improving the performance of uv cure coatings & adhesives...
TRANSCRIPT
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Improving the performance of UV cure coatings & adhesives on plastic substratesAdhesives & Sealants Council 2017
Andy Stecher, Plasmatreat USA, LLC
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• Motivation for the use of UV Cure materials
• Why UV materials have adhesion problems
• A coating innovation: UV powder coating
• What is plasma? How does it work?
• The UV powder coating solution
• UV cure adhesives examples
Outline of my remarks
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• High Speed• Low Heat• Hard, durable, water-clear
finish• Environmentally friendly
technology
The advantages of UV Curing
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Typical UV coated products
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Overview of the UV curing process
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(UV = Highly Cross-linked)
UV vs. thermal chemistry comparison
Conventional Coating
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Strong cohesive and adhesive forces needed in bonding
Crosshatch tape testing
The Desired ResultThe desired outcome is easy
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• Getting UV materials to stick is not easy
• Adhesion is often hard to control (Substrate, Ambient Condition, Contamination)
• Sometimes requires some kind of reformulation to the chemistry, change of substrate, or more commonly surface treatment
However there are adhesion issues
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• Economy• Excellence of Finish• Energy Efficiency• Easy to Apply• Environmentally Friendly
Powder Coating Benefits: The 5 “E’s”Example: Powder Coating
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Powder coated products
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Tem
pera
ture
Build Hold
Time
15-60Minutes
375oF
Melt & Flow Cure
Thermoset Powder Cure ProfileThermoset Powder Thermal Profile
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Chemistry Standard Cure Low Temp. Cure
Epoxy 20’ @ 350⁰F 25’ @ 235⁰F
Epoxy Polyester 20’ @ 375⁰F 25’ @ 250⁰F
Polyester 20’ @ 375⁰F 25’ @ 275⁰F
Polyurethane 20’ @ 390⁰F 25’ @ 295⁰F
Acrylic 25’ @ 350⁰F 30’ @ 250⁰F
Silicone 25’ @ 420⁰C N/A
Typical Powder Thermal Profile
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Problem: Plastic Deflection Temp.
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• Use a higher temperature plastic• Use a lower temperature powder• Use UV curing
Possible Thermal Solutions
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Powder Application
Apply Heatto Melt Powder
Powder Flow/Leveling
Exposure to UVfor Polymerization
hν
The UV Powder Coating Process
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Tem
pera
ture
Melt/Flow Stage
Exposure to UV
Time
UV Powder Temperature Profile
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• Excellent Surface Properties
• Low Heat/High Speed Processing
• No Waste
• Heat Sensitive Substrates
A highly desirable technology:
UV Powder Coatings
Thermoset UV Cure
400oF
200oF
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A Flashback…
In 1998 Baldor Electric Motor began UV powder coating pre-assembled electric motors.
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• STATIC REMOVAL: Static attracts dust and similar contaminants which interfere with surface processes
• CLEANING: All surfaces, no matter how clean they seem, have surface contaminants that interfere with bonding and coating applications
• ACTIVATION: Advanced engineering polymers tend to be chemically inert – with few or no functional groupson which to bond
• PASSIVATION: Metals are prone to oxidation and require treatment to retard the oxidation process
The Needs for Surface Preparation?
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Note: Water Surface Energy 72 mN/m (dyne)
Plastics with Low Surface Energy
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Courtesy Texas A&M University
The Challenges of Solvents
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• What is plasma? • How is plasma generated and applied
• Functions of plasma treatment• Cleaning of glass, plastics, metals, ceramics• Activation of Plastics (Polyolefins, etc) and Hybrids (GFRP)• Functionalization of ceran and galvanized steel
Plasma Surface Treatment
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Naturally Occurring Plasmas
Low Pressure (vacuum) Atmospheric Pressure
What is Plasma?Nature’s plasma
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Photo: Safe, Cost-Effective, Environmentally Friendly Man-Made Plasma
Man-made Plasma
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Substrate
Inner Electrode
Ring Electrode (SS casing)
Discharge Chamber
Ionization GasHigh voltage
Current
Plasma Beam
The Plasma Treatment Process
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OO
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H H H H H H H
C C CCC C C
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Attack surface contamination
Cleaning effect
Polymer Substrate-UV varnish
- OPP, PE, PET, Acetate….
Surface Contamination-Organic layers(Additives, waxes, grease…..)
Plasma Surface Treatment
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Polymer SubstrateOPP, PE, PET, Acetate….
UV varnish
Surface contamination
Cleaning effect
Plasma Surface Treatment
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Polymer SubstrateOPP, PE, PET, Acetate….
UV varnish
Form functional sites
Stable wetting
Plasma Surface Treatment
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Topological Modification ( AFM Study of PET [1 µm] )
Untreated Plasma Treatd
Courtesy: Fraunhofer Institute for Processing Technology and Materials Research
Plasma Surface Treatment
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Atmospheric Pressure Plasma Process - Activation
Plasma Surface Treatment
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35
20
5
020406080
20 18 16 14 12 10 8 6 4Speed [m/min]
mN/m
Gap [mm]
Surface Energy of PolypropyleneAfter Plasma Treatment
60-80
40-60
20-40
0-20
Plasma Treatment ResultsPlasma Surface Treatment
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A wide selection of standard and custom jets adapt to a wide range of part shapes and sizes..
Flexibility for many applications
Plasma flexibility
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Atmospheric plasma generators are easy to
install and integrate with simple connections.
Integration of plasma onto the process line
Plasma flexibility
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Powder Coating on Automotive Plastic!
