US5045114A — Reflective composition aluminum particles milled …

Claim 1

Independent Claim 106 words

A process of preparing a powder coating material which can be applied to a substrate to form a glossy, highly reflective, finish, which process comprises: (a) milling together a resinous binder and about 1 to 12 parts of aluminum particles per 100 parts of binder to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; and (c) removing milling media and particles of powder material greater than about 250 microns from the powder material, wherein a powder coating material having a particle size of about 5 to 250 microns is obtained.

Claim 2

Dependent Claim 106 words

A process of preparing a powder coating material which can be applied to a substrate to form a glossy, highly reflective, finish, which process comprises: (a) milling together a resinous binder and about 1 to 12 parts of aluminum particles per 100 parts of binder to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; and (c) removing milling media and particles of powder material greater than about 250 microns from the powder material, wherein a powder coating material having a particle size of about 5 to 250 microns is obtained.

Claim 3

Dependent Claim 16 words

The process of claim 1 wherein the aluminum particles are introduced as a leafing aluminum paste.

Claim 4

Dependent Claim 29 words

The process of claim 2 wherein the leafing aluminum paste comprises about 40 to about 90 wt-% leafing aluminum particles and about 10 to 60 wt-% of a solvent.

Claim 5

Dependent Claim 13 words

The process of claim 1 wherein the aluminum particles comprise leafing aluminum particles.

Claim 6

Dependent Claim 23 words

The process of claim 4 wherein the leafing aluminum particles are present at about 2 to 6.5 parts per 100 parts of binder.

Claim 7

Dependent Claim 23 words

The process of claim 3 wherein the leafing aluminum particles are present at about 2.5 to 4.5 parts per 100 parts of binder.

Claim 8

Dependent Claim 16 words

The process of claim 1 comprising removing particles of coating material greater than about 100 microns.

Claim 9

Dependent Claim 25 words

The process of claim 7 wherein at least 80% of the powdered coating material produced has a particle size of about 10 to 40 microns.

Claim 10

Dependent Claim 19 words

The process of claim 1 wherein the resin binder comprises a thermoplastic resin, a thermosetting resin or mixtures thereof.

Claim 11

Dependent Claim 26 words

The process of claim 9 wherein the thermoplastic resin comprises a vinyl homo- or copolymer, a polyacrylic, a cellulosic, a polyester, a polyamide, or mixtures thereof.

Claim 12

Dependent Claim 10 words

The process of claim 10 which further comprises a plasticizer.

Claim 13

Dependent Claim 37 words

The process of claim 7 in which the thermosetting resin comprises an epoxy, a phenolic resin, a saturated polyester having functional groups, a polyurethane, an unsaturated polyester, an acrylic based on crosslinkable acrylate resins, or mixtures thereof.

Claim 14

Dependent Claim 24 words

The process of claim 12 which further comprises about 1 to about 2 parts of a flow control agent per hundred parts of binder.

Claim 15

Dependent Claim 18 words

The process of claim 1 in which the fluidizing agent comprises fumed silica, aluminum oxide, or mixtures thereof.

Claim 16

Dependent Claim 11 words

The process of claim 1 wherein the milling comprises ball milling.

Claim 17

Dependent Claim 126 words

A process of preparing a powder coating material which can be applied to a substrate to form a glossy, highly reflective, finish, which process comprises: (a) ball milling together a resinous binder and about 2.5 to 4.5 parts of leafing aluminum particles per 100 parts of binder for about 22 to 28 hours to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; and (c) removing milling media and particles of powder coating material greater than about 100 microns from the powder coating material; wherein the leafing aluminum particles are introduced as a paste and a powder coating material having a particle size of about 10 to 100 microns is obtained.

Claim 18

Dependent Claim 126 words

A process of preparing a powder coating material which can be applied to a substrate to form a glossy, highly reflective, finish, which process comprises: (a) ball milling together a resinous binder and about 2.5 to 4.5 parts of leafing aluminum particles per 100 parts of binder for about 22 to 28 hours to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; and (c) removing milling media and particles of powder coating material greater than about 100 microns from the powder coating material; wherein the leafing aluminum particles are introduced as a paste and a powder coating material having a particle size of about 10 to 100 microns is obtained.

