How can we make coatings Powder on Plastic even more robust, more durable, and suitable for a broad range of substrates?
PagePage___ 1 11 Powder Trends & developments
• Industry trends - Use of Powder Coatings on HSS (heat sensitive substrates) - Alternative for ‘pure’ Epoxy systems by PE systems - Replacement of SB coatings in certain markets segments, like Heavy Machinery/Automotive and General Industry - Move to lower temperature curing systems - Sustainability-carbon footprint reduction.
• Product trends - Improved outdoor durability - One shot matte systems - Corrosion protection in combination with outdoor durability - Full range of low temperature curing powders, gloss as well as matte
Page 2 Page___ 33 Ultra low temperature curing Powder Coatings (LTC POCO)
Integrated powder coating solution for heat sensitive substrates (wood and plastic)
14 CONFIDENTIAL Uralac® Ultra
Integrated powder coating solution for heat-sensitive substrates
Powder Coating Coating Process End Product
• Advanced Formulation • Robust Process • Freedom of Application • Comprehensive Technical Support
Page 55 CONFIDENTIAL
Powder coaten on recycled polypropylene
Lectoraat Kunststoftechnologie Windesheim Tommie Stobbe CONFIDENTIAL
Why powder coating on recycled PP?
• High quality recycling
• Color of recycled material difficult to control.
• Powder coating can be a environmental friendly alternative. CONFIDENTIAL
Chalenges for powder coating PP
Temperature resistance: PP normally not ressistant against T ≥ 180 °C
Conductivity: Powder coatings are sprayed electrostatic. Object needs some conductivity
Adhesion: Apolar behavior of PP makes it difficult for paint to adhere to the surface CONFIDENTIAL
Curing • PP normally not ressistant against T ≥ 180 °C
• DSM Powdercoating Resins, new developments of innovative powder coatings.
• Curing temperature 130°C during 3-10 minutes • Hybrid system • Polyamide system • Radical cure system (Uralac Ultra) • UV or peroxide CONFIDENTIAL
Powder adherence (pre-cure) Surface resistance and powder adherence as function of m% carbon black ? CONFIDENTIAL
Coating adhesion (post-cure) CONFIDENTIAL
Coating adhesion (post-cure)
• PP is known as apolar/hydrofobic behavior.
• Pre-treatment is needed.
• Plasma treatment (MAAN Research & Development) CONFIDENTIAL
Coating adhesion (post-cure) 4,0 Pull-off values after Different types of 3,5 plasma-treatments 3,0 2,5 2,0
1,5 MPa 1,0 0,5 0,0 Gas CONFIDENTIAL
Coating adhesion (post-cure)
From: Master thesis Gydo Willemsen 15
Appearances
• 60° Gloss levels : 20-95 (textured 5-60) • PCI flow: 0-6 (higher flow possible with in-mould coating) • Layer thickness: 40-150µm (1 layer) • Colors: All inorganic pigments and some organic pigments can be used (some organic pigments can cause pre-reaction) only limited experience with effect pigments
Cure temperature: 3 minutes 130°C – IR. Optional: UV to enhance surface properties even further.
Next generation Ultra is under development. Cure temperature will be reduced (<100°C) 16 Staining resistance
Ultra Dryblend, Uralac Ultra powder coatings Textured next generation Smooth matt Dual cure*
DIN 68861 1B contact time Required 3’ 130°C 3’ 130°C 3’ 95° + UV Acetone 10 seconds 4 5 4 4 Ethanol 48% 1 hour 4 5 4 5 Red Wine 6 hours 5 5 5 3 Coffee (fresh) 16 hours 5 5 4 3 Water 16 hours 5 5 5 5 Mustard 6 hours 5 5 5 5 Onions (fresh) 6 hours 5 5 4 3 Total 34 35 31 28
IKEA R2 contact time Required Ethanol 48% 1 hour 4 5 4 5 Coffee (fresh) 1 hour 4 5 5 3 Water 24 hours 4 5 5 5 Total 12 15 14 13
Ketchup, ketjap, sambal, Required 4 Achieved: 5 16 hr Hand creme, 24 hr Required 4 Achieved 4-5
1-very bad, 5-unattached/invisible 17 Hardness
Ultra Uralac Ultra powder coatings Textured Dryblend, matte next generation Dual cure
3’ 130°C 3’ 130°C 3’ 95° + UV
Universal scratch Test ISO 4586-2 1,5N 1,2N 1,2N
Konig Hardness DIN 53157 200 180 165
Pencil hardness 8H 6H 8H
The hardness of textured and dryblend can be increased even further by additives or extra UV cure Pencil hardness only tested up to 8H!
Impact/flexibility depends on adhesion of coating. When adhesion is good, the flexibility will also be good. Adhesion on thermoplastics can be achieved by plasma treatment 18
Food approval
• Most of the polyester resins are food approved, or can be modified to food approval versions. • Migration limits needs to be evaluated in the final application formulation. • some adjustment on systems might be needed i.e dryblend resin contains not listed components. CONFIDENTIAL
Summary
• One of the most sustainable coating solutions. • Hard and tough coatings. • High chemical resistance. • One layer, maximum properties. • Application on plastic possible. • Health and environmental friendly. • Fast cure by UV possible. • Many colors and special effects possible: eg – High gloss, matte, textured, sandpaper like, metallic, etc.
19 CONFIDENTIAL
Future
Present investigations:
• Conductivity in PP/CNT compounds
• Coating of “3D-objecten”
Future research:
• Optimasation plasma-parameters
• Testing of more reactive powder coating systems