Matte textured powder monocoat coating compositions

Abstract

The present invention includes matte textured powder monocoat coating compositions that can be used to coat substrates, such as automobile bodies, and methods of coating such substrates. A powder coating composition may comprise an acrylic resin, a UV light stabilizer, a matting agent, and a texturing additive, wherein the cured powder coating composition transmits less than about 0.1% of UV light at 290 nm and less than about 0.5% of UV light at 400 nm.

1 . A method of coating as substrate comprising applying a matte textured powder coating composition to the substrate and curing the coating matte textured powder coating composition, wherein the matte textured powder coating composition comprises:
 a) an acrylic resin that includes a glycidyl methacrylate resin, a carboxyl acrylic resin, a hydroxyl acrylic/tetramethoxymethyl glycoluril resin, or combination thereof;   b) a UV light stabilizer;   c) a matting agent; and   d) a texturing additive,   wherein a monocoat film with a measured film thickness of 50 to about 100 μm cured from the matte textured powder coating composition has a non-uniform thickness with hills and valleys having a valley:hill thickness ratio from about 1:4 to about 1:2, exhibits a 60° gloss of less than about 10, transmits less than about 0.1% of UV light at 290 nm and less than about 0.5% of UV light at 400 nm.   
     
     
         2 . The method of  claim 1 , wherein the substrate is an automobile body. 
     
     
         3 . The method of  claim 1 , wherein an electrocoat is coated between the substrate and the powder coating composition. 
     
     
         4 . The method of  claim 1 , wherein the the carboxyl acrylic resin comprises a carboxyl acrylic resin/betahydroxyalkylamide resin system. 
     
     
         5 . The method of  claim 1 , wherein the UV light stabilizer is at least one of a hydroxyphenyl benzotriazole, a hindered amine light stabilizer, an oxalanilide, a hydroxybenzophenone, or a hydroxyphenyl-s-triazine. 
     
     
         6 . The method of  claim 1 , wherein the matting agent includes at least one of barium sulfate, magnesium silicate, silicon dioxide, an alumino silicate, an alkali alumino silicate ceramic microsphere, an alumino silicate glass microsphere or flake, a polyolefin wax in combination with the salt of an organic anion, or a polymeric wax additive. 
     
     
         7 . The method of  claim 1 , wherein the texturing additive includes at least one of a polytetrafluoroethylene powder, a PTFE/polyethylene wax mixture, or a PTFE/talc. 
     
     
         8 . The method of  claim 1 , wherein the matte textured powder coating composition further comprises one or more of a pigment, a degassing agent, an antioxidant, a filler, a flow aid, or a catalyst. 
     
     
         9 . The method of  claim 1 , wherein the acrylic resin is present in an amount from about 25 weight % to about 65 weight % of the powder coating composition. 
     
     
         10 . The method of  claim 1 , further comprising a curing agent and/or co-reacting resin comprising an aliphatic polyanhydride, a dibasic acid, a hydroxyalkylamide, triglycidyl isocyanurate, a glycidyl methacrylate acrylic resin, a polyester resin, a hydrogenated Bisphenol A epoxy resin, a tetramethoxymethyl glycoluril, a polyisocyanate curing agent, or a combination thereof. 
     
     
         11 . An automobile body coated with a matte textured powder coating composition, wherein the matte textured coating composition comprises:
 a) an acrylic resin that includes a glycidyl methacrylate resin, a carboxyl acrylic resin, a hydroxyl acrylic/tetramethoxymethyl glycoluril resin, or combination thereof;   b) a UV light stabilizer;   c) a matting agent; and   d) a texturing additive,   wherein a monocoat film with a measured film thickness of 50 to about 100 μm cured from the matte textured powder coating composition has a non-uniform thickness with hills and valleys having a valley:hill thickness ratio from about 1:4 to about 1:2, exhibits a 60° gloss of less than about 10, transmits less than about 0.1% of UV light at 290 nm and less than about 0.5% of UV light at 400 nm.   
     
     
         12 . The automobile body of  claim 11 , wherein an electrocoat is coated between the automobile body and the matte textured powder coating composition. 
     
     
         13 . A substrate coated with a dual-coat coating composition, the dual-coat coating composition comprising an electrocoat coated between the substrate and a matte textured powder coating composition comprising:
 a) an acrylic resin that includes a glycidyl methacrylate resin, a carboxyl acrylic resin, a hydroxyl acrylic/tetramethoxymethyl glycoluril resin, or combination thereof;   b) a UV light stabilizer;   c) a matting agent; and   d) a texturing additive,   wherein a monocoat film with a measured film thickness of 50 to about 100 μm cured from the matte textured powder coating composition has a non-uniform thickness with hills and valleys having a valley:hill thickness ratio from about 1:4 to about 1:2, exhibits a 60° gloss of less than about 10, transmits less than about 0.1% of UV light at 290 nm and less than about 0.5% of UV light at 400 nm.   
     
     
         14 . The substrate of  claim 13 , wherein the the carboxyl acrylic resin comprises a carboxyl acrylic resin/betahydroxyalkylamide resin system. 
     
     
         15 . The substrate of  claim 13 , wherein the UV light stabilizer is at least one of a hydroxyphenyl benzotriazole, a hindered amine light stabilizer, an oxalanilide, a hydroxybenzophenone, or a hydroxyphenyl-s-triazine. 
     
     
         16 . The substrate of  claim 13 , wherein the matting agent includes at least one of barium sulfate, magnesium silicate, silicon dioxide, an alumino silicate, an alkali alumino silicate ceramic microsphere, an alumino silicate glass microsphere or flake, a polyolefin wax in combination with the salt of an organic anion, or a polymeric wax additive. 
     
     
         17 . The substrate of  claim 13 , wherein the texturing additive includes at least one of a polytetrafluoroethylene powder, a PTFE/polyethylene wax mixture, or a PTFE/talc. 
     
     
         18 . The substrate of  claim 13 , wherein the matte textured powder coating composition further comprises one or more of a pigment, a degassing agent, an antioxidant, a filler, a flow aid, or a catalyst. 
     
     
         19 . The substrate of  claim 13 , wherein the acrylic resin is present in an amount from about 25 weight % to about 65 weight % of the powder coating composition. 
     
     
         20 . The substrate of  claim 13 , further comprising a curing agent and/or co-reacting resin comprising an aliphatic polyanhydride, a dibasic acid, a hydroxyalkylamide, triglycidyl isocyanurate, a glycidyl methacrylate acrylic resin, a polyester resin, a hydrogenated Bisphenol A epoxy resin, a tetramethoxymethyl glycoluril, a polyisocyanate curing agent, or a combination thereof.