Method for preparing and top coating a powder coated wood substrate

Abstract

The invention includes a method for preparing and top coating an item made of powder coated MDF (or other substrate containing wood) with the end result of improved visual and tactile smoothness; the invention includes the steps of cutting and machining the part, pre-powder preparation and sanding of the part, powder coating the part, post-powder preparation and sanding, and applying the liquid top coat to the part, resulting in a smoother finish than is currently available in any other powder coated MDF finish while requiring less coats than similar liquid paint finishes.

1 . (canceled) 
     
     
         2 . A method of manufacturing an article, the method comprising:
 obtaining or producing a substrate of a desired size and shape;   applying an inner coating layer of fused powder coating overlying and bonded to the substrate; and   applying an outer coating layer of liquid finish overlying and bonded to the powder coating wherein a resulting finish has improved PCI smoothness and improved visual and tactile smoothness as compared to another powder coated article without the liquid finish.   
     
     
         3 . The method as claimed in  claim 2 , further comprising selecting the substrate to contain a wood product that is selected from a group consisting of wood, medium-density fiberboard (MDF) and high-density fiberboard (HDF). 
     
     
         4 . The method as claimed in  claim 2 , further comprising applying the powder coat surface coating to be least 5 mils in thickness and to have a PCI smoothness of at least 6. 
     
     
         5 . The method as claimed in  claim 2 , further comprising selecting the powder coat surface coating to comprise an ultraviolet cured powder coating material, a thermoplastic powder coating material, thermoset powder coating material, or UV polymer powder coating material. 
     
     
         6 . The method as claimed in  claim 2 , further comprising selecting the liquid finish to be a pre-catalyzed lacquer, a post-catalyzed conversion varnish or to incorporate color pigment. 
     
     
         7 . The method as claimed in  claim 2 , further comprising applying the liquid finish to have a PCI smoothness of at least 8. 
     
     
         8 . The method as claimed in  claim 2 , further comprising applying the liquid finish to achieve a minimum top coat thickness of 2 wet mils. 
     
     
         9 . The method as claimed in  claim 2 , further comprising applying the liquid finish to achieve a PCI smoothness of 10 and a visual depth equivalent to a five coat wet sanded liquid paint finish. 
     
     
         10 . A method of finishing an article, the method comprising:
 receiving a substrate of a desired size and shape with a pre-applied inner coating layer of fused powder coating overlying and bonded to the substrate; and   applying an outer coating layer of liquid finish overlying and bonded to the powder coating wherein a resulting finish has improved PCI smoothness and improved visual and tactile smoothness as compared to another powder coated article without the liquid finish.   
     
     
         11 . The method as claimed in  claim 10 , further comprising receiving the substrate wherein the substrate comprises a wood product that is selected from a group consisting of wood, medium-density fiberboard (MDF) and high-density fiberboard (HDF). 
     
     
         12 . The method as claimed in  claim 10 , further comprising receiving the substrate wherein the powder coat surface coating is least 5 mils in thickness and has a PCI smoothness of at least 6. 
     
     
         13 . The method as claimed in  claim 2 , further comprising receiving the substrate wherein the powder coat surface coating includes an ultraviolet cured powder coating material, a thermoplastic powder coating material, thermoset powder coating material, or UV polymer powder coating material. 
     
     
         14 . The method as claimed in  claim 10 , further comprising selecting the liquid finish to be a pre-catalyzed lacquer, a post-catalyzed conversion varnish or to incorporate color pigment. 
     
     
         15 . The method as claimed in  claim 10 , further comprising applying the liquid finish to have a PCI smoothness of at least 8. 
     
     
         16 . The method as claimed in  claim 10 , further comprising applying the liquid finish to achieve a minimum top coat thickness of 2 wet mils. 
     
     
         17 . The method as claimed in  claim 10 , further comprising applying the liquid finish to achieve a PCI smoothness of 10 and a visual depth equivalent to a five coat wet sanded liquid paint finish.