European Coatings Conference, 4 – 5 February 2014, Düsseldorf, Germany
SHORT COURSE: PRINCIPLES OF PARQUET AND FURNITURE COATINGS
Dipl. Chemie-Ing. Jorge Prieto, 3P International Coating Consulting
Copyright Pagnosoft© - 3P Lünen
Region [kt] Europe 509 China 560 NAFTA 215 L-America 164 Asia 142 RoW 101
Quelle: Bayer 2009, Irfab 2008/2009, KNG 2008, SRI-CEH 2009, Eastman 2010, DSM 2010, 3P 2013
Europe and China / Asia are the biggest market for Industrial Wood Coatings
* Deco/ Field applied Wood Flooring products are included
Industrial Wood Coatings Global Market 2011: 1690 kt*
Europe30,10 %
China33,10 %
Asia8,40 %
L.-America9,70 %
NAFTA12,70 %
RoW6,00 %
Industrial Wood Coatings 2012 European Market by Outlet (kt)
Industrial Wood Coatings (paints)
Source: Bayer 2009, Irfab 2008/2009, KNG 2008, SRI-CEH 2009, Asefapi, DSM 2010, Eastman 2010, 3P 2011
The Furniture market is the largest outlet for Industrial Wood Coatings in Europe
Joinery23 %
Furniture71 %
Flooring6%
* Deco/ Field applied Wood Flooring products are included
European Coatings Market for Furniture 2011 by Technologies 325 kt
Technologie [kt] 2C-PU-Lacquers 110 Radiation Curing-Lacquers 75 Nitrocellulose-Lacquers 49 Waterbased-Lacquers 62 Acid Curing-Lacquers 16 Unsaturated Polyester-Lacquers
13
Quelle: 3P 2013
Solventborne Polyurethan-Lacquers dominating the Industrial Wood Coatings Market
Nitrocellulose 15% Acid Curing
5%
Unsaturated Polyester
4%Waterbased19%
RadiationCuring
23%
2C-PU34%
Furniture Coatings Market Europe by Application (volume)
Wood Coatings market for Flooring Description
European industrial and manually coated Wood Flooring
• In all used literature a distinction is made between industrial floor coatings (factory applied) and
(re-) coating of already used or freshly applied floorings (field applied / on-site) by the do-it-
yourselver or parquet flooring professional.
Polyurethanes10,5 %
Furniture Coatings Market Europe by Application (volume)
Wood Coatings market for Flooring (Paints) Europe by Segment and Technology (2012)
Industrial On-site (Field applied)
1C water based 56 % Formulations contain Acrylic and PUDŒs
2C PU water based 19,1 %
Alkyd enamel Oxidative 10 %
Acid curing 3,5 %
Oil (oxidative curable) 0,7 %
1C water based (UV-curing) 0,2 %
• In Factory applied coatings, 100 % UV-coatings are dominating.
• The use of oxidative curing oils has grown steadily
• In Europe, water based sealing systems are dominant in field applied floor coatings.
Paint formulations
Quelle: Bayer 2009, 3P
Ecofriendly Coating resins by technology World Consumption* 2008 – 2016 (forecast)
Quelle: 3P 2011
emergence growth maturity age
Powder Coatings (thermisch- und
UV-härtend)
Waterborne-Lacquers
Radiation-Lacquers
1C- and 2C- Polyurethane-Lacquers
Unsaturated-Polyester Lacquers
Acid Curing-Lacquers
CN-Lacqers
Curve of live of different wood coatings technologies for industrial use
Quelle : J.Prieto, J. Keine, Holzbeischichtung
0
50
100
80 70 70 10 10 5
Geh
alt
an o
rgan
isch
en L
öse
mit
tel
[%]
CN Acid-Curing 2C-PU UP Radiation Curing Waterborne Lacquers ingredients: Formaldehyde Isocyanate Styrene Monomers
Solvent content [%]
Emission behaviour of different wood coatings technologies based on 100 % clear-coat
Industrial Wood Coatings
Interior Exterior
Joinery Furniture Flooring Joinery
Window frames
Doors / Panels
Garden furniture
Cladding shutters
Skirting boards
Window frames
Doors / Panels
Assembled for offices
Assembled for residential homes
Solid wood parquet
Multilayer hardwood flooring
Flat stock for self assembled furniture
Kitchen and bathroom cabinets
Coated Laminate
Industrial Wood Coatings Segmentation by end-use applications
Quelle: 3P 2011
Wood-Stains
Resins Organic dyes
thixotroping agent, thickenerr,
neutralisation medium Pigments
Additivee defoamer,
silicone oils, dispersing agents
Raw materials for Stains (indoor) Solvent- und waterborne wood stains
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Typical roller coat application processes for wood stains
Quelle : J.Prieto, J. Keine, Holzbeischichtung
…..
