How can the disadvantages of applying ultrafine powder coatings be overcome?
Powder coatings and painting are rapidly developing powder coatings with the outstanding advantages of being environmentally friendly, economical, efficient and energy-saving. They are 100% solid ingredients and, unlike liquid paints, do not contain large amounts of solvent emissions. They are environmentally friendly coating products that do not cause pollution. Powder that is not used during powder coating spraying can be recycled and reused. The spraying process is simple and stable, with low energy consumption. Compared to liquid paints, it has the characteristics of low cost and good performance.
Powder coatings are developing very quickly, and in China, the development is much faster than in other countries. The main reason is that China’s economic development is very fast, and powder coatings are the first choice for many newly built coating lines. China has become a major user and producer of powder coatings, but there is still a gap between China and developed countries in the production of high-end raw materials and the development of high-end products.
How to target cutting-edge topics with great practical significance, use high-tech at home and abroad to tackle these topics, and achieve industrialization is an important decision facing Chinese scientists and industry insiders.
Powder coatings have shown great competitiveness in their development over the past decade or so, but there are also shortcomings and limitations in their development that need to be overcome. Powder coating is recognized to have four shortcomings: the coating is too thick, the appearance of the coating is poor, it cannot be cured at low temperatures, and it is difficult to change colors.
In response to these limitations and shortcomings, scientists and engineers from various countries have conducted a great deal of research, and considerable progress has been made in many areas.
For example, the development of low-temperature curing powder coatings has resulted in commercial products that can be cured at 120°C and are used for coating wood and composite panels. Research into the UV curing of powder coatings has also made breakthroughs and has been applied industrially.
Under the current circumstances, the greatest contribution to industrial users’ acceptance of powder coatings is considered to be the high quality and cost-effectiveness of the products, as well as their compliance with environmental regulations.
Powder coatings do not have a large market share compared to other types of coatings. However, in the relatively mature industrial coatings sector, powder coatings are one of the few types of products that can maintain high growth rates for many years.
02
Introduction to superfine powder coating technology
Powder coating has developed rapidly due to its outstanding advantages of being environmentally friendly, cost-effective and energy-saving. However, powder coating also has shortcomings and limitations that need to be overcome urgently. The two recognized shortcomings of powder coating are: the coating is too thick and the surface flatness of the coating is poor.
The reason is that the particle size of powder coating is relatively large, far exceeding the thickness of ordinary paint film. Not only does this result in material waste, but in many cases a thick coating can also result in a decrease in the performance of the paint film.
For example, the coating is prone to flaking and the hardness of the film is reduced. To overcome these defects, scientists from various countries have conducted a great deal of research and developed ultra-fine powder coatings. These powders have a finer particle size, a good coating surface effect and can achieve thin coating.
Scientists at the Canadian company Phoseon Technology Inc. have successfully overcome the molecular attraction between ultra-fine powder particles using a special technique. This avoids agglomeration and results in a powder coating with a particle size of 10-20 pm and very good fluidization properties.
This coating can form a very flat coating surface and can also be applied in thin layers. The surface effect of the ultra-fine powder coating has been greatly improved, and salt spray tests have shown that a very thin ultra-fine powder coating has excellent corrosion resistance. The main reason is that the thickness of the ultra-fine powder coating is higher than that of the coarse powder coating at the thinnest part of the coating.
03
Fine powderization of powder coatings and its development
Among the four main disadvantages of powder coatings, the coating being too thick and the coating’s poor appearance are the most important.
The coating thickness of powder coatings is usually 60-100 pm, which is much thicker than that of ordinary paint films. This not only causes unnecessary waste, but also in some cases the thick coating can lead to a decrease in film performance, such as the coating peeling off easily. Poor coating appearance reduces the decorative effect of powder coatings, thus limiting the application and development of powder coatings. In particular, powder coatings cannot be used to paint some high-end products (such as cars).
