liquid paint system design & applications ii wednesday june 6, 2001 considerations for applying...

Liquid Paint System Design & Applications II

Wednesday June 6, 2001

Considerations for Applying UV Coatings

Presented by: John OwedITW Ransburg Electrostatic Systems

Considerations for Applying UV CoatingsConsiderations for Applying UV CoatingsConsiderations for Applying UV CoatingsConsiderations for Applying UV Coatings

What are “UV” Coatings?What are “UV” Coatings?

Where are “UV” Coatings used?Where are “UV” Coatings used?

Advantages of “UV” Coatings?Advantages of “UV” Coatings?

Evaluating Existing Application Equipment Evaluating Existing Application Equipment

for use with UVfor use with UV

– Fluid Delivery EquipmentFluid Delivery Equipment

– Application EquipmentApplication Equipment

Testing UV Materials for Your ApplicationTesting UV Materials for Your Application

– Application TestingApplication Testing

– Performance RequirementsPerformance Requirements

Considerations for Applying UV CoatingsConsiderations for Applying UV CoatingsConsiderations for Applying UV CoatingsConsiderations for Applying UV Coatings

What are UV CoatingsWhat are UV CoatingsWhat are UV CoatingsWhat are UV Coatings

UV coatings are formulated with 100% UV coatings are formulated with 100% reactive liquid vehicles such as:reactive liquid vehicles such as:

– OligomersOligomers– MonomersMonomers– PhotoinitiatorsPhotoinitiators– AdditivesAdditives

What are “UV” Coatings?What are “UV” Coatings?What are “UV” Coatings?What are “UV” Coatings?

Coatings which are cured using various Coatings which are cured using various wave lengths of ultraviolet light.wave lengths of ultraviolet light.

- Resin- Resin

- Solvent- Solvent

- Catalyst- Catalyst

- Additives- Additives

Where are UV Coatings UsedWhere are UV Coatings UsedWhere are UV Coatings UsedWhere are UV Coatings Used

Where are “UV” Coatings used?Where are “UV” Coatings used?Where are “UV” Coatings used?Where are “UV” Coatings used?

• Wheel Cover • Rims• Brake Components

• Mirror Housings• Door Handles• Exterior Trim

• Headlamps • Tail Lights• Starter Motors

• Adhesives • Sealant• Electrical Potting

Automotive Applications


• Restaurant Seating• Flooring• Cabinet Frames and Doors

Advantageous of UV CoatingsAdvantageous of UV CoatingsAdvantageous of UV CoatingsAdvantageous of UV Coatings

Advantages of “UV” Coatings?Advantages of “UV” Coatings?Advantages of “UV” Coatings?Advantages of “UV” Coatings?

South Coast Air Quality Management District South Coast Air Quality Management District (SCAQMD) has recognized UV as an exempt process.(SCAQMD) has recognized UV as an exempt process.

– Eliminates need to wait months for Eliminates need to wait months for permitting.permitting.

– Minimizes cost associated with Minimizes cost associated with permitting.permitting.

Environmental friendly processEnvironmental friendly process– UV Coatings are available in 100% solid formulations, no UV Coatings are available in 100% solid formulations, no

solvents = no VOC.solvents = no VOC.

Advantages of “UV” Coatings?Advantages of “UV” Coatings?Advantages of “UV” Coatings?Advantages of “UV” Coatings? Instantaneous Cure TimeInstantaneous Cure Time

– Once exposed to high intensity UV light, coating converts from liquid to plastic in a fraction of a second.Once exposed to high intensity UV light, coating converts from liquid to plastic in a fraction of a second.

– Minimizes opportunity for contamination by air borne dirt.Minimizes opportunity for contamination by air borne dirt.

– Reduces floor space requirements typically associated with thermal cure ovens.Reduces floor space requirements typically associated with thermal cure ovens.

– Less inventory tied up in the manufacturing process.Less inventory tied up in the manufacturing process.

Reduced manufacturing cycle.Reduced manufacturing cycle.– Utilizes and consumes less energy.Utilizes and consumes less energy.

Spray Area

Cure Chamber

Unload

Load



Low Temperature ProcessLow Temperature Process– Works well with products that are temperature Works well with products that are temperature

sensitive.sensitive.– Idea for large metallic parts which would Idea for large metallic parts which would

typically require a long cool down time. typically require a long cool down time. – Final surface temperature will depend on Final surface temperature will depend on

length of exposure and mass of product length of exposure and mass of product cured.cured.

