European Coatings Conference, 4 – 5 February 2014 ... · 3 Jet dryer 60 – 80 ˚C air circulation temperature 4 Ejector brushes (2) 5 Single roller coater with a hard roller for

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


Typical roller coat application processes for wood stains


…..

…..

…..

…..

…..

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


Foamed rubber roller

General composition of cellulose nitrate wood lacquers


Cellulose nitrate

Resins

plasticizer

Pigments / filling material

Additives

Solvents

CN-Lacquers

Molecular structure of cellulose and cellulose nitrate


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)


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


Application line for oxidavtive curing oils


General chemical resitances of oxidavtive cured oils


Requirments for oil surfaces


trends 2013/2014 colouring trends

„Antique-like effects upon solid oak“

Quelle Bilder: 3P

oak natural bright medium dark


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


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)


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


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


thixotroping agents

Cellulose acetobutyrate Cellulose nitrate


Examples of different polyisocyanates

Allgemeine Zusammensetzung von 2K-PUR Holzlacken


NCOOCN

O OH

N N OOH

O O

OHOH+

Diisocyanate Diol

Polyurethane

Polyaddition to produce polyurethane lacquers


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


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 unsaturated 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



0 % 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)


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


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


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)


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


• 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)


OO

OO

OO

OCH3

N

O

N

N

N

O

O O

OCN

OCN

H


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


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


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


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


General composition of UV-curing lacquers

UV-Lacquers

Resins, UV-curable

Reactive thinner, Monomers

Photoinitiators, synergists


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


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


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

„Sweat out“ of uncured monomers and low molecular weight compounds from oak veneer

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

Automatic surface spraying systems

http://www.dds-online.de/images/Artikel/402615.jpg

Walther Trowal GmbH & Co. KG Rheinische Straße 35-37 D-42781 Haan

Coatings drum to coat small pieces

Trommeln / drum process

Quelle: Jorge Prieto 3P

Trommeln / drum process

Lab drum

Prinzip der Gießmaschine

Lackbehälter

Lackpumpe

Vorschubrichtung

Transportband

Gießkopf

Lackvorhangaufgegossener Lackfilm

Holzwerkstück

Lackauffangrinne

Lackzufuhr


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


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


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


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.


Stain resistance according to EN 12720 (resistance against cold liquids)


Abrasion resistance according to EN 15185


Light fastness according to EN 15187


Example for a test device for determination of light fastness according to EN 15187

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Documents

European Coatings Conference, 4 – 5 February 2014 ... · 3 Jet dryer 60 – 80 ˚C air circulation temperature 4 Ejector brushes (2) 5 Single roller coater with a hard roller for