engineering gf paints and...
TRANSCRIPT
EngineeringGFPaintsandCoatingsInstructors:RyanDenny&AlexHade
TableofContents1. Briefhistoryofthepaintsandcoatingsindustry2. Compositionofmodernpaintsandcoatings3. RawMaterials4. Manufacturingprocess5. QualitycontrolandExperimentaltestingprocedures6. Applicationtechniques
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Introduction1. Tryandimaginesomethingthatdoesnothavea
coatingonit2. PerhapstheWorld’ssecondoldestprofession3. Constantlyevolvingwithnosingleinventor
a. Oil-based,solventborne,waterbornetechnologiesb. Advancesinrawmaterialtechnologyc. Greeninitiative(ZeroVOC)
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PaintsandCoatingsTimeline
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••30,000yearsagocavedwellersusedcrudepaintstoleaverepresentationsoftheirlives••1,000BCGumArabicfirstusedtodeveloppaintsandvarnishes
••600BC-400ADVariouscivilizationsbeginusingoilsasvarnishesandpigmentandbindercombos••1500sArtistsbeginaddingdryingoilstohastenevaporation;linseedoilbecomesthemostcommon
••1856HenryPerkindiscoversfirstrealsyntheticdye••1865D.P.Flinn obtainspatentforthefirstwater-basedpaint
••1867D.R.Averillpatents"ready-mixed"paints••1930sAlkydsforhousepaintsandindustrialuse
••Late1930sEpoxiesaredevelopedforindustrialuses••1940sNewsyntheticbindersaredeveloped(polyurethanesandacrylics)
••1970sPowdercoatingsaredeveloped••TodayhybridandUVtechnologiesarebeingdeveloped••Currentlyenvironmentalregulationsarepushingwater-basedlowVOC/zeroVOCpaintsandcoatings
Composition1. Vehicles
a. Solids- Resinb. Volatiles- Solvents
2. Pigmentsa. Color- hidingpigments(TiO2,Carbonblack,Redironoxide)b. Inert- fillerpigments(calciumcarbonate)c. Effectpigments(Metallic)
3. Additivesa. Dispersantsb. Driersc. FlowandRheologicalmodifiersd. Substratewetting/surfacetensionmodifiers 5
Composition
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MilkPaintComposition
ChalkPaintComposition
Pigments
Volatiles
ResinSolids
Additives
• Paintismanufacturedandrawmaterialsarepurchasedviaweightforaccuracy.
• Paintisusedandsoldbyvolume6
CompositionalVocabularyWeight/Gallon=weightperunitvolumePigmenttoBinderratio=pigmentweight/resinsolidsweightPigmentVolumeConcentration(PVC)=pigmentvolume/volumesolids(criticalPVCisapproximately60%)VOC=weightoforganicsolvent/gallon-water
*NotethatwaterdoesnotcountinthecalculationofVOC,soagallonof100%organicsolventhasthesameVOCasagallonof50%waterand50%organicsolvent
*Notesomeorganicsolventsareexempt,meaningtheydonotcontributeVOCtothecalculation.HenceyoucanhaveapaintorcoatingthatsayszeroVOCthatstillhasorganicsolventwithinit 7
Solvents• Aliphatic• Aromatic• Alcohols• Glycolethers• Ketones• Acetates• Water• Blendsofthesolventsabove
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Water1. Considereda“universal
solvent”2. Physicalcharacteristicsgovern
theapplicationofwaterbornecoatings
3. Evaporationrateistemperatureandhumiditydependent
a. Controls/Effectsthedryrateandopentimeofthecoating
b. Optimumconditionsare70Fand40%humidity
4. Airmovementwillalterdrytime 9
VOC’s1. Organicsolventsareregulatedbyhowmuchozone/smog
formationtheycausecomparedtoethaneasastandard2. Exemptsolventsdonotcontributetosmogformationorthe
formationisconsiderednegligiblea. Acetone,Methylacetate,andT-butylacetatearesomeexempt
solventsb. Noticethatanexemptsolventcanstillbetoxictohumanseven
thoughitisnotregulatedasaVOC
3. Apaintorcoatingcanandwillhaveotherorganicsolventswithinthemeventhoughtheyareconsideredzero/lowVOC
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IndustryStandards&Regulations
VOC:volatileorganiccompound;limitedtolessthan420g/LorlowerdependingonlocationLabeling:certainmaterialsrequirespecificwarningsSafetyDataSheet(SDS):mustmeetOSHAstandard,mayneedANSIcompliance
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ResinBinders1. Alkyds2. Polyesters3. Acrylics4. Latexes5. Melamine6. Urethanes7. Epoxies8. Hybrids
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AlkydsAlkydsaremodifiedwithoilandweusethemineachofouroil-basedproductsonthemarket.