Claim 19

Dependent Claim 66 words

A powder coating composition which comprises: (a) a resinous binder; (b) about 1 to 12 parts of aluminum particles per 100 parts of binder; and (c) an effective amount of a fluidizing agent per 100 parts of binder; wherein the powder composition has a particle size of about 5 to 250 microns and the binder and aluminum particles are milled together producing a powder coating material.

Claim 20

Dependent Claim 66 words

A powder coating composition which comprises: (a) a resinous binder; (b) about 1 to 12 parts of aluminum particles per 100 parts of binder; and (c) an effective amount of a fluidizing agent per 100 parts of binder; wherein the powder composition has a particle size of about 5 to 250 microns and the binder and aluminum particles are milled together producing a powder coating material.

Claim 21

Dependent Claim 30 words

The composition of claim 17 in which the leafing aluminum particles are introduced as a leafing aluminum paste having an initial aluminum particle size of less than about 45 microns.

Claim 22

Dependent Claim 28 words

The composition of claim 18 in which the leafing aluminum paste comprises about 40 to 90 wt-% leafing aluminum and about 10 to 60 wt-% of a solvent.

Claim 23

Dependent Claim 23 words

The composition of claim 17 wherein the leafing aluminum particles are present at about 2 to 6.5 parts per 100 parts of binder.

Claim 24

Dependent Claim 23 words

The composition of claim 20 wherein the leafing aluminum particles are present at about 2.5 to 4.5 parts per 100 parts of binder.

Claim 25

Dependent Claim 18 words

The composition of claim 17 wherein the powder composition has a particle size of 5 to 100 microns.

Claim 26

Dependent Claim 25 words

The composition of claim 22 wherein at least 80% of the powdered coating material produced has a particle size of about 10 to 40 microns.

Claim 27

Dependent Claim 19 words

The composition of claim 17 wherein the resin binder comprises a thermoplastic resin, a thermosetting resin or mixtures thereof.

Claim 28

Dependent Claim 26 words

The composition of claim 24 wherein the thermoplastic resin comprises a vinyl homo- or copolymer, a polyacrylic, a cellulosic, a polyester, a polyamide, or mixtures thereof.

Claim 29

Dependent Claim 10 words

The composition of claim 25 which further comprises a plasticizer.

Claim 30

Dependent Claim 36 words

The composition of claim 24 wherein the thermosetting resin comprises an epoxy, a phenolic resin, a saturated polyester having functional groups, a polyurethane, an unsaturated polyester, an acrylic based on crosslinkable acrylate resins, or mixtures thereof.

Claim 31

Dependent Claim 23 words

The composition of claim 27 which further comprises about 1 to 2 parts of a flow control agent per hundred parts of binder.

Claim 32

Dependent Claim 17 words

The composition of claim 17 wherein the fluidizing agent comprises fumed silica, aluminum oxide, or mixtures thereof.

Claim 33

Dependent Claim 129 words

A process of preparing coated articles having a glossy, highly reflective metallic finish, the process comprising: (a) milling together a resinous binder and about 1 to 12 parts of leafing aluminum particles per 100 parts of binder to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; (c) removing milling media and particles greater than about 250 microns from the powder material, wherein a powder coating material having a particle size of about 5 to 250 microns is obtained; (d) applying the powder coating material onto a substrate to be coated to form a coated substrate; and (e) heating the coated substrate to form a coated article having a glossy, highly reflective metallic finish.

Claim 34

Dependent Claim 129 words

A process of preparing coated articles having a glossy, highly reflective metallic finish, the process comprising: (a) milling together a resinous binder and about 1 to 12 parts of leafing aluminum particles per 100 parts of binder to produce a powder coating material; (b) adding an effective amount of a fluidizing agent per 100 parts of binder to the powder coating material; (c) removing milling media and particles greater than about 250 microns from the powder material, wherein a powder coating material having a particle size of about 5 to 250 microns is obtained; (d) applying the powder coating material onto a substrate to be coated to form a coated substrate; and (e) heating the coated substrate to form a coated article having a glossy, highly reflective metallic finish.

Claim 35

Dependent Claim 15 words

The process of claim 30 wherein the leafing aluminum particles are introduced as a paste.

Claim 36

Dependent Claim 27 words

The process of claim 31 wherein the leafing aluminum paste comprises about 40 to 90 wt-% leafing aluminum and about 10 to 60 wt-% of a solvent.

Claim 37

Dependent Claim 23 words

The process of claim 32 wherein the leafing aluminum paste comprises aluminum particles having initial particle size of less than about 45 microns.