Powder coatings that are too thick and have a poor appearance are mainly caused by the large particle size of the powder coating. The particle size of ordinary powder coatings is usually 30-40μm, and it is difficult to achieve a flat surface and a good surface effect after electrostatic spraying with such a particle size.
If the particle size of the powder coating can be reduced, a coating with a very good surface finish can be achieved, and thin-film coating can be realized. The fine pulverization of powder coatings can achieve significant cost savings with thin coatings while still obtaining a very good coating surface. It can be said that this is one of the most important topics in the research and development of powder coatings.
Scientists from various countries and major powder coating companies around the world have invested heavily in this topic, which has also attracted the attention of other industries and some national governments.
Due to market demand and the attention it has received, research into the fine pulverization of powder coatings has achieved many breakthroughs.
■ The most common method is to add some lubricant to the powder coating to prevent it from agglomerating, thereby reducing the particle size appropriately.
■ Some large companies produce products with a narrow particle size distribution, and choose high-leveling products with added lubricant adjustment to further reduce the particle size of the powder coating and achieve thin-film coating.
■ Ferro Corporation in the United States has developed a new process for preparing powder coatings using supercritical carbon dioxide, which can produce powder coating products with uniform dispersion and a narrow particle size distribution.
■ In China, many companies produce high-leveling products and claim to have achieved thin-film coating. In fact, the particle size of the powder has not been reduced, but because a thinner coating can be obtained, it is indeed very popular in the market.
The above methods are just some of the ways to achieve fine powderization of powder coatings. They have indeed brought a lot of benefits to the powder coating industry, but they have not really achieved the fine powderization of powder coatings.
The fine powderization of powder coatings refers to the particle size of powder coatings reaching 20 mm or less. Generally, a coating thickness of 2.5 times the particle size of the powder produces a better surface effect. However, ultrafine powders have their own characteristics, namely poor gas fluidization. This is because as the particle size decreases, the mass of the powder decreases exponentially, while the surface area of the powder increases exponentially. The result is that the molecular force is greatly enhanced, causing the ultrafine powders to clump together and prevent normal fluidization.
Normal fluidization is a prerequisite for electrostatic spraying of powder coatings, so frequent fluidization has become the main technical reason why fine powderization of powder coatings is difficult to achieve. Clumping of fine powders is a natural characteristic of ultrafine powders. To achieve fine powderization, it is necessary to first overcome the molecular forces between ultrafine powders.
04
Advances in ultrafine powder preparation technology
1. Mechanical and chemical methods
The main methods for preparing ultrafine powders are mechanical pulverization and chemical synthesis. Mechanical pulverization involves the use of mechanical force to ultra-fine conventional bulk or powder materials.
Chemical synthesis, on the other hand, involves the use of chemical reactions to generate the basic particles of matter—molecules, atoms, ions, etc.—which grow into ultrafine powders through nucleation, growth, and coalescence. This method has three major advantages:
- First, versatility. It can prepare ultrafine powders with a variety of compositions, morphologies and particle sizes.
- Second, it can control product quality at the molecular or atomic scale.
- Third, the process can be precisely controlled and adjusted, making it easy to achieve industrial production.
From the perspective of ultrafine powder preparation and application, the chemical synthesis method of ultrafine powder represents the development direction of ultrafine powder preparation technology and has also become a research and development focus in various countries.
2. Engineering issues in the preparation of ultrafine powders
Compared with the production process of ultra-fine powder materials, which has its own special industrial reaction process, the main difference is that the proportion of material costs is relatively reduced, and the function of the material determines the high added value of the product, which largely depends on the form of the product (shape, size distribution, crystal composition and shape, etc.).
The form of powder materials is the key to industrial production. Solving the engineering problems of material preparation is the premise of industrial control and process amplification. Mastering the regularity of ultra-fine powder processes is the basis for solving engineering problems.
