To provide a process for producing a coated article, capable of producing a coated article having a coating film excellent in weather resistance, using a powder coating material.

A process for producing a coated article having a substrate, comprising:

applying a curable powder coating material containing a curable polymer containing no fluorine atom, a curing agent and a pigment to a surface of a substrate, to form a first coating layer composed of the curable powder coating material, then

applying a powder coating material containing a fluorinated polymer and containing no pigment to a surface of the first coating layer, to form a second coating layer composed of the powder coating material, and

heating the first coating layer and the second coating layer simultaneously to form a coating film on the surface of the substrate.

The invention relates to a one component heat-curable powder coating composition comprising a resin containing reactive unsaturations and wherein all said reactive unsaturations are carbon carbon double bonds connected directly to an electron withdrawing group, a thermal initiation system comprising a transition metal catalyst and a peroxide, wherein the peroxide is chosen from the group of peroxyesters, mono-peroxycarbonates and mixtures thereof and a co-crosslinker chosen from the group of vinylethers, vinylesters, vinylamides, itaconates, enamines and mixtures thereof.

The invention relates to a one component heat curable powder coating composition comprising a resin containing reactive unsaturations and wherein all said reactive unsaturations are carbon carbon double bonds connected directly to an electron withdrawing group, a thermal initiation system comprising a peroxide chosen from the group of compounds represented by formula (1) ##STR00001##
wherein R.sup.1 and R.sup.2 each independently stand for an optionally substituted alkyl of 1 to 30 C-atoms, wherein the 1 to 30 C-atoms do not include the C-atoms of the substituents or for an optionally substituted aryl of 6 to 18 C-atoms, wherein the 6 to 18 C-atoms do not include the C-atoms of the substituents, and a co-crosslinker chosen from the group of vinylethers, vinyletherurethanes, vinylesters, vinylamides, itaconates, enamines, vinylureas and mixtures thereof.

To provide a powder paint whereby an external defect such as orange-peel skin is less likely to be formed on a formed cured film. The powder paint is characterized by comprising: a fluororesin (A); from 2 to 60 mass ppm relative to the fluororesin (A), of at least one metal element (B) selected from a group comprising potassium, sodium, and magnesium; from 10 to 10,000 mass ppm relative to the fluororesin (A), of a light stabilizer (C); and from 10 to 5,000 mass ppm relative to the fluororesin (A), of a polymerization inhibitor (D).

A particulate coating composition, preferably a powder coating composition, comprising: (i) at least one hardener such as at least one epoxy containing compound, (ii) at least one polyester polymer, (iii) at least one amino alcohol; and (iv) at least one metallic pigment.

A method for producing a thermal spray powder includes: a preparing step of preparing a powder mixture containing a first particle made from zirconia-based ceramic containing a first additive agent and a second particle made from zirconia-based ceramic containing a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 m and not more than 10 m; and a secondary-particle producing step of producing a plurality of secondary particles each of which includes the first particle and the second particle sintered with each other.

To provide a powder coating material capable of forming a coating film that is excellent in weather resistance, processability and impact resistance and that improves corrosion resistance of a substrate (in particular, a substrate made of aluminum or of an aluminum alloy).

A powder coating material comprising a powder of a resin composition, wherein the resin composition comprises a fluorinated polymer (A) having a number average molecular weight of from 10,000 to 50,000 and a fluorine content of at least 10 mass %, a resin (B) having a fluorine content of less than 10 mass % or containing no fluorine atom, a curing agent, a plasticizer having a melting point of from 50 to 150 C. and core-shell particles, and wherein the absolute value of the difference between the melting point of the plasticizer and the glass transition temperature of a polymer of a shell portion in the core-shell particles is within 30 C. and the content of the plasticizer is from 5 to 25 parts by mass based on 100 parts by mass of the fluorinated polymer (A).

To provide a coated article, in which formation of a cured film having a fluororesin layer and a polyester layer is not cumbersome, and the cured film is excellent in weather resistance. A coated article having a cured film formed by coating a substrate with a powder coating material comprising a fluorinated polymer (A), a polyester polymer (B), an ultraviolet absorber (C) and titanium oxide (E), wherein the thickness of the cured film is from 20 to 1,000 m, the atom number concentration of Ti element present in a region (I) within 5 m in depth from the surface of the cured film is from 0 to 9%, the atom number concentration of Ti element present in a region (II) beyond 10 m in depth from the surface of the cured film is from 8.5 to 10%, and the proportion of the ultraviolet absorber (D) contained in the region (I) (100 mass %) is from 0.5 to 10 mass %.

A powder coating composition is provided herein. The powder coating composition includes a glycidyl-functionalized (meth)acrylic resin as a film-forming binder, a cross-linking agent (hardener) for the binder, particles chosen from the group comprising aluminum oxide Al.sub.2O.sub.3 and aluminum hydroxide Al(OH).sub.3 particles, and a coating additive, the wt % based on the total weight of the powder coating composition. A process for the production of a scratch resistant powder coating is also provided herein. The process includes the steps of a) applying a transparent clear coat or a pigmented top coat directly onto a substrate surface or onto a prior coating, and b) curing the clear coat or the top coat applied in step a) wherein the transparent clear coat or the pigmented top coat includes the powder coating composition.

Provided is a powder coating composition, whereby a cured film excellent in water resistance, chemical resistance and weather resistance, can be formed by single coating operation, wherein a fluorinated resin layer and a polyester layer are layer-separated in the process of melting and curing the powder coating composition. A powder coating composition comprising a fluorinated resin (A), a polyester polymer (B), a curing agent (C) and an ultraviolet absorber (D), wherein the polyester polymer (B) is a polyester polymer comprising units derived from a C.sub.8-15 aromatic polybasic carboxylic acid compound and units derived from a C.sub.2-10 a polyhydric alcohol compound.