US5108799A
Expired / Lapsed
US
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Liquid spray application of coatings with supercritical fluids as diluents and spraying from an orifice
Assignee: Union Carbide Chemicals and Plastics Technology LLC
•
Filing: 1988-07-14
•
Granted: 1992-04-28
•
Expires: 2008-07-14
Abstract
Abstract A liquid coatings application process and apparatus is provided in which supercritical fluids, such as supercritical carbon dioxide fluid, are used to reduce to application consistency viscous coatings compositions to allow for their application as liquid sprays. The coatings compositions are sprayed by passing the composition under pressure through an orifice into the environment of the substrate.
Inventors
- 👤 Kenneth L. Hoy
- 👤 Kenneth A. Nielsen
- 👤 Chinsoo Lee
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 22:47
CPC Classifications
B; B05; B05D; B05D1/00; B05D1/02; B05D1/04; B05D1/025; C; C09; C09D; C09D7/00; B05D2401/00; B05D2401/90; Y; Y02; Y02P; Y02P20/00; Y02P20/50; Y02P20/54
Claims Analysis
Total Claims: 103
Claim 1
Independent Claim
138 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) a coating formulation comprising at least one liquid polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing at least one supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon having substantially the composition of the said coating formulation by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 2
Dependent Claim
138 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) a coating formulation comprising at least one liquid polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing at least one supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon having substantially the composition of the said coating formulation by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 3
Dependent Claim
19 words
The process of claim 1 wherein the orifice size ranges from about 0.004 to about 0.072 inch in diameter.
Claim 4
Dependent Claim
19 words
The process of claim 2 wherein the orifice size ranges from about 0.004 to about 0.072 inch in diameter.
Claim 5
Dependent Claim
19 words
The process of claim 3 wherein the orifice size ranges from about 0.007 to about 0.015 inch in diameter.
Claim 6
Dependent Claim
26 words
The process of claim 1 wherein the spray pressure ranges from about the critical pressure of the supercritical fluid to about 5000 pounds per square inch.
Claim 7
Dependent Claim
17 words
The process of claim 5 wherein the spray pressure is below about 3000 pounds per square inch.
Claim 8
Dependent Claim
25 words
The process of claim 1 wherein the viscosity of the liquid mixture of (a) and (b) is less than about 300 centipoise at spray temperature.
Claim 9
Dependent Claim
27 words
The process of claim 7 wherein the viscosity of the liquid mixture of (a) and (b) ranges from about 5 to about 150 centipoise at spray temperature.
Claim 10
Dependent Claim
27 words
The process of claim 8 wherein the viscosity of the liquid mixture of (a) and (b) ranges from about 10 to about 50 centipoise at spray temperature.
Claim 11
Dependent Claim
34 words
The process of claim 1 further comprising, prior to step (2), heating said liquid mixture to a temperature sufficient to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 12
Dependent Claim
17 words
The process of claim 10 wherein the liquid temperature ranges from about 35° to about 90° centigrade.
Claim 13
Dependent Claim
17 words
The process of claim 11 wherein the liquid temperature ranges from about 45° to about 75° centigrade.
Claim 14
Dependent Claim
13 words
The process of claim 1 wherein supercritical fluid comprises supercritical carbon dioxide fluid.
Claim 15
Dependent Claim
13 words
The process of claim 1 wherein supercritical fluid comprises supercritical nitrous oxide fluid.
Claim 16
Dependent Claim
30 words
The process of claim 1 wherein said at least one polymeric component is selected from the group consisting of thermoplastic resins, thermosetting resins, crosslinkable film forming systems, and mixtures thereof.
Claim 17
Dependent Claim
47 words
The process of claim 15 wherein said at least one polymeric component is selected from the group consisting of enamels, varnishes, lacquers, acrylic resins, vinyl resins, styrenic resins, polyesters, alkyds, polyurethanes, urethanes, epoxies, phenolics, cellulosic esters, amino resins, natural gums, natural resins, and interpolymers and mixtures thereof.