…..
…..
…..
…..
A
E
D
C
B
1 Single roller coater with foamed rubber roller
2 Conveyor belt and evaporation zone
3 Jet dryer 60 – 80 ˚C air circulation temperature
4 Ejector brushes (2)
5 Single roller coater with a hard roller for stain application
6 Single roller coater with a hard roller for UV-coat application
7 UV-Tunnel with two mercury lamps (80 W/cm)
8 Sanding machine
9 Dust removal installation
1 2 3
1 2 4 3
1 2 5 3
6 2 7 8 9 2 5 3
5 2 3
Typical roller coat application processes for wood stains
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Foamed rubber roller
General composition of cellulose nitrate wood lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Cellulose nitrate
Resins
plasticizer
Pigments / filling material
Additives
Solvents
CN-Lacquers
Molecular structure of cellulose and cellulose nitrate
Quelle : J.Prieto, J. Keine, Holzbeischichtung
O
OH
OH
O
CH2OH
O O
OH
OH
CH2OH
OO
CH2OH
OH
OH
OO
CH2OH
O
OH
OH OH
OH
O
CH2OH
O O
OH
OH
CH2OH
O
General composition of acid curing lacquer (AC-Lacquer)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
AC-Lacquers
Amino resins Urea- und
Melamine resins
Resins Alkyd resins
Cellulose nitrate
Organic solvents Esters, Ketones,
Aromatics, Alcoholes
Pigments, Filling materials, Matting agenst,
Thixotroping agents
Acid Para-Toluenesulfone-
acid
Base Lacquer Hardener
Additives
Anti foaming agents, Silicone oils,
Amines, plasticizer
Structure of long oil alkyd resins
Renewable Raw Materials – oxidative curable
Triglycerids fatty acid phthalic acid
Source: P-Marie Baudoin, Vandeputte Oleochemicals, Industrial applications of linseed oil and industry outlook
Renewable Raw Materials – oxidative curable
Quelle: P-Marie Baudoin, Vandeputte Oleochemicals, Industrial applications of linseed oil and industry outlook
Renewable Raw Materials
Comparison of color between blown and stand oil
Quelle: P-Marie Baudoin, Vandeputte Oleochemicals, Industrial applications of linseed oil and industry outlook
Renewable Raw Materials
trends 2013/2014 colouring trends
„Antique-like effects upon solid oak“
Quelle Bilder: 3P
oak natural bright medium dark
Quelle : J.Prieto, J. Keine, Holzbeischichtung
UP-Lacquers
Unsaturated polyester resins
Reactive thinner Styrene,
Vinyltoluen
Paraffine wax melting range
between 50 – 60 ˚C
Pigments, filling materials, matting agents,
thixotroping agents
Accelerators e.g. Cobalt salts
Initiator Peroxide
Base coat Hardner Accelerator
Additives
Anti foaming agents, Silicone oils,
inhibitors
General composition of UP-Lacquers (unsaturated Polyester)
Principle polycondensation to produce unsaturated Polyester
Quelle : J.Prieto, J. Keine, Holzbeischichtung
COOHHOOC
O
O O
O
OO
O
O
O
O
OR R
O
O
O
O
+ +- H2O
OHHO
Maleinsäure Propylenglykol-1,3 o-Phthalsäure
Workflow to produce high gloss surfaces with unsaturated polyester resins for car interiors (wood veneer)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Day 1 Sanding and wood staining
Day 2 Isolation of the wood ingredients 2C-PU-Lacquer coat with a patina (3 – 20 h)
Day 3 Application of the UP-Lacquer (unsaturated Polyester)
4 – 10 layers (spraying process). Each layer approx. 200 g/m2 (wet). The total amount is 700 – 800 µm (dry).