OilTypes
Drying Semi-Drying Non-Drying
Linseed Soya Coconut
Tung Safflower Castor
DehydratedCastorOil
TallOilAcids
FishOil
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Alkyds• Highlyversatilechemistry• Householdpaint• Industrialapplications
• Dryviaoxidation• Canbemodifiedwithotherresinsandchemicals• Styrene• Phenolic• BenzoicAcid• VinylToluene• Rosin• Acrylic• Silicone 14
Acrylics• Dryviasolventevaporation(lacquer)orcrosslinkingmechanism(urethaneormelamine)
• HighestUVresistanceofallorganiccoatings• Contributevaryingdegreeofcoatinghardnesstothesystem• Canbeblendedwithotherresinsystemstoimpartdifferentproperties• Polyurethanesincreasechemicalresistancewhenblendedwithacrylics
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Polyurethanes• AlsoreferredtoasurethanesorPUD’s• Ambientcurecoatings• Impartexcellentchemicalresistanceanddurability• Cancrosslinkwithacatalyst(2Ksystem)forincreasedperformance,butreducingpotlife
• Canbeblendedwithacrylicstogetbothsurfacehardnessandchemicalresistance
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FilmFormationMinimumFilmFormingTemperature(MFFT)=theminimumtemperatureneededtoformacontinuousfilm
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ColorPigments1. TiO2(Titaniumdioxide)istheonlyhidingpigmentthat
scatters/reflectslight2. Allothercoloredpigmentsabsorblightatspecific
wavelengths3. Blackpigmentsabsorballwavelengthsoflight
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Opacity1. Opacityisdefinedbyhowmuchthepaintabsorbs,reflects
orscatterslighttohidetheunderlyingsubstrate2. Measuredasapercentonaspectrophotometerovera
sealedwhite,sealedblack,andunsealedwhitesurface
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ExtenderPigments1. Calciumcarbonate/claysactasfillersatalowcosttospace
outTiO2moleculesforimprovedlightrefraction2. Talc/Magnesiumsilicateactsasflatteningagents3. Amorphoussilicaactsasahigh-efficiencyflattener4. Crystallinesilicaimprovesadhesion,fills,andflattens5. Fumedsilicaimpartsrheologicalcontrolandflattens
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Additives1. Dispersants:surfactantsthathelpthesystemacceptdry
pigmentwithinthegrindphase2. Flow&Leveling:surfacemodifierssuchasfluorosurfactants
andsilanes thatimprovethewettabilityoftheproductovertheapplicationsurface
3. Rheologymodifier:actstothickenthepaintorcoating4. Defoamers/Deaerators:knockdownfoamformationduring
themanufacturingandapplicationprocess5. Slipaids:surfacemodifiersthatalterhowslipperyasurface
feels6. Biocides:killersofbacteria,mildew,andfungusbothincan
andinfilmforincreasedstability 21
ManufacturingProcessGrindPhaseHighspeeddisperseanydrypigmentorflatteningagentintoeitherwaterortheresinsystemwithadispersantmakingsureyouhaveagoodvortexPremixInaseparatevesselmixtogetherwaterandanysolventneededforcoalescenceofthecoatingsoyoudonotshocktheresinsystemwhenaddedLet-downReducethespeedofyourdispersionandaddyourpremixandanyslip-aids,rheologicalmodifiers,biocides,andsurfacemodifieradditivestoimproveyourcoatingsperformance 22
ManufacturingProcessTechnology:HighspeeddispersionusingaCowlesblade• Agoodvortexpullsthecontentsofthevesseltothebladesedge
• Overchargingorundercharginganyonematerialcanresultinapoordispersion
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PerformanceCharacteristics1. ChemicalResistance2. WaterResistance3. Heat/HumidityResistance4. YellowingResistance/TanninBleedResistance5. Weathering6. Adhesion7. Incanstability
a. OvenStabilityb. Freeze/ThawStability
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ChemicalResistanceMethod1. Spraybirchpanelswiththreecoatsofproduct(3drymils)2. Dryeachpanelundera120Fheatlampbetweeneachcoat
andallowthepanelstocureforfivedays3. Applythe21differenthouseholdproductstoeachpanel
beingtested4. Placewatchglassesontopofeachchemicalandallowtosit
foronehourbeforescoring5. Scorethecoating’sresistancetoeachchemicalwithascore
from1-5(1-completedegradation,5-noeffect)6. Addupthescoresandcomparetheexperimental