Claim 18
Dependent Claim
37 words
The process of claim 1 further comprising, prior to step (2), admixing to said liquid mixture pigments, pigment extenders, metallic flakes fillers, drying agents, antifoaming agents, antiskinning agents, wetting agents, ultraviolet absorbers, cross-linking agents, and mixtures thereof.
Claim 19
Dependent Claim
23 words
The process of claim 1 further comprising, prior to step (2), filtering said liquid mixture to remove particulates that would plug said orifice.
Claim 20
Dependent Claim
27 words
The process of claim 1 further comprising, prior to step (2), promoting turbulent or agitated flow of said liquid mixture to aid atomization of said liquid spray.
Claim 21
Dependent Claim
30 words
The process of claim 1 further comprising utilizing jets of compressed gas to assist formation and atomization of said liquid spray and to modify the shape of said liquid spray.
Claim 22
Dependent Claim
12 words
The process of claim 20 wherein said compressed gas is compressed air.
Claim 23
Dependent Claim
20 words
The process of claim 21 wherein said compressed air has lowered oxygen content to reduce flammability of said liquid spray.
Claim 24
Dependent Claim
13 words
The process of claim 20 wherein said compressed gas is compressed carbon dioxide.
Claim 25
Dependent Claim
24 words
The process of claim 20 wherein said compressed gas is selected from the group consisting of compressed nitrogen, helium, argon, xenon, and mixtures thereof.
Claim 26
Dependent Claim
23 words
The process of claim 20 wherein the pressure of said compressed gas ranges from about 5 to about 80 pounds per square inch.
Claim 27
Dependent Claim
23 words
The process of claim 25 wherein the pressure of said compressed gas ranges from about 5 to about 20 pounds per square inch.
Claim 28
Dependent Claim
33 words
The process of claim 20 wherein said compressed gas is heated to supply heat to the liquid spray to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 29
Dependent Claim
20 words
The process of claim 27 wherein the temperature of said compressed gas ranges from about 35° to about 90° centigrade.
Claim 30
Dependent Claim
20 words
The process of claim 28 wherein the temperature of said compressed gas ranges from about 45° to about 75° centigrade.
Claim 31
Dependent Claim
31 words
The process of claim 1 wherein the substrate is selected from the group consisting of metal, wood, glass, plastic, paper, cloth, ceramic, masonry, stone, cement, asphalt, rubber, and composite materials thereof.
Claim 32
Dependent Claim
14 words
The process of claim 1 further comprising curing said liquid coating on said substrate.
Claim 33
Dependent Claim
26 words
The process of claim 1, wherein the liquid mixture includes an additive selected from the group consisting of pigments, drying agents, anti-skinning agents, and combinations thereof.
Claim 34
Dependent Claim
148 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) at least one polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing at least one supercritical fluid and at least one active solvent in which said polymeric component is soluble and which is at least partially miscible with the supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 35
Dependent Claim
148 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) at least one polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing at least one supercritical fluid and at least one active solvent in which said polymeric component is soluble and which is at least partially miscible with the supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 36
Dependent Claim
37 words
The process of claim 33 wherein said at least one active solvent is selected from the group consisting of ketones, esters, ethers, glycol ethers, glycol ether esters, alcohols, aromatic hydrocarbons, nitroalkanes, unsaturated hydrocarbons, halocarbons, and mixtures thereof.
Claim 37
Dependent Claim
15 words
The process of claim 33 wherein the solvent component includes at least one hydrocarbon solvent.
Claim 38
Dependent Claim
19 words
The process of claim 33 wherein the orifice size ranges from about 0.004 to about 0.072 inch in diameter.
Claim 39
Dependent Claim
19 words
The process of claim 36 wherein the orifice size ranges from about 0.004 to about 0.025 inch in diameter.
Claim 40
Dependent Claim
19 words
The process of claim 37 wherein the orifice size ranges from about 0.007 to about 0.015 inch in diameter.