Day 4/5 Drying / Curing
The drying time should be 24 to 48 hours (23 °C/50 % rel. Air humiditiy) Luftfeuchte).
Day 6 Sand of the Polyester surfaces
Graded sanding to get a flat surface.
Day 7 Polishing
It is necessary to polish the surface to get the high gloss effect.
Different curtain coater application processes for unsaturated polyester Lacquers
ca. 15 g/m2 80-450 g/m2
RT 1. Active base coat process
Cobalt paint
Per unit 125 g/m2
per unit 125 g/m2
Approx.. 15 Min RT
2. Double head - (1:1) process Cobalt- paint Peroxide- paint
Co- paint Peroxid-paint
200 g/m2 100 g/m2 200 g/m2
RT
10-20 Min.
3. Sandwich-process Co- paint Peroxid-paint
Co-paint
4. Reverse- (4:1) process Co- paint, Peroxid-paint
400 g/m2 100 g/m2
RIM-Process (Reaction Injection Molding)
Quelle: BayerMaterial Scienes
tool
moulding
mixing chamber
dosing machine depot
depot
General compositon of 2C-PU-Lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
2-C-PU Lacquer
Organic solvent Ester, Ketone,
Aromatics
Resins
Polyacrylate Polyester
Alkyd resins
Polyisocyanates
Base coat Hardner
Additives
Anti foaming agents, Silicone oils, catalysts Amines, plasticizer,
water scavengers
Pigments, filling materials, matting agents,
thixotroping agents
Cellulose acetobutyrate Cellulose nitrate
Allgemeine Zusammensetzung von 2K-PUR Holzlacken
Quelle : J.Prieto, J. Keine, Holzbeischichtung
NCOOCN
O OH
N N OOH
O O
OHOH+
Diisocyanate Diol
Polyurethane
Polyaddition to produce polyurethane lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
High-gloss Lacquer Base coat withe 2C-UP or 2C-PU-Filler Top-Coat pigmented 2C-PU (Spraying process)
Optional :
2-C-PU-Isolation
Isolation and stabilisation of the milled edges and interior
profile
2-C-UP-Filler white (styrene) 300 – 500 g/m² wet application in different working steps
2-C-PU-Filler white alternative
to 2-C-UP-Filler white
150 – 500 g/m² 1 – 3 working steps
Drying / chemical curing at
room temperature
23˚C und 50 % rel. air humidity
Paint sanding 400 – 500er grain
High-gloss top coat 2-C-PU-Topcoat in different colours
1 – 3 application steps with intermediate drying (15 – 30
min. at 23˚C and 50 % rel. air humidity
Drying / chemical curing at
room temperature
At least 24 – 48 hours at 23˚C and 50 % rel. Humidity
Post-treatment Depending of the quality requirement
Sanding and polishing of the surface
Quelle : J.Prieto, J. Keine, Holzbeischichtung
7. 6. 5. 4. 3. 2. 1.
