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Powder Coatings:

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1955- Dr. Erwin Gemmer patents fluidized bed application ... Electrostatic Fluidized Bed. Similar to above, but powder particles are charged. Flame Spray ... – PowerPoint PPT presentation

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Title: Powder Coatings:


1
Powder Coatings
  • History, Types, and Applications

James Baker
2
Outline
  • Conventional Coatings
  • Powder Coating History
  • Types of Powder Coatings
  • Advantages/ Disadvantages
  • Applications

3
Lacquers
  • -Lack of durability
  • -High maintenance
  • -High VOC content
  • Fast Drying
  • Deep shine

4
Enamels
  • Good flexibility and durability
  • Cross-linking
  • Long drying times
  • Oxidation

5
Urethanes
  • Dry fast
  • Very durable and flexible
  • - Isocyanate component is highly toxic

6
History
  • Late 1940s- Flame spraying of thermoplastic
    powder developed
  • 1955- Dr. Erwin Gemmer patents fluidized bed
    application
  • 1962- Electrostatic spray method introduced
  • Late 1970s- rapid growth in powder use in Europe
  • Early 1980s- rapid growth in North America and
    Japan
  • Today-
  • Fastest growing finishing technology in North
    America
  • Powder coatings account for gt10 of all
    industrial finishing applications
  • Powder coating engine blocks for automobiles
    is the largest volume job in the history of the
    powder industry

7
Application Methods
  • Electrostatic spray-
  • Most common method
  • High voltage, low amperage field generated by
    spray gun imparts electrostatic charge on powder
  • Charged powder sticks to grounded substrate
  • Object is heated in oven to cure, powder flows to
    form a continuous film

8
Application Methods (cont)
  • Fluidized Bed
  • Heated object is dipped into an air fluidized bed
    of powder
  • Electrostatic Fluidized Bed
  • Similar to above, but powder particles are
    charged
  • Flame Spray
  • Powder is air fed through a propane flame
  • Molten polymer is deposited on substrate
  • Suitable for non-conductive substrates or very
    large objects
  • Tribocharge
  • Similar to electrostatic spray, but no
    high-voltage system
  • Friction between powder and barrel induces weak
    static charge

9
Powder Coating Types
  • In general powder coatings offer excellent
  • Hardness
  • Corrosion protection
  • Chemical resistance

10
Epoxy
  • Excellent flexibility
  • Fair resistance to over-baking
  • Poor exterior durability (low UV resistance)
  • Epoxy-urethane hybrids
  • Similar to epoxy
  • Improved flow properties
  • - Lower hardness

11
Urethane Polyesters
  • Very good flexibility and weatherability
  • outstanding thin film appearance

12
Acrylics
  • Excellent color, gloss, weatherability
  • Excellent thin film appearance
  • Fair flexibility and corrosion resistance

13
TGIC Polyesters
  • Excellent exterior durability
  • - Exposure limits when spraying due to TGIC

14
Advantages of Powder Coating
  • No VOC emissions
  • Improved durability
  • Over-spray may be reused
  • Lower operating and maintenance costs for
    finishing lines

15
Disadvantages
  • Material must be able to withstand curing
    temperatures, gt260º F (125ºC)
  • Forming films thinner than 1.5mil is difficult
  • Electrostatic spraying may only be used for
    electrically conductive materials
  • Powder is highly flammable
  • Conversion from conventional to powder coating
    line requires large capital investment

16
Automotive Applications
  • Engine Blocks
  • Frames
  • Suspension and Wheels
  • Trim and Moldings
  • BMW and Volvo have developed powder clearcoats
  • Chrysler, Ford, and GM have powder clearcoats in
    development

17
Other Common Applications
  • Metal Objects
  • Appliances
  • Highway signs
  • Tools
  • Lawn and garden equipment
  • Office furniture
  • A/V furniture and equipment
  • Sports equipment
  • Non-metal Objects
  • Home-office furniture
  • Kitchen cabinets
  • Sinks/shower stalls
  • Ceramics

18
References
  • Industrial Paint and Powder Magazine
    http//www.ippmagazine.com/CDA/ArticleInformation/
    features/BNP__Features__Item/0,6897,119461,00.html
  • North Carolina DENR Division of Pollution
    Prevention and Environmental Assistance
    http//www.p2pays.org/ref/01/00777/alternat.htmGe
    neral20Description203
  • The powder coating institute- http//www.powderco
    ating.org/media/pressreleases/
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