Claim 41
Dependent Claim
26 words
The process of claim 33 wherein the spray pressure ranges from about the critical pressure of the supercritical fluid to about 5000 pounds per square inch.
Claim 42
Dependent Claim
17 words
The process of claim 39 wherein the spray pressure is below about 3000 pounds per square inch.
Claim 43
Dependent Claim
25 words
The process of claim 33 wherein the viscosity of the liquid mixture of (a) and (b) is less than about 300 centipoise at spray temperature.
Claim 44
Dependent Claim
27 words
The process of claim 41 wherein the viscosity of the liquid mixture of (a) and (b) ranges from about 5 to about 150 centipoise at spray temperature.
Claim 45
Dependent Claim
27 words
The process of claim 42 wherein the viscosity of the liquid mixture of (a) and (b) ranges from about 10 to about 50 centipoise at spray temperature.
Claim 46
Dependent Claim
34 words
The process of claim 33 further comprising, prior to step (2), heating said liquid mixture to a temperature sufficient to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 47
Dependent Claim
17 words
The process of claim 44 wherein the liquid temperature ranges from about 35° to about 90° centigrade.
Claim 48
Dependent Claim
17 words
The process of claim 45 wherein the liquid temperature ranges from about 45° to about 75° centigrade.
Claim 49
Dependent Claim
13 words
The process of claim 33 wherein supercritical fluid comprises supercritical carbon dioxide fluid.
Claim 50
Dependent Claim
13 words
The process of claim 33 wherein supercritical fluid comprises supercritical nitrous oxide fluid.
Claim 51
Dependent Claim
30 words
The process of claim 33 wherein said at least one polymeric component is selected from the group consisting of thermoplastic resins, thermosetting resins, crosslinkable film forming systems, and mixtures thereof.
Claim 52
Dependent Claim
47 words
The process of claim 49 wherein said at least one polymeric component is selected from the group consisting of enamels, varnishes, lacquers, acrylic resins, vinyl resins, styrenic resins, polyesters, alkyds, polyurethanes, urethanes, epoxies, phenolics, cellulosic esters, amino resins, natural gums, natural resins, and interpolymers and mixtures thereof.
Claim 53
Dependent Claim
37 words
The process of claim 33 further comprising, prior to step (2), admixing to said liquid mixture pigments, pigment extenders, metallic flakes, fillers, drying agents, antifoaming agents, antiskinning agents, wetting agents, ultraviolet absorbers, cross-linking agents, and mixtures thereof.
Claim 54
Dependent Claim
23 words
The process of claim 33 further comprising, prior to step (2), filtering said liquid mixture to remove particulates that would plug said orifice.
Claim 55
Dependent Claim
27 words
The process of claim 33 further comprising, prior to step (2), promoting turbulent or agitated flow of said liquid mixture to aid atomization of said liquid spray.
Claim 56
Dependent Claim
30 words
The process of claim 33 further comprising utilizing jets of compressed gas to assist formation and atomization of said liquid spray and to modify the shape of said liquid spray.
Claim 57
Dependent Claim
12 words
The process of claim 54 wherein said compressed gas is compressed air.
Claim 58
Dependent Claim
20 words
The process of claim 55 wherein said compressed air has lowered oxygen content to reduce flammability of said liquid spray.
Claim 59
Dependent Claim
13 words
The process of claim 54 wherein said compressed gas is compressed carbon dioxide.
Claim 60
Dependent Claim
24 words
The process of claim 54 wherein said compressed gas is selected from the group consisting of compressed nitrogen, helium, argon, xenon, and mixtures thereof.
Claim 61
Dependent Claim
23 words
The process of claim 54 wherein the pressure of said compressed gas ranges from about 5 to about 80 pounds per square inch.
Claim 62
Dependent Claim
23 words
The process of claim 59 wherein the pressure of said compressed gas ranges from about 5 to about 20 pounds per square inch.