1. Conveyer belt2. Dust collection system3. Conveyer belt (encapsulated area)4. Dedusting unit with compressed air5. Spraying robot (encapsulated area)
with 4 spraying guns6. Drying rack (with 6 drying zones) approx. 25 – 30 °C
actual time approx. 45 minutes7. Conveyer belt
Application line for High-gloss 2C-PU-Lacquers (pigmented)
General composition of water-borne lacquers
Water-borne Lacquer
Resins • Dispersions / Emulsions
Reactive thinner, hardner • saturated and un- saturated Monomers/ Oligomers • Polyisocyanates
Fotoinitiator and Synergists for UV-curing water-borne lacquers
Pigments, filling materials, Matting agents
Additives Anti foam agents, Leveling agents, Inhibitors, Neutralisation medium, Thickner, Emulsifiers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Quelle : J.Prieto, J. Keine, Holzbeischichtung
0 % addition of solvent
1 % addition of solvent
5 % addition of solvent
4 % addition of solvent
2 % addition of solvent
6 % addition of solvent
microscopic imaging Stereomicroscope , 12,5 x magnification
The influence of added quantity (coalescing agents for film forming of polyacrylic dispersion)
Differences in Polyacrylic dispersions used for in- and outdoor applications (Wood Coatings Lacquers)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Polyacrylic dispersions, used for furniture lacquers show frequently different properties to polyacrylic dispersions used for outdoor wood lacquers.
• high film hardness
• low elasticity
• higher minimum film-forming temperature
• better resistance to chemicals
• varied morphology
Structural parameter of aqueous dispersion particles
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Wasser
Structural parameter
D
C B
A
A Initiator B Emulsifier C Protectiv colloid D Polymer
Polymer properties Chemical composition Glas transition temperature (Tg) Cross-linking Molecular weight Functionalgroups
colloid properties Emulsifier, type, quantity
charge of the latex cover protective colloid Particle properties Particle size (50-200 nm) Particle distribution Particle morphology
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Individual particle (hard)
Individual particle (soft)
Core-shell particle
Hemispheric particle
Inverse Core-shell particle
Particle with „Raspberry-Morphology“
Particle producing through gradient process
Particle morphology of single- and multi-phase aqueous emulsions
The influence of the polymer structure of polyacrylate dispersions to the penetration depth in pine wood (optical microscope)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Grobteilige Acrylatdispersion
geringe Penetration (2 Zellschichten)
Feinteilige Acrylatdispersion ca. 50 nm
gute Penetration (3-6 Zellschichten)
coarse-particle polyacrylic dispersion low penetration (2 cell layer)
fine-particle polyacrylic dispersion good penetration (3 – 6 cell layer)
A B C B A
A = Polyester-/Epoxy-/Urethan-/Polyesteracrylat
B = Diisocyanat
C = Hydrophilierung (Carboxylat-, Ammonium- oder Sulphonatgruppen)
A = Polymeres oder monomeres Diol
H
N
O
H
N
H
N
O
H
NCH3 COO
OO
O
NR3+
_
O
O
O
O
O
OR O
R
O
O
Structure of high molecular, acrylate- functional Polyurethanedispersionen
Quelle: Weikard, J., Fischer, W., Lühmann, E.: Haftung von UV-härtenden Lacken. Bayer AG
Important water-borne lacquer technologies for wood coatings
Quelle : J.Prieto, J. Keine, Holzbeischichtung
• 1-C-Water-borne lacquers (physical drying) non self-crosslinking mechanism (NSC)
• 1C-Water-borne lacquers (physical drying and self-crosslinking mechanism) SC
• 1-C-UV-curing-Water-borne lacquers, physical drying or not physical drying
• 2-Component-Polyurethane-Water-borne lacquers (addition of polyisocyanate as hardner)
• 2-Component-Polyurethane and UV-curing water-borne lacquers (dual cure lacquer)
addition of polyisocyanate as hardner
Structure of polyether modified polyisocyanates (HDI-trimeric)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
OO
OO
OO
OCH3
N
O
N
N
N
O