competitiveproductstothestandard (105max)
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HouseholdProducts• Water• Ketchup• Mustard• Coffee• Iodine• HydrogenPeroxide• Windex• 409Cleaner• Ammonia• IPA• SuntanLotion
• DEET• Ethanol• RedWine• DenaturedAlcohol• Naptha• Bleach(6%)• AmmoniumHydroxide(37%)
• OliveOil• SulfuricAcid(10%)• SulfuricAcid(37%) 26
TestingPanels
OldExterior450Satin NewExterior450Satin
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WaterResistance1. Applyagenerousamountof
waterovertheblackportionofthechemicalresistancepanel
2. Placealargewatchglassoverthewaterspotandallowtositforonehourbeforescoring
3. Givethespottestascorefrom1-5similarlytothechemicaltesting
4. Lookforblushingandpermanentwaterspots
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YellowingResistance1. Applyeachtopcoatoveraleneta chartwithsnowwhitemilk
paint2. Allowthetopcoattodryatambientconditions(70-75F,40-
50%humidity)3. Takeaninitialcolorreadingusingaspectrophotometerto
showthechangeincolorationfromthepainttothetopcoat4. Heatstresseachleneta chartina125Fovenandtake
additionalcolorreadingsevery24hours5. Analyzethedifferencesincolorationfromboththesnow
whitemilkpaintstandardandtheinitialtopcoatreading
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Adhesion1. Applya1mm.and2mm.crosshatchtothechemical
resistancepanelsafter24hrs ofambientcure2. Placecoatingindustrystandardtapetothecenterofthe
crosshatch3. Applypressureandremovethetapetoassessany
delaminationofthecoatingfromthewoodsubstrate
5- PerfectScore 1- Completeadhesionloss
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QualityControl1. Viscosity2. Gloss3. Color4. Opacity
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Viscosity1. Viscosityisavaryingstateofthicknessorconsistency
relativetotemperature2. CommonlymeasuredinmPas,cPs,orKreb units3. Temperaturemustbecontrolledwhenmeasuringviscosity
(75Fistheindustrystandard)4. Therearemanydifferentwaytomeasureviscosity,butwe
useaFordcup#4forallofourtopcoatsandaBrookfieldandKrebsviscometersforourpaintsandstains
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Gloss1. Glossismeasuredonanangletothepaintsurface2. Determinestheamountoflightreflectedbythesurfaceand
ismeasuredinglossunitsnotpercent3. Gloss:85+Semi-gloss:50-60Satin:25-35Flat:lessthan154. FlatoutFlat:lessthan5
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Color1. Viewcolorchangesbasedonvisualobservationofthein
processproductdrawndownonaleneta chartagainstastandard
2. Useaspectrophotometertomeasurethedifferenceincolorfromtheinprocessproducttoastandard
3. Colorvalueslessthanoneareundetectabletothehumaneye
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ApplicationTechniques• Brush• Roller• AirAtomizedSpray• AirlessSpray• ElectrostaticSpray• CentrifugalAtomization• AirAssistedAirlessSpray• Dip• DirectorReverseRollcoat(coilcoatings)• CurtainCoating• FlowCoating• FluidizedBed(Powder) 35
SubstrateandPreparation• Wood:sandand/orprime• Sheetrock:sandand/orprime• Steel:ironorzincphosphatizing,prime• Aluminum:passivateandseal• Plastics:solventselection,productscreening,flametreatment• Magnesium:passivateandseal• Galvanizedsteel:problematicforconsumer,zincphosphate• Glass:acidetchoruseofadhesionpromoters• Commontheme:Preparationiskeyforperformance
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Wood• Tannins(TannicAcid):Solubleinwater;causeofmajoryellowinganddiscolorationofwater-basedpaintsandcoatings
• MineralStreaks:Concentratedareasoftannin• VeneerGlue:Somegluesaresolubleinwaterandmigratetothesurfacecausingyellowinganddiscoloration
• Solution:GFSTAINBLOCKINGPRIMER• Oilinessofthewood:Bewaryofsubstratedifferences• Off-labeluse:DONOTRECOMMEND,butsomepeoplehavehadsuccess
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StainBlockingPrimer
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Thankyou!
39CourtesyofGeneralFinishes2016Flippin'FurnitureExpo