Claim 63
Dependent Claim
33 words
The process of claim 54 wherein said compressed gas is heated to supply heat to the liquid spray to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 64
Dependent Claim
20 words
The process of claim 61 wherein the temperature of said compressed gas ranges from about 35° to about 90° centigrade.
Claim 65
Dependent Claim
20 words
The process of claim 62 wherein the temperature of said compressed gas ranges from about 45° to about 75° centigrade.
Claim 66
Dependent Claim
31 words
The process of claim 33 wherein the substrate is selected from the group consisting of metal, wood, glass, plastic, paper, cloth, ceramic, masonry, stone, cement, asphalt, rubber, and composite materials thereof.
Claim 67
Dependent Claim
14 words
The process of claim 33 further comprising curing said liquid coating on said substrate.
Claim 68
Dependent Claim
26 words
The process of claim 33, wherein the liquid mixture includes an additive selected from the group consisting of pigments, drying agents, anti-skinning agents, and combinations thereof.
Claim 69
Dependent Claim
147 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) at least one polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing supercritical carbon dioxide fluid and at least one active solvent in which said polymeric component is soluble and which is at least partially miscible with the supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 70
Dependent Claim
147 words
A process for the liquid spray application of coatings to a substrate, which comprises: (1) forming a liquid mixture in a closed system, said liquid mixture comprising: (a) at least one polymeric component capable of forming a coating on a substrate; and (b) a solvent component, containing supercritical carbon dioxide fluid and at least one active solvent in which said polymeric component is soluble and which is at least partially miscible with the supercritical fluid, in at least an amount which when added to (a) is sufficient to render the viscosity of said mixture to a point suitable for spray application; and (2) spraying said liquid mixture, forming droplets having an average diameter of 1 micron or greater, onto a substrate to form a liquid coating thereon by passing the mixture under pressure through an orifice into the environment of the substrate to form a liquid spray.
Claim 71
Dependent Claim
37 words
The process of claim 67 wherein said at least one active solvent is selected from the group consisting of ketones, esters, ethers, glycol ethers, glycol ether esters, alcohols, aromatic hydrocarbons, nitroalkanes, unsaturated hydrocarbons, halocarbons, and mixtures thereof.
Claim 72
Dependent Claim
15 words
The process of claim 67 wherein the solvent component includes at least one hydrocarbon solvent.
Claim 73
Dependent Claim
21 words
The process of claim 67 wherein the viscosity of the liquid mixture is less than about 300 centipoise at spray temperature.
Claim 74
Dependent Claim
23 words
The process of claim 68 wherein the viscosity of the liquid mixture ranges from about 5 to about 150 centipoise at spray temperature.
Claim 75
Dependent Claim
19 words
The process of claim 67 wherein the orifice size ranges from about 0.004 to about 0.072 inch in diameter.
Claim 76
Dependent Claim
19 words
The process of claim 72 wherein the orifice size ranges from about 0.004 to about 0.025 inch in diameter.
Claim 77
Dependent Claim
19 words
The process of claim 73 wherein the orifice size ranges from about 0.007 to about 0.015 inch in diameter.
Claim 78
Dependent Claim
20 words
The process of claim 67 wherein the spray pressure ranges from about 1070 to about 3000 pounds per square inch.
Claim 79
Dependent Claim
20 words
The process of claim 75 wherein the spray pressure ranges from about 1200 to about 2500 pounds per square inch.
Claim 80
Dependent Claim
34 words
The process of claim 67 further comprising, prior to step (2), heating said liquid mixture to a temperature sufficient to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 81
Dependent Claim
17 words
The process of claim 77 wherein the liquid temperature ranges from about 35° to about 90° centigrade.
Claim 82
Dependent Claim
17 words
The process of claim 78 wherein the liquid temperature ranges from about 45° to about 75° centigrade.
Claim 83
Dependent Claim
30 words
The process of claim 67 wherein said at least one polymeric component is selected from the group consisting of thermoplastic resins, thermosetting resins, crosslinkable film forming systems, and mixtures thereof.