O O
OCN
OCN
H
Quelle : J.Prieto, J. Keine, Holzbeischichtung
N
N
N
O
O O
OCN
NH
N
O
OO
OO
OO
OCH3
O
N
N
N
O
O O
OCN
OCN
OCN
Structure of polyether modified polyisocyanates (HDI-trimeric) (HDI trimeric / Allophanat-Type)
Structure of aminosulfone acid modified HDI-trimeric
Quelle : J.Prieto, J. Keine, Holzbeischichtung
H
N NR
SO3
ON
N
N
O
O O
OCN
OCN
-NR3H
+
Quelle : Bayer MaterialScience, „Toolbox for waterborne 2C Polyurethane coating systems“
PIC-in-polyol emulsion containing fine droplets, formulated with a waterborne 2 component PU system
Quelle : Bayer MaterialScience, „Toolbox for waterborne 2C Polyurethane coating systems“
PIC-in-polyol emulsion containing coarse, non-uniform droplets, formulated with a waterborne 2 component PU system
Air • Temperature Tair (t) • Humidity • Air flow velocity v
v
Paint film • Temperature Tpaint (t) • Thickness d (t) • Formulation
Substrate • Temperatur TSubstrate (t) • Wood humidity F • Absorption characteristics (t)
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
influencing factors in the drying of water-borne lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
without heating with heating 50 ˚C
High swelling low swelling
The influence of the heating of the substrate before coated to reduce the swelling of the wood fibre
Spraying line with vertical dryer cycle time approx. 25 – 50 minutes
Example for an application line for pigmented 2C-PU-UV-curing waterborne lacquers
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
The influence of the UV-curing parameters on the coffee resistance
2C-PU-UV-Waterborne lacquer (structured, pigmented) Base coat + 5 % hardner
coffee-test
Applied quantity: approx. 150 g/m2 Air dryer: approx. 30 minutes 40 – 48 ˚C UV-curing: 1 x Ga-lamp + 1 x Hg-lamp half-load , object temperature 44˚C
coffee-Test
Applied quantity: approx. 150 g/m2 Air dryer: approx. 30 minutes 40 – 48 ˚C UV-curing: 1 x Ga-lamp + 1 x Hg-lamp full load , object temperature 52˚C
Quelle : J.Prieto, J. Keine, Holzbeischichtung
General composition of UV-curing lacquers
UV-Lacquers
Resins, UV-curable
Reactive thinner, Monomers
Photoinitiators, synergists
Pigments, filling materials, matting agents,
thixotroping agents
Additives
defoaming agent, silicone oils, inhibitors, stabilisers
• Increasingly stringent by government regulations to solvent emissions (1999/13/EG) 31. BimSchV, EU-VOC-Regulation
• Optimisation and simplification of production processes
• To improve the properties of the surfaces (scratch resistance, hardness, chemical resistance
Why are the uv-curing lacquers gaining in the last years in the market?
1967 introduction of the UV-PE-process in Germany through the Bayer AG company (Roskydal-UV-10)
Paint formulations with paraffin based , styrene based unsaturated polyester resins („Holzpolierlacke“ wood polishing lacquer)
Unsaturated polyester 65% in Styrene 79,00 % Styrene (Reactive thinner 16,15 % Benzoinisopropylether (Photoinitiator) 4,00 % Highly dispersed silica (thickner) 0,75 % Paraffin wax melting point 42-58 ˚C 0,10 % ------------- 100,00 %
Benzoinisopropylether
History of the uv-curable lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
500 µm
Mercury low pressure lamps
„UV-Angelierung“
UV-Paraffin-Polyester
Substrate Substrate
floating of the paraffin wax to the surface
Substrate
UV-curing
Mercury high pressure lamps
Substrate
cured paint film
UV-hardening methods for paraffin based, unsaturated polyester lacquers
Quelle : J.Prieto, J. Keine, Holzbeischichtung
R 1 C O
O
R 2 OHOH n
R 1 C O
O
R 2 OO n
OO
O
OH
+
2
2 H2O
+
OH-functionell Polyester Acrylic acid
Unsaturated polyester acrylates
Unsaturated polyester acrylate - hardness/elasticity
Hard or elastic are possible Hard and elastic is limited
Pendel hardness (König) in [s]
• a wide range of properties
• In most cases you need reactive thinner to reduce the viscosity
• low cost resins
• The main application are paints for wood, paper, printing inks ect.