05
Requirements of ultra-fine powder coatings
Ultra-fine powder coatings can achieve a flat, thin coating. In other words, powder coatings characterized by ultra-fine powder thin coatings may have some special technical requirements for both the coating and the coating process.
Generally, powder coatings require a resin with a low melting viscosity but a high glass transition temperature; good pigment dispersion and hiding power; and a narrow particle size distribution with a small particle size, which requires good grinding and classification effects from the grinding equipment.
Powder coatings also need to have good dry powder fluidity and electrostatic properties. To comprehensively solve these problems, the joint efforts of raw material manufacturers, powder manufacturers, equipment manufacturers, and users are required.
This paper studies ultra-fine powder coatings with very good fluidity. The focus of the research is that users can normally apply the coatings without having to change any equipment. Below, we will list a series of technical problems encountered during the actual development and application process.
1. Hiding power
Ordinary powders are difficult to apply in thin layers, with a film thickness of 60-90mm, and generally do not have hiding power problems. It was soon discovered in application that the ultra-fine powder obtained using a normal formula did not have sufficient hiding power when the coating was less than 50mm, especially for white products, which could not meet the requirements in actual painting.
For this reason, we appropriately increased the pigment content to give it the high hiding power of liquid paint. White products are special in that we need to use rutile titanium dioxide, which has the strongest hiding power, and increase the amount at the same time, otherwise the requirements cannot be met.
As the film thickness decreases, the sensitivity of the coating to hiding power increases exponentially. During the development process, we found that a series of measures must be considered to prevent uneven melting of the product as the pigment content increases.
One is to use resins with better melting properties; the other is to use titanium dioxide with better melting properties or titanium dioxide treated with a coating. In addition, it is also necessary to enhance the kneading effect during extrusion. Therefore, to achieve very good hiding power, corresponding improvements must be made to the powder formulation.
2. Leveling
The leveling and sagging of ordinary powder coatings are a contradiction. When the leveling is good, it is easy to sag. Ultra-fine powder coatings are not prone to sagging due to thin coating,so the amount of leveling agent can be increased to achieve better leveling performance. Ultra-fine powders have a very flat coating surface due to their fine particle size and uniform spraying.
3. Powder chargeability
Ultrafine powders have a small mass and are not easy to powder. Theoretically, some power-increasing agents should be added to improve the powdering rate. However, it has been found in practical applications that a low initial powdering rate is actually an advantage.
Because of the low powdering rate, the selectivity of spraying is enhanced, which means that a uniform coating thickness can be easily obtained during spraying. Because ultrafine powders solve the fundamental problem of powder fluidization, there is no problem with the recycling and reuse of ultrafine powders.
4. Cost
The cost of ultrafine powder coating will be greatly reduced due to the greatly reduced film thickness. However, the percentage of cost reduction is not directly related to the percentage of powder savings. Because the use of many high-end raw materials increases production costs, ultrafine powder is usually much more expensive than ordinary powder.
White ultra-fine powder products have a higher cost increase than other colors because they use a lot of high-grade titanium dioxide. The cost increase of dark ultra-fine powder is very small. Overall, ultra-fine powder coating still has a significant advantage in terms of overall cost, and the more high-end the product, the more significant the cost reduction.
The market experience of the past six months is that, due to insufficient awareness of the new product, the customers who took the lead in using ultrafine powder were not attracted by the cost reduction factor of the coating. The driving force was to improve the product grade for a smooth appearance. Of course, even now the cost savings are significantly higher than the cost increase.
06
Ultrathin powder coating
1. Spraying equipment and process
The starting point for solving the problem of ultra-fine powder coating is to thoroughly solve the fluidization of ultra-fine powders, so that in theory, no coating process is changed.
In actual application, ultra-fine powders can indeed be completely fluidized like ordinary coarse powders, and there are no problems with poor fluidization such as gun blockage. However, there are still some specificities to ultra-fine powder spraying. Ultra-fine powders have a small mass and a large surface area, so although the individual particles have a low charge, the overall charge increases significantly.