High Abrasion and Stain ResistanceHigh Abrasion and Stain Resistance

Evaluating Existing Application Evaluating Existing Application Equipment for use with UVEquipment for use with UV

Evaluating Existing Application Evaluating Existing Application Equipment for use with UVEquipment for use with UV

Fluid Supply OptionsFluid Supply Options

– Peristaltic pumpPeristaltic pump

– Diaphragm pumpDiaphragm pump

– Piston PumpPiston Pump

Evaluating Application EquipmentEvaluating Application EquipmentEvaluating Application EquipmentEvaluating Application Equipment

– Pressure pot \ fluid regulatorPressure pot \ fluid regulator

Regardless of the system used, the following items must be Regardless of the system used, the following items must be considered:considered:

– All wetted components in the fluid stream must be stainless steel or Teflon.All wetted components in the fluid stream must be stainless steel or Teflon.

– All fluid supply lines and tubes All fluid supply lines and tubes should be opaque.should be opaque.

– Minimize exposure of coating to all light sources Minimize exposure of coating to all light sources (fluorescent and sunlight).(fluorescent and sunlight).

– UV coatings are shear sensitive UV coatings are shear sensitive and are not compatible with and are not compatible with piston or gear pumps.piston or gear pumps.


Pressure pot \ fluid regulatorPressure pot \ fluid regulator– Basic systemBasic system– Grounded for solvent borne coatingsGrounded for solvent borne coatings

Variable Pneumatic Signal

Pressure Pot60 - 80 psi air

pressureTo Paint Applicator

Coating Material

Pressure Pot

Fluid Regulator


Non-conductive drive shaft

Variable Speed Drive Motor

Return From Three-way Valve

To Applicator

SolventFlush

To Applicator

Pump Head

Cover

Gravity Feed Container

Note: Used to feed a single applicator.Three-way Valve

Positive displacement pumpPositive displacement pump


Pump

Drum

Back Pressure Regulator

Fluid Regulator

Paint Filter

Paint Heater (optional)

Return From CCV Stack

Solvent

PaintAir

To Applicators

SolventFlush

To Applicators

Diaphragm or piston pumpDiaphragm or piston pump– Used for circulating systems and bulk supplyUsed for circulating systems and bulk supply


Effects of heat on coatingEffects of heat on coating– Heat will lower viscosity of coating Heat will lower viscosity of coating

material.material.

Effects of heat on product coatedEffects of heat on product coated– A heated part cause UV material to flowA heated part cause UV material to flow

– Part should be cured immediately after coating (note: any residual Part should be cured immediately after coating (note: any residual solvents must be “flashed-off”).solvents must be “flashed-off”).

– Aids in atomization of coatings.Aids in atomization of coatings.– Simplifies fluid handling.Simplifies fluid handling.


Viscosity Curve - Pigmented UV Coating

0102030405060

77 86 95 105 115 125 135 140Temperature (F)

Zah

n #3

(S

econ

ds)


Most end users start out using their Most end users start out using their existing equipment configuration.existing equipment configuration.

– Equipment can not properly Equipment can not properly atomize the coating material.atomize the coating material.

– Solvents are used to reduce the Solvents are used to reduce the material, defeating the original material, defeating the original objective to eliminate solvents.objective to eliminate solvents.


UV materials can be applied with a wide variety of spray UV materials can be applied with a wide variety of spray application equipment.application equipment.


Air atomization - air is used to atomize Air atomization - air is used to atomize

coating into fine particles.coating into fine particles. Conventional air spray - Conventional air spray -

high pressure, low volumehigh pressure, low volume

HVLP air spray - HVLP air spray -

high volume low pressurehigh volume low pressure

Works best with lower Works best with lower

solids coatingssolids coatings


Hydraulic atomization - material is forced Hydraulic atomization - material is forced through a fixed orifice at high pressure.through a fixed orifice at high pressure.

Conventional Airless: 2000 - 3500 psi fluid Conventional Airless: 2000 - 3500 psi fluid pressure.pressure.

Air Assisted Airless: 300 - 1500 psiAir Assisted Airless: 300 - 1500 psi

High shear is induced on coatings with High shear is induced on coatings with piston style pumps.piston style pumps.


Rotary atomizer - centrifugal force is used Rotary atomizer - centrifugal force is used to atomize coating material.to atomize coating material.

– Ability to atomize high viscosity Ability to atomize high viscosity coatings.coatings.

– Serrated edge “bell” cup Serrated edge “bell” cup aids in atomization process.aids in atomization process.