Unsaturated polyester acrylates
reaction equation to produce polyether acrylates
Polyether + 3
- 3
O
O
O
O
O
O
O
Polyether
OH
O
O
OHH
O
H
H 2
Polyether acrylates
acrylic acid
Amine modified polyether acrylates (Michael-Addition)
Polyether Polyether+
Polyether PolyetherO
O
O
O
O
O
O
O O
ONR
HH
OO N
RO OO
O
O
O
O
O
O
O
O
O
Polyether acrylatee
• In comparison to polyester acrylates lower viscosity and molecular weight
• Oligomers with lowest viscosities
• processing without reactive thinner possible
• High uv reactivity and low viscosity
Polyether acrylates
Synthesis of epoxy acrylates
OOR + 2
O
OH
O
O
R
OH OH
O
O
EpoxidacrylatEpoxid
wobei R beispielsweise =
O O
OH
OO n
Acrylic acid
Epoxy acrylates
• Aromatic epoxy acrylates dominating the market
• Makes possible to formulated very high uv reactive lacquers with high hardness and very good scratch resistances
• High viscosity need reactiv thinner
• Very good adhesive strenght and exellent wetting behaviour of pigments
Epoxy acrylates
0
2
4
6
8
10Härte
Elastizität
Zähigkeit
Abriebfestigkeit
Haftung
Viskositätsspektrum
Chemikalienbeständigkeit
Reaktivität
Range of properties aromatic epoxy acrylates
hardness
elasticity uv reactivity
Chemical resistance
Viscosity spectrum
Adhesive strenght
abrasion-resistance
toughness
NCO
NCO
OH O
O
+ +
Polyol Toluylendiisocyanat TDI Hydroxyethylacrylat
2 2R OHOH
O NH
O
NH
O
O
O
O
NH
NH
O
O
OO
OO
R
Urethane acrylatee
• very good toughness, chemical- resistance and good adhesive strength
• very good abrasive resistance and flexibility
• special to formulated lacquers for e.g. pvc flooring, parquet, printing inks, leather coatings and for plastic coatings
• suitable for oudoor (aliphatic typs)
Urethane acrylates
• a wide range of properties
Formulation clear coat: 57,5 Polyester acrylate 20,0 Polyurethane acrylate 10,0 Reactive thinner 6,0 Matting agent 2,0 Wax 1,5 Additives 3,0 Photoinitiator
Formulation of an UV-Topcoat for parquet (roller coater)
Formulation UV-base coat: 60,0 Polyester acrylate 20,0 Polyurethane acrylate 5,0 Reactive thinner 6,0 Corundum 4,0 Matting agent 2,0 Additives 3,0 Photoinitiator
Formulation of an uv base coat for parquet (roller coater)
The influence through oxygen inhibition depending from the applied quantity
Realtime-spectroscopic measurements
conversion rates of the double bonds depending from the applied quantity
Quelle: Eigene Messungen Jorge Prieto, 2009
OCNN
O O
O
O
O
N
H
N
O O
O
O
O
N
H
NCO
1,1
Patentschrift: WO 00/39183
Chemical structure of the Isocyanato-Acrylate ICA 9000
Quelle: BASF SE Ludwigshafen
properties: NCO-Wert: 15 % DB-Gehalt: 2 mol/kg Molekulargewicht: 800 g/mol Festkörper (nfA): 100 % Viskosität: 1200 mPas (23˚C) Rest HDI: < 0,5 % Geruch: sehr gering
OH OH OHOH
OCN R OCN R OCN R OCN
O O
R
NH
R
NHO O
O O
R
NH
R
NHO O
UV-Angelierung
„Dual-Cure“Adhesion promoter on wood
0
500
1000
1500
2000
2500
1300 mg/m2
5 mg/m2
Extrakt TPGDA [mg/m2] 2250 mg/m2
160 mg/m2
Buche UV-Decklack
mit 40 % TPGDA
Buche UV-Sperrgrund + UV-Decklack
mit 40 % TPGDA
Eiche UV-Decklack
mit 40 % TPGDA
Eiche UV-Sperrgrund + UV-Decklack
mit 40 % TPGDA
Extraction results of different UV-coatings with and without Dual-Cure barrier-primer
adhesion problems between the two layers
under cured UV-clear coat on MDF-substrate
Adhesive strenght problems between a not full cured uv base coat
and a 2C-PUR-Top-Coat (white pigmented)
Quelle: Jorg Prieto, 3P
O O
O
HO
.