Claim 84
Dependent Claim
47 words
The process of claim 80 wherein said at least one polymeric component is selected from the group consisting of enamels, varnishes, lacquers, acrylic resins, vinyl resins, styrenic resins, polyesters, alkyds, polyurethanes, urethanes, epoxies, phenolics, cellulosic esters, amino resins, natural gums, natural resins, and interpolymers and mixtures thereof.
Claim 85
Dependent Claim
37 words
The process of claim 67 further comprising, prior to step (2), admixing to said liquid mixture pigments, pigment extenders, metallic flakes, fillers, drying agents, antifoaming agents, antiskinning agents, wetting agents, ultraviolet absorbers, cross-linking agents, and mixtures thereof.
Claim 86
Dependent Claim
23 words
The process of claim 67 further comprising, prior to step (2), filtering said liquid mixture to remove particulates that would plug said orifice.
Claim 87
Dependent Claim
27 words
The process of claim 67 further comprising, prior to step (2), promoting turbulent or agitated flow of said liquid mixture to aid atomization of said liquid spray.
Claim 88
Dependent Claim
30 words
The process of claim 67 further comprising utilizing jets of compressed gas to assist formation and atomization of said liquid spray and to modify the shape of said liquid spray.
Claim 89
Dependent Claim
12 words
The process of claim 85 wherein said compressed gas is compressed air.
Claim 90
Dependent Claim
20 words
The process of claim 86 wherein said compressed air has lowered oxygen content to reduce flammability of said liquid spray.
Claim 91
Dependent Claim
13 words
The process of claim 85 wherein said compressed gas is compressed carbon dioxide.
Claim 92
Dependent Claim
24 words
The process of claim 85 wherein said compressed gas is selected from the group consisting of compressed nitrogen, helium, argon, xenon, and mixtures thereof.
Claim 93
Dependent Claim
23 words
The process of claim 85 wherein the pressure of said compressed gas ranges from about 5 to about 80 pounds per square inch.
Claim 94
Dependent Claim
23 words
The process of claim 90 wherein the pressure of said compressed gas ranges from about 5 to about 20 pounds per square inch.
Claim 95
Dependent Claim
33 words
The process of claim 85 wherein said compressed gas is heated to supply heat to the liquid spray to prevent the adverse effect caused by rapid cooling when said liquid mixture is sprayed.
Claim 96
Dependent Claim
20 words
The process of claim 92 wherein the temperature of said compressed gas ranges from about 35° to about 90° centigrade.
Claim 97
Dependent Claim
20 words
The process of claim 93 wherein the temperature of said compressed gas ranges from about 45° to about 75° centigrade.
Claim 98
Dependent Claim
31 words
The process of claim 67 wherein the substrate is selected from the group consisting of metal, wood, glass, plastic, paper, cloth, ceramic, masonry, stone, cement, asphalt, rubber, and composite materials thereof.
Claim 99
Dependent Claim
14 words
The process of claim 67 further comprising curing said liquid coating on said substrate.
Claim 100
Dependent Claim
29 words
The process of claim 67 wherein the supercritical carbon dioxide fluid is present in an amount ranging from about 10 to about 60 weight percent of the liquid mixture.
Claim 101
Dependent Claim
28 words
The process of claim 97 wherein the supercritical carbon dioxide is present in an amount ranging from about 20 to about 60 weight percent of the liquid mixture.
Claim 102
Dependent Claim
23 words
The process of claim 98 wherein the viscosity of the liquid mixture ranges from about 10 to about 50 centipoise at spray temperature.
Claim 103
Dependent Claim
26 words
The process of claim 67, wherein the liquid mixture includes an additive selected from the group consisting of pigments, drying agents, anti-skinning agents, and combinations thereof.
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| 3.5 Years (Year 4) | 1995-04-28 | 1995-10-28 | 1996-04-28 | $2000.00 | Window Closed / Lapsed |
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