• Plasma Cleaning & Activation
• Conductive Agent
• Powder Application
• Heat (IR or Convection)
• UV Cure
UV Powder / Plasma Process
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Objective: To compare adhesion results of several powder coated plastics when untreated and treated with plasma.Powder Coating: PCRG 002-36-113 UV Curable powder
Substrates:• PT Natural (proprietary formulation)• Nylon• Polypropylene• ABS• PC/ABS
UV Powder Coatings
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Plasma Treated No Treatment
Glass-Filled Polypropylene Substrate
UV Cured
Plasma results
Source: Powder Coating Research Group
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Source: Powder Coating Research Group
Plasma results
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Source: Powder Coating Research Group
Plasma results
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Source: Powder Coating Research Group
Plasma results
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Source: Powder Coating Research Group
Plasma results
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Source: Powder Coating Research Group
Plasma results
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SubstrateRating without
Openair® Plasma
Rating with Openair® Plasma
PT Natural 0B 4B
Nylon 0B 0B
Polypropylene
0B 3B
ABS 0B 4B
PC/ABS 4B 4B
Cross Hatch Test Criteria: ASTM D3359 02 “0B – 5B)
Plasma results summary
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The environmental benefits of atmospheric plasma are a good fit for UV technology
• Elimination of high VOC content primers or adhesive promoters – replace these with environmentally safe plasma
• Low power consumption
• No ozone generation
• No pollutants
Plasma + UV Powder Coatings = Fit
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0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Without Plasma With Plasma
Pull
Stre
ngth
Mean Std. Dev.
Not only anIncrease in
Bond performance
Increase Bond Strength
(Source: Kegel & Schmid 1999)
Plasma results on adhesives
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0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Without Plasma With Plasma
Pull
Stre
ngth
Mean Std. Dev.
Not only anIncrease in
Bond performance
But a Decreasein Variance
(Source: Kegel & Schmid 1999)
Decrease Bond VariancePlasma results on adhesives
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0
1
2
3
4
5
6
7
8
9
10
HDPE PP PVDF PET Nylon6
Lap
Shea
r Str
engt
h [ M
Pa]
Control Plasma treatment
SOURCE: M. Noeske et al., “Plasma jet treatment of five polymers at atmospheric pressure: surface modifications and the relevance for adhesion”, International Journal of Adhesion & Adhesives September 2003
Plasma results on adhesives
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0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
8.9
MP
a
8.4
MP
a
0.3
MP
a
12
.4M
Pa
12.0
MP
a
0.5
MP
a
10 .
1M
Pa
11.1
MP
a
0.2
MP
a
Tens
ile L
ap-s
hear
Str
engt
h [M
Pa] PP AP-Plasma (directly bonded)
PP AP-Plasma (bonded after 8w 60°C, 50% r.h.)
PP (without pretreatment)
PVDF AP-Plasma (directly bonded)
PVDF AP-Plasma (bonded after 8w 60°C, 50% r.h.)
PVDF (without pretreatment)
ECTFE AP-Plasma (directly bonded)
ECTFE AP-Plasma (bonded after 8w 60°C, 50% r.h.)
ECTFE (without pretreatment)
2-part epoxy system:Curing: 175°F, 2 hours
Plasma results on adhesives
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UV cure: shear strength
0
5
10
15
20
25
30
Initial value 2 w 85°C/85% humidity
2 w 40°C/100% humidity
Com
pres
sion
she
ar s
treng
th (M
Pa)
PBT/PET Blend Substrate
Degreased
Atmosphericplasma
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Polyamide with Cationic Bonding
0
2
4
6
8
10
12
14
16
18
20
KB554 45952
com
pres
sion
she
ar s
tren
gth
[MP
a]
CATIONIC BONDING PROCESS
Initial valuecleaned
Initial valueAPP
14 d 40 °C / 95 %cleaned
14 d 40 ° C / 95 %APP
![Page 50: Improving the performance of UV cure coatings & adhesives ...media.mycrowdwisdom.com.s3.amazonaws.com/asc/2017 Annual C… · Adhesives & Sealants Council 2017 Andy Stecher, Plasmatreat](https://reader036.vdocuments.us/reader036/viewer/2022063011/5fc71c51f7c13666a24939c2/html5/thumbnails/50.jpg)
Polyamide free-radical curing
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5
10
15
20
25
30
4494 AD494
com
pre
ssio
n s
he
ar
stre
ng
th
[MP
a]
Initial valuecleaned
Initial valueAPP
14 d 40 °C / 95 %cleaned
14 d 40 ° C / 95 %APP
![Page 51: Improving the performance of UV cure coatings & adhesives ...media.mycrowdwisdom.com.s3.amazonaws.com/asc/2017 Annual C… · Adhesives & Sealants Council 2017 Andy Stecher, Plasmatreat](https://reader036.vdocuments.us/reader036/viewer/2022063011/5fc71c51f7c13666a24939c2/html5/thumbnails/51.jpg)
• UV offers attractive benefits to manufacturer (e.g., low heat, fast cure, tough surfaces)
• However, UV also presents greater challenges to adhesion due to the highly crosslinked chemistry
• Plasma has been shown to improve UV coating adhesion even on UV powder coatings
• Plasma improves UV adhesive bond performance.
Summary of take-aways
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THANK YOU FOR YOUR ATTENTION!
Plasmatreat North AmericaElgin, IL Belmont, CA Ancaster, ON
Tel. (855) 4TH-STATEwww.plasmatreat.com