HO
.+h v
HO
H- .
O
O
. Hydroxy-cyclohexyl-Radikal
Benzaldehyd Geruch nach Bittermandelöl
1-Hydroxy-cyclohexyl-phenyl-ketone
Cyclohexanon
Benzil
+ H.
O
H
Cleavage products of photoinitiator (alpha-Hydroxyketones)
OOH
CH3CH3
O
OOH
O
CH3CH3CH3 CH3
O
OH
O
CH3CH3
CH3CH3
OH
OHCH3
CH3
. +.
+
Benzil Aceton
1-phenyl-2-hydroxy-2-methyl-propan-1-on
Cleavage products of photoinitiator (alpha-Hydroxyketones)
wet film paint shrinkage thorught dryed paint film solvent evaporation
Schematic figure Matting of coatings
Querschnitt eines mattierten Lackfilms
matt surface uv coating
Quelle: Foto Degussa/Evonik
Cross-section through a matting paint film
very good W/G/N/N high N/N
W/G/W W/G/N/N
N/N W/G/W
not optimum W low W
surface quality Gloss (uniformity of the paint )
W = 1 x roller coater N/N = roller wet in wet w/w G = „slightly cured “ (not full curing paint film))
Effect of the application and curing process to quality and gloss results (roller coater)
47
38
26
29
25
39
34
25
35
39
24
0
20
40
60
roller coaterwet/wet
roll coater not fullcuring wet/wet
Walzen gelierenWalzen
roller coater notfull curing a.roller coater
cold substrate
hot substrate
hot substrate + lacquer
Gloss 60˚
cold substate (Gloss in relation to roller wet/wet)
100% ca. 80 % ca. 50 % - 55 % ca. 50% - 60%
23
Degree of gloss (100 % UV-Lacquer) depending on the temperature of the lacquer and roller coater process
Quelle: Prieto/Kiene “Holzbeschichtung”
• Dipping process
• Flow coater
• Drum process
• Spraying
• Curtain coater
• Roller coater
• Vacuum process
Application processes to coat wood pieces
• Manual spraying stations with turnstiles or hanging of parts
• Spray booth in the cycle with overhead or board conveyors
• Automatic surface spraying system in continuous mode for
flat components
• Automatic surface spraying system (robotic spray system in
batch mode )
Spraying processes in the wood coatings industry
Walther Trowal GmbH & Co. KG Rheinische Straße 35-37 D-42781 Haan
Coatings drum to coat small pieces
Trommeln / drum process
Prinzip der Gießmaschine
Lackbehälter
Lackpumpe
Vorschubrichtung
Transportband
Gießkopf
Lackvorhangaufgegossener Lackfilm
Holzwerkstück
Lackauffangrinne
Lackzufuhr
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
Principle of the curtain coater machine
Conveyer belt
pump
Wood substrate
Paint supply Paint curtain
Feed direction
Paint reservoir
Depositing head
Applied paint
Paint collectors
Roller coater (unidirectional principle)
Application roller
Paint
Substrate
Counter roller
Blade
Dosing roller
Feed direction
Blade
Substrate
Paint
Application roller Dosing roller
Feed direction
Counter roller
Roller coater (unidirectional principle)
Sanding Wood stain UV-base coat UV-base coat UV-top coat
Application process for furniture - Roller coater process -
Quelle: Karl Heesemann Maschinenfabrik
Längsaggregat / Queraggregat / cross and longitudinal sanding Queraggregat / Längsaggregat / Bürstenwalzen Anwendung: Flexible Konfiguration für furnierte Platten mit Längs- und Querfurnieren
Sanding machine for wood
1. Conveyer belt 2. Sanding machine 3. Dust cleaner unit 4. Roller coater (smooth roller ), UV base coat approx. 8 – 10 g/m2 5. UV-tunnel with 2 mercury lamps 80 W/cm, (not full cured) 6. Roller coater (smooth roller), UV base coat approx. 8 g/m2 7. UV-tunnel with 3 mercury lamps 80 W/cm („full curing“) 8. Sanding machine