After more than a year of testing and application, we found that the spraying equipment basically does not need to be changed, whether it is a manual spray gun in a simple spray booth or a state-of-the-art automatic spray gun in a modern spray booth.
However, the spraying process needs to be slightly adjusted according to specific circumstances. For example, the distance can be slightly closer, and the voltage can be slightly lower. The spraying process parameters for ultrafine powders are the same as those for ordinary coarse powders. Each production line has its own optimal coating conditions to suit its own requirements, and it requires technicians to conduct certain trial and error tests on site.
2. Powder application rate and selectivity
Ordinary coarse powder has a lot of fine powder in the recycled powder, and when it is reused, it often has problems with poor fluidization, such as agglomeration and powder spitting, which causes trouble for the recycling of powder coatings.Therefore, it is necessary to mix the recycled powder with coarse powder in a certain ratio before recycling.
Due to their small size, ultrafine powders are not as likely to adhere to the surface of the workpiece as coarse powders. The first-time powder application rate is worse than that of coarse powders, but this is not necessarily a bad thing. A poor powder application rate makes it easy to achieve a very even coating with a thin film thickness when spraying with a better ultrafine powder, which is difficult to achieve with coarse powders.
On the other hand, since the ultra-fine powder solves the fluidization problem of the fine powder, its recycled powder does not have the problem of poor fluidity. As long as the equipment has a recovery device, the coating is completely problem-free.
3. Recovery performance and recoating performance
The commonly used recovery systems now are cyclone recovery and bag filter recovery. Both methods can effectively recover all unused powder. Whether it is coarse powder or ultra-fine powder, they both contain particles of various sizes, but in different proportions.
Although the average particle size of ultrafine powder is much smaller than that of coarse powder, its particle size is within the range of recovery designed by existing recovery equipment. It can be said that there is no problem with normal recovery. Recycled powder usually has a smaller particle size than virgin powder.
The key to ultrafine powder coating technology is to thoroughly solve the fluidization of ultrafine powder. Therefore, recycled ultrafine powder has the characteristics and applications of ultrafine powder coating.
4. Coating performance
The coating of ultrafine powder is actually a process that successfully achieves spraying by solving the fluidization of fine powder. For the following reasons, ultrafine powder coating has different coating properties from ordinary powder.
- First, the particles are fine, the coating is dense, and the surface is smooth, so the surface scratch resistance and flatness are enhanced.
- Second, the coating is thin, which avoids the disadvantages of thick coatings such as coating peeling.
In addition, it is difficult to achieve a thin coating with a coarse powder coating, and a thick coating actually results in a lot of waste. In order to save costs, conventional powder coatings must be mixed with a large amount of cheap fillers.
Although these fillers do not affect the hiding power of the coating, they do affect the chemical properties and corrosion resistance of the coating to a certain extent. Due to the thin coating and the high hiding power required, ultra-fine powder must use the best raw materials, and because the coating is thin, it can also afford the best raw materials.
Therefore, the performance of ultra-fine powder coatings is in many ways significantly superior to that of ordinary powder coatings, such as corrosion resistance, weather resistance, flexibility, adhesion, hardness, etc. Of course, if a strong resistance to mechanical friction is required, then a thin coating is not as good as a thick coating.
07
Examples of ultra-fine powder coating applications
1. Black parts
Most interior automotive parts can be coated with powder coatings, which mainly serve a protective function. However, because ordinary powders cannot be used to apply thin coatings, the coating film thickness is usually 60-100 pm, so they are not widely used.
Black ultrafine powders, on the other hand, do not have problems with hiding power or surface evenness. In practical applications, the film thickness can be reduced to an average of 20 pm, which saves a lot of costs. The corrosion resistance of the coating is equivalent to that of ordinary powders, and the hardness and adhesion have also increased.
