywall surface via the applicator to detect rough, un-sanded, or improperly sanded areas that can then be re-sanded as needed. Further, the second method of the system involves applying the compound to a drywall surface wherein the powder adheres to any high spots, low spots, or imperfections in the surface, wherein said spots can be re-sanded as needed.

Powder paint composition, processes for preparing and uses for the same. The composition includes (a) at least one polymer powder redispersible in water, (b) pigment and filler and (c) optionally further additives. Where (a) is a polymer stabilized with polyvinyl alcohol, based on (a1) 20 to 100% by weight of at least one monomer from the group consisting of acrylic esters of branched or unbranched alcohols having 1 to 12 carbon atoms, (a2) 0 to 60% by weight of at least one monomer from the group consisting of methacrylic esters of branched or unbranched alcohols having 1 to 12 carbon atoms and styrene, (a3) 0 to 40% by weight of at least one monomer from the group consisting of vinyl esters of branched or unbranched carboxylic acids having 2 to 12 carbon atoms, and (a4) 0 to 20% by weight of other ethylenically unsaturated comonomers copolymerizable therewith.

To provide a powder coating material capable of forming a film excellent in metallic hue, concealing property and weather resistance. The powder coating material comprises the following fluororesin (A), the following resin (B) and the following pigment (C) as constituents thereof, wherein the content of the pigment (C) is from 0.7 to 23 mass %; Fluororesin (A): a fluororesin having a fluorine content of at least 10 mass %; Resin (B): a resin having a SP value larger than that of the fluororesin (A), and the difference between the SP value thereof and the SP value of the fluororesin (A) is at least 0.4 (J/cm.sup.3).sup.1/2; Pigment (C): a pigment which is a metallic pigment covered with a covering material, and the SP value of the covering material exceeds the SP value of the fluororesin (A) and less than the SP value of the resin (B).