9. Dust cleaner unit 10. Roller coater (smooth roller), UV top coat 11. Roller coater with fluted structured rubber roller, approx. 30 Shore and 80 threads per inch Wet in wet application (Pos. 10 and 11 approx. 25 – 30 g/m2) 12. UV-tunnel with 4 mercury lamps 80 W/cm („full curng“) 13. Conveyer belt
Line speed 20 – 25 m/min maple, beech, oak, cherry veneer
UV-roller coater line for furniture
1 2 3 4 5 6 7 8 9 10 11 12 13
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
Line speed 30 – 40 m/min Parquet flooring like maple, beech, oak
1. Conveyer belt 2. Sanding machine 3. Dust cleaner unit 4. Roller coater (smooth rubber roller) UV-Primer (water based) approx. 10 g/m2 5. Jet dryer 80 – 90 ˚C 6. Filling roller coater for UV-Filler, approx. 25 – 30 g/m2 7. UV-tunnel with 2 mercury lamps 80 W/cm („not full curing“) 8. Roller coater (smooth rubber roller)
UV base coat (Anti-abrasiv coat) approx. 10 – 12 g/m2
9. UV-tunnel with 2 mercury lamps 80 W/cm („not full curing“) 10. Roller coater (smooth rubber roller) UV base coat (Anti-abrasive coat) approx. 10 – 12 g/m2
11. UV tunnel with 2 mercury lamps 80 W/cm („not full curing“)
12. Transport unit (curve) 13. Roller coater (smooth rubber roller) UV base coat (sanding base coat) approx. 10 g/m2
14. UV tunnel with 3 mercury lamps 80 W/cm („full curing“) 15. Sanding machine 16. Dust cleaner unit 17. Roller coater (smooth ruber roller) for UV top coat, approx. 5 – 8 g/m2 18. UV tunnel with 2 mercury lamps 80 W/cm („not full curing“) 19. Roller coater (smooth ruber roller) for UV top coat, approx. 5 – 8 g/m2
20. UV tunnel with 4 mercury lamps 80 W/cm („full curing“) 21. Conveyer belt
21 20 19 18 17 16 15 14 13
UV-roller coater line for wooden parquet
1 2 3 4
5 6 7 8 9 10 11 12
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
1. Appearances: Leveling, homogeneity, matting effect, pore wetting,
brilliance, structure, gloss
2. Mechanical: scratch resistance, stress due to shock (Impact-test),
abrasion resistance, adhesive strength (Cross-cut or Coin-test)
3. Chemical: EN 12720, humidity and dry heat, cigarette ash
4. Test chamber: Emission/VOC-, Cold-check-Test,
Yellowing (Xeno-, Sun-Test), Weatherometer
Testing of furniture surfaces
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Test standards for furniture surfaces
Test standard: No.
DIN 68861-1:2011-01 Furniture surfaces Part 1: resistance to chemical attack
DIN 68861 Part 2 Furniture surfaces - Part 2: Behavior at abraison DIN EN 15185
DIN 68861 Teil 4 Furniture surfaces - Part 4: Behaviour at scratches
EN 438 Part 2 Determination of the resistance against cigarette burn acording to EN 438 part 2
EN 15187 Light fastness according to EN 15187
DIN EN 12720 Furniture Stain resistance according to EN 12720 (resistance against cold liquids)
DIN EN 12721 Furniture Resistance against wet heat according to EN 12721
DIN EN 12722 Furniture Resistance against dry heat according to EN 12722
DIN EN 13501-1:
2010-01
Fire classification of construction products and building elements – Part1
IOS-MAT-0066 This specifications describes the IKEA minimum requirements on surface coatings and coverings in respect of chemical content,
physical properties, visual qualities and documentation.
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Stain resistance according to EN 12720 (resistance against cold liquids)
Quelle : J.Prieto, J. Keine, Holzbeischichtung
Example for a test device for determination of light fastness according to EN 15187
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