2. Furniture, containers and other interior products
Some customers choose ultra-fine powder because they produce high-quality export products with high surface requirements. In order to achieve the best appearance quality, the film thickness is reduced very little, but the cost is not reduced. This shows that in the low-priced interior product market, the application of ultra-fine powder does not have a cost advantage for the time being.
3. Outdoor weather-resistant products
The first requirement for the spraying of aluminum profiles is excellent weather resistance, followed by better appearance. Ultra-fine powders use high-grade weather-resistant polyester and inorganic weather-resistant pigments to achieve coating products with very good performance in both aspects. More importantly, the cost savings are significant.
4. Automotive field
For many years, automotive clear coats have been considered a difficult area for powder coatings to enter. However, due to the advantages of powder coatings in terms of cost-effectiveness and environmental protection,
Recently, the successful application of one-pack powder coatings in the automotive coating field has led automakers and coating manufacturers to conduct extensive research in this area.
BMW was the first automaker in the world to use powder clear coats in its standard products. By the end of 2000, powder clear coats had been put into commercial production at BMW’s German factory, with a total of 500,000 cars produced.
5. Other application markets
Other markets for powder coatings include the use in pipes and the use of anticorrosive powder coatings to reinforce steel bars. These powder coatings are mainly based on pure epoxy systems (fusion bonded).
The rebar market is almost ignored in Europe, but from a technical point of view, this field is considered to have a lot of room for growth. Due to the different statistical classification methods in different regions, it is very difficult to assess the consumption of powder coatings in different fields.
When comparing the cost of powder coatings with some VOC (volatile organic compound) coatings that meet the selection criteria, it is important to pay attention to the total cost, including the cost of painting.
Compared to other environmentally friendly coatings, the advantages of using powder coatings in the actual painting process are an increase in raw material utilization from 95% to 99%; a 30% reduction in energy consumption (compared to traditional low-solids carbon paints); labor costs will be reduced by 40% to 50%; and the amount of material discarded due to surface defects will be reduced by about 4 to 6 times, resulting in a nearly 90% reduction in waste.
08
The progress of ultrafine powder coatings in various fields
The latest developments in coating equipment have resulted in coating lines that are easier to clean and change colors faster. The trend towards the development of low-temperature curing and highly reactive powder coatings can increase line speeds and save energy, making the economic advantages of powder coatings even more attractive.
MDF using powder electrostatic spraying has the advantages of excellent coating performance, high construction efficiency, and low energy consumption. The powder coating with 100% solid content can prevent the volatilization of harmful substances inside the wood after encapsulating the wood products, making it a veritable green product.
Of course, there is still room for improvement, such as the chemical storage stability of the powder: potential catalysts or additives that can prevent the base material from reacting at storage temperatures without affecting curing conditions; physical storage stability: increasing the glass temperature of the system without affecting the reaction rate and viscosity of the system.
Coil coating is a kind of pre-coating, which is different from the traditional “post-coating” process. Due to a series of advantages such as simplifying the production process, efficient construction, saving investment and operating costs, complying with environmental protection regulations, and the film performance being superior to traditional methods, coil coating has become one of the development directions of the coatings industry today.
Color plate production technology was first developed in the United States in 1927. China began to introduce coil coating and coating technology in the 1980s.
In the late 1990s, the consumption and production of color plates began to rise in China, and the growth momentum was extremely rapid. By the end of 2003, 124 enterprises had built 169 coating units with a production capacity of 8.74 million tons.
The powder coating device is under a strong electrostatic field. The rotating powder brush generates a cloud of coating powder. The solid coating particles in the cloud are highly charged and fly towards the substrate running at high speed, generating a large enough boundary penetration force. The powder particles are then evenly deposited on the surface of the strip.
With the country’s strict environmental protection requirements and cost-effectiveness considerations, the powder coating of coils will gradually become more widely recognized and will become the development trend of coil coating.
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