Claim 38

Dependent Claim 23 words

The process of claim 30 wherein the leafing aluminum particles are present at about 2 to 6.5 parts per 100 parts of binder.

Claim 39

Dependent Claim 23 words

The process of claim 30 wherein the leafing aluminum particles are present at about 2.5 to 4.5 parts per 100 parts of binder.

Claim 40

Dependent Claim 16 words

The process of claim 30 comprising removing particles of coating material greater than about 100 microns.

Claim 41

Dependent Claim 25 words

The process of claim 33 wherein at least 80% of the powdered coating material produced has a particle size of about 10 to 40 microns.

Claim 42

Dependent Claim 19 words

The process of claim 30 wherein the resinous binder comprises a thermoplastic resin, a thermosetting resin or mixtures thereof.

Claim 43

Dependent Claim 26 words

The process of claim 38 wherein the thermoplastic resin comprises a vinyl homo- or copolymer, a polyacrylic, a cellulosic, a polyester, a polyamide, or mixtures thereof.

Claim 44

Dependent Claim 10 words

The process of claim 39 which further comprises a plasticizer.

Claim 45

Dependent Claim 36 words

The process of claim 38 wherein the thermosetting resin comprises an epoxy, a phenolic resin, a polyurethane, a saturated polyester having functional groups, an unsaturated polyester, an acrylic based on crosslinkable acrylate resins, or mixtures thereof.

Claim 46

Dependent Claim 24 words

The process of claim 41 which further comprises about 1 to about 2 parts of a flow control agent per hundred parts of binder.

Claim 47

Dependent Claim 11 words

The process of claim 30 wherein the milling comprises ball milling.

Claim 48

Dependent Claim 82 words

A coated article comprising: (a) a substrate; (b) a coating comprising: (i) a resinous binder, (ii) about 1 to 12 parts of leafing aluminum particles, having a size of less than about 45 microns, per 100 parts of binder, and (iii) an effective amount of a fluidizing agent per 100 parts of binder wherein the coating has a reflectance of greater than about 50% of incident light energy and the binder and aluminum particles are milled together producing a powder coating material.

Claim 49

Dependent Claim 82 words

A coated article comprising: (a) a substrate; (b) a coating comprising: (i) a resinous binder, (ii) about 1 to 12 parts of leafing aluminum particles, having a size of less than about 45 microns, per 100 parts of binder, and (iii) an effective amount of a fluidizing agent per 100 parts of binder wherein the coating has a reflectance of greater than about 50% of incident light energy and the binder and aluminum particles are milled together producing a powder coating material.

Claim 50

Dependent Claim 15 words

The coated article of claim 44 wherein the aluminum particles comprise a leafing aluminum paste.

Claim 51

Dependent Claim 29 words

The coated article of claim 45 wherein the leafing aluminum paste comprises about 40 to 90 wt-% leafing aluminum particles and about 10 to 60 wt-% of a solvent.

Claim 52

Dependent Claim 26 words

The coated article of claim 44 wherein the coating is formed from a powder coating material having a particle size of about 5 to 250 microns.

Claim 53

Dependent Claim 20 words

The coated article of claim 44 wherein the resin binder comprises a thermoplastic resin, a thermosetting resin or mixtures thereof.

Claim 54

Dependent Claim 27 words

The coated article of claim 48 wherein the thermoplastic resin comprises a vinyl homo- or copolymer, a polyacrylic, a cellulosic, a polyester, a polyamide, or mixtures thereof.

Claim 55

Dependent Claim 11 words

The coated article of claim 49 which further comprises a plasticizer.

Claim 56

Dependent Claim 37 words

The coated article of claim 48 wherein the thermosetting resin comprises an epoxy, a phenolic resin, a saturated polyester having functional groups, a polyurethane, an unsaturated polyester, an acrylic based on crosslinkable acrylate resins, or mixtures thereof.

Claim 57

Dependent Claim 24 words

The coated article of claim 44 which further comprises about 1 to 2 parts of a flow control agent per hundred parts of binder.

Claim 58

Dependent Claim 18 words

The coated article of claim 44 which exhibits a reflectance of about 55 to 60% incident light energy.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-09-02	1995-03-04	1995-09-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-09-02	1999-03-04	1999-09-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-09-02	2003-03-04	2003-09-03	$7700.00	Window Closed / Lapsed

Reflective composition aluminum particles milled together with resinous binder and process for preparing same

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