What are the key points of the UV water-based process for custom solid wood?
As the state pays more and more attention to the environmental protection of the home industry, the requirements for corporate environmental protection are getting higher and higher. Painting is a special part of the manufacturing process of solid wood custom furniture and has become one of the focuses of the furniture manufacturing industry. Today, I’d like to take you through the mainstream UV and water-based painting processes in the field of environmentally friendly painting.
What challenges does traditional furniture coating face?
Traditionally, there have been three main characteristics of traditional coating as understood by furniture manufacturers.
1 Low production efficiency
From coating to drying, the process is repeated many times over a long period of time, sometimes taking up more than half of the total production time of the entire piece of furniture.
2 Harsh working environment
Whether it is the pungent smell or the VOCs released from traditional paints, there is a risk of harming the coating workers, and the workers are reluctant to approach the coating workshop.
3 Instability of quality
Due to the very low degree of automation in traditional painting and the high degree of uncontrollability of manual operations, coupled with the complexity of the painting process and the great emphasis on operating techniques, the resulting quality problems are a major headache for manufacturers.
In the new era of economic restructuring and a “low-carbon” economy, companies using traditional furniture coatings face increased pressure on environmental protection and production models. UV coatings and water-based coatings are therefore the key national support for the development of furniture coating projects. Therefore, the future development direction of furniture coatings will also be: UV coatings and water-based coatings.
UV-cured coatings
The emergence of UV coatings has been hailed as one of the most environmentally friendly types of paint. Their advantages include high efficiency during application, stability due to equipment coating, improved construction environment, fast curing speed, and recyclability. They can not only meet the needs of furniture manufacturers for high-speed process production, but also easily meet the environmental regulations of governments or legislative bodies. Judging from the current development of coating technology, UV coatings will become the main alternative to traditional coatings.
The main advantages of UV coatings (ultraviolet light curing coatings) are:
1. Extremely high solid content
2. Good hardness and high transparency
3. Excellent resistance to yellowing
5. Long activation period
6. High efficiency and low coating cost (normally half the cost of conventional coating) which is dozens of times the efficiency of conventional coating.
Solving five common difficulties in UV coating
However, in order to better achieve environmentally friendly painting, companies now need to solve the following four common difficulties in UV painting:
1. How to achieve UV?
Difficult to transform? Difficult to mechanize? Low efficiency?
Starting from the source design, consider the possibility of mechanized production, standardize parts, and change from fixed installation to disassembly.
2 What about late cracking and whitening of UV paint?
The main reasons for late cracking and whitening of UV paint are as follows. Paying more attention to the actual production process can effectively reduce the problem of late cracking and whitening of UV paint:
1. Short leveling section
2. No hot air
3. Too thick coating
4. Low light source energy (below 120)
3 Is UV varnish harmful?
The old-model varnish can injure hands and skin, so we need to take extra precautions when using it! The new LED-UV varnish developed by Junzi Lan has the characteristics of not injuring skin, good adhesion, short drying time, and good color perception, greatly improving the shortcomings of the old model.
4 Can mechanization reduce costs?
Blind mechanization is likely to increase operating costs and is unlikely to promote development. Therefore, when furniture manufacturers implement mechanization of production, we have the following suggestions:
1. No spraying of rollers
In practice, rollers and spraying are used cleverly.
2. Reasonable and neat arrangement
According to the order quantity, the production line is reasonably collected.
3. Avoid high and choose low, save time and electricity
Reasonable use of time periods for production work.
LED-UV curing coating
Under the pressure of upgrading production and environmental protection in the home furnishing industry, traditional UV curing has reached a bottleneck. The mainstream production process of mercury lamp irradiation will be phased out due to its high equipment price, high maintenance cost, fast attenuation of UV light intensity, high surface temperature of the irradiated component, bulky size, expensive consumables, mercury pollution and other defects.
At this time, the maturity of UV-LED curing technology has brought revolutionary changes to the curing industry. LED has the characteristics of constant light intensity, excellent temperature control, portability and environmental protection. Although the unit purchase cost is higher, its service life has increased exponentially, making the overall cost lower and promoting the improvement of the quality of the UV curing process and energy conservation and consumption reduction.
The performance of LED and traditional mercury lamps is compared as follows:
For LED-UV products that have solved these difficulties, there will be new breakthroughs in terms of leveling properties, fullness, sagging, interlayer adhesion, sanding and other properties, bringing simple, environmentally friendly and efficient coating effects to solid wood customization.
The following figure shows the actual coating application effect of LED-UV products:
▲Clivia Paint “Lan Elf” LED-UV Product Application Effect
Water-based coatings
As the concept of environmental protection becomes more deeply rooted, consumers are placing higher and higher demands on furniture products, and more companies are beginning to focus on water-based paints.
However, at present, the application level of water-based paints in the entire industry is still in its infancy, and problems such as uneven colors, bulging and cracking, and peculiar smells have always been technical bottlenecks that plague companies. The following is an analysis of the typical difficulties with water-based paints
1 How to prevent and deal with swelling of water-based paint
Water-based paint contains water, which causes the wood fibers to absorb a large amount of water. The water causes the wood fibers to swell, and the phenomenon of bulges appears around the wood pores. Water-based paint products have now overcome this problem. Using a swelling-proof sealer can effectively prevent swelling of the wood.
2 How to prevent and deal with yellowing of the paint film
Tannic acid in wood and glue can cause yellowing of the paint film. A special tannin-resistant sealing primer can effectively seal the substrate and protect the surface of the paint film from yellowing. Using a special tannin-resistant sealing primer can effectively solve the problem of yellowing of white paint.
▲Example of custom-made environmentally-friendly coating for solid wood in Wanjia Garden
3 Upgrading and transformation of spray paint booths
The biggest advantage of water-based paint is that it is water-soluble and has a low content of harmful substances (VOC), meeting national safety emission standards. Its film-forming substances mainly come from water-based resins. The three factors that affect the drying of water-based paint are temperature, humidity and air circulation. Therefore, upgrading the drying room is particularly important for water-based painting, which will determine the final result of the film formation of water-based paint.
▲Floor plan of the water-based spray paint room set up by Junzilan in Wanjia Home
UV primer + water-based topcoat (sealed)
Although the market for water-based paints is growing, the thickness of the paint film has always been a difficult problem. An insufficient paint film thickness first affects the feel of the wooden product, and secondly it does not provide good protection, and finally it also affects the visual effect.
Therefore, the first step to address this problem is to improve the hardness of the paint film of the water-based paint product itself. Secondly, the coating process of UV base plus water-based topcoat is adopted. Due to the strong hardness of the UV paint film, it can provide strong support for the water-based topcoat, and can fully meet the hardness requirements of traditional PU paint. After these technical improvements, the film hardness of water-based paint products can fully meet consumer needs.
If UV base + water-based topcoat is used, the labor cost of water-based painting will not increase, and the overall cost of paint will also be reduced. However, if water-based paint is used exclusively for the sealing coating, the water-based paint must be re-coated multiple times with primer to fill the wood pores, which causes the labor cost of sanding and spraying to rise sharply and production efficiency to decline. Therefore, the UV base + water-based topcoat painting process will be another key point for companies to “oil to water”.
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