– Electrostatic applicator yields Electrostatic applicator yields high transfer efficiencyhigh transfer efficiency


Unique feature of 100% solids material:Unique feature of 100% solids material:

wet film thickness = dry film thicknesswet film thickness = dry film thickness

Dry Film = 1.0 mils 1.0 mil

2.0 mil“wet”

4.0 mil“wet”

25% solids by volume material



Dry Film = 1.0 mils Dry \Wet Film


Regardless of the application equipment used, fluid delivery Regardless of the application equipment used, fluid delivery rate is one of the most critical parameters to control (very rate is one of the most critical parameters to control (very critical with pigmented systems, excessive film may not cure critical with pigmented systems, excessive film may not cure properly). properly).

Positive displacement pump offers good control of fluid Positive displacement pump offers good control of fluid flow rate since delivery is based on rotation of pump drive flow rate since delivery is based on rotation of pump drive mechanism.mechanism.

With pressure pot or diaphragm pump system, a flow meter With pressure pot or diaphragm pump system, a flow meter can be placed in the fluid stream and interfaced with a flow can be placed in the fluid stream and interfaced with a flow controller.controller.


Closed Loop flow ControlClosed Loop flow Control

Flow Meter Fluid Regulator

Fluid Inlet Fluid

Outlet

Flow

Controller

Transducer

ElectricalSignal

Pneumatic Signal Compare

Adjust

Measure


Testing UV Materials for Your Testing UV Materials for Your ApplicationApplication

Testing UV Materials for Your Testing UV Materials for Your ApplicationApplication

– Coating SupplierCoating Supplier– Equipment SupplierEquipment Supplier– Lamp SupplierLamp Supplier

Find a place to test the process.Find a place to test the process.

Testing UV for Your ApplicationTesting UV for Your ApplicationTesting UV for Your ApplicationTesting UV for Your Application

– Need to simulate proposed or existing process as closely Need to simulate proposed or existing process as closely as possible.as possible.

– Conveyor system, application equipment, curing system.Conveyor system, application equipment, curing system.– Keep safety in mind Keep safety in mind

Form a team:Form a team:

Must confirm coating meets physical Must confirm coating meets physical properties.properties.

Performance RequirementsPerformance RequirementsPerformance RequirementsPerformance Requirements

– AdhesionAdhesion– Corrosion resistanceCorrosion resistance– HardnessHardness– AbrasionAbrasion– GlossGloss

Coating supplier will make Coating supplier will make recommendations on type of lamps to userecommendations on type of lamps to use– Wave length of lamps must be matched to Wave length of lamps must be matched to

photoinitiators in coating to ensure proper Cure. photoinitiators in coating to ensure proper Cure.

– Provides acceptable coverage on the product.Provides acceptable coverage on the product.– Able to obtain good overall appearance.Able to obtain good overall appearance.


Equipment SupplierEquipment Supplier

– Achieves good atomization quality Achieves good atomization quality with equipment demonstrated.with equipment demonstrated.

– Save coated samples.Save coated samples.

– Measure dry film thickness.Measure dry film thickness.

– Document material usage \ parts Document material usage \ parts per gallon.per gallon.


– Have them make recommendation on lamp Have them make recommendation on lamp configuration and quantity.configuration and quantity.

– Lamps must be installed with safety in mind, Lamps must be installed with safety in mind, lights must be interlocked and shielded to lights must be interlocked and shielded to prevent operator exposure.prevent operator exposure.

Lighting SupplierLighting Supplier

– Although lights can fit in a small Although lights can fit in a small footprint, keep maintenance and footprint, keep maintenance and accessibility in mind.accessibility in mind.

ConclusionConclusionConclusionConclusion

UV Coatings can offer:UV Coatings can offer:– An environmentally friendly solution. An environmentally friendly solution.

– A more streamlined manufacturing process.A more streamlined manufacturing process.

Existing fluid delivery and application equipment Existing fluid delivery and application equipment may be adapted to apply UV materials.may be adapted to apply UV materials.

Assemble a team consisting of coating Assemble a team consisting of coating manufacture, equipment supplier and lamp manufacture, equipment supplier and lamp supplier.supplier.

Thank-youThank-youThank-youThank-you

If I can be of any additional assistance'sIf I can be of any additional assistance's

Please contact me:Please contact me:

John OwedJohn Owed

ITW Ransburg Electrostatic SystemsITW Ransburg Electrostatic Systems

320 Phillips Ave.320 Phillips Ave.

Toledo, Ohio 43612Toledo, Ohio 43612

Phone: 419\470-2066Phone: 419\470-2066

Fax: 419\470-2185Fax: 419\470-2185

E-mail: [email protected]: [email protected]

liquid paint system design & applications ii wednesday june 6, 2001 considerations for applying...

Documents

uv slide

uv coatings n

n uv coatings

n coatings

n advantages of uv coatings

advantageous of uv coatings

high intensity uv light

stain resistance slide