DESIGN OUTSIDE THE SQUARE

Powder Coating of Heat Sensitive Substrates

3 Innovative powder coating technologies from:

UV and low temperature powder coatings for HHeat SSensitive SSubstrates

Introducing

Powder Coating Powder Coating Powder Coating Powder Coating -- What & howWhat & howWhat ?

Powder coating is a dry finishing process, using finely ground particles of pigment and resin, which are electrostatically charged and sprayed onto a part to be coated. The charged particles adhere to the parts until melted and fused into a tough, even coating through the application of heat and energy.

ElectrostaticIn this method of application, a high voltage generator is used to charge an electrode at the tip of the powder gun. This creates an electrostatic field (or corona) between the gun and the substrate. Gas molecules in the air pick up electrons emitted from the corona. This negative charge is, in turn, transferred to the powder particles as they are propelled from the gun head towards the substrate. The charged powder particles are deposited on the earthed substrate.

How ?

powder coating - the benefits• one coat process• durable & tough• chemical resistant• humidity resistant• no harmful solvents• design flexibility• cost effective• seamless finish• cut/drill without damage• environmentally friendly

• High performance, Low Temperature cured powder coating

– excellent edge coverage & post cure cracking resistance– very good moisture / heat resistance -“steam test”– very good appearance & surface hardness– very good chemical resistance – various finishes possible including

• low gloss• smooth surface, medium or coarse texture• all colours

• Low Temperature cured powder coating for non-critical applications– an extensive range of technologies and capabilities for HSS

substrates– includes primers, top coats & single coat finishes– good appearance, chemical resistance & surface hardness– various finishes possible including

• matt to gloss• smooth surface, medium or coarse texture• all colours

• Xienta® - UV Cured Powder Coating– outstanding flow and appearance– excellent moisture / heat resistance– very good chemical resistance– very good scratch & mar resistance– excellent surface hardness– excellent exterior durability– various finishes possible including

• low to high gloss• smooth surface, medium or coarse texture

Current Uses• Office / Laboratory furniture – MDF ( desks , cabinets, partitions, benches)

• Kitchen cupboard doors – MDF ( plain, profiled, )

• Kitchen shelving and carcasses- MDF ( usually white, rounded edges )

• Nursery furniture, chairs, cots, tables, etc - MDF ( bright colours, rounded edges, )

• Shelving, - MDF ( domestic, commercial, rounded edges, special effects, special colours )

• Storage boxes / cubes - MDF ( plants, books, CD’s, cloths, etc )

• Domestic furniture – MDF ( bed ends, tables, chairs, doors, wall panels, )

• Table tennis table tops – MDF ( blue, green, hard wearing )

• Sanding Primer – Any HSS surface ( one coat, eliminates multi sanding, )

Low temperature cured powder coatingsCurrent Uses cont’d• Ceiling tiles – ( gypsum board, soft board, hard board, smooth, textured, )

• White sign board – smooth Plywood ( prepainted white for sign writing use )

• Stained decorative timber panels – Plywood ( transparent coated ply panels for ceilings, walls, shops fitouts, )

• Pre primed plywood panels – Plywood ( preprimed to save time and cost for decorative coating with “wet paint” )

• FRC Sheet – cement based sheet ( decorative exterior / interior cladding, )

• Colour coded Plant racking shelves - Plywood ( assist with customer identification, non slip, water resistant )

• Clear coated Pallet tops / Flooring – Plywood / Particle Board (water proof, E0 formaldehyde emissions )

• Colour coded Fruit Bin ends – Plywood ( identify various fruits in bins )

Low temperature cured powder coatingsCurrent Uses cont’d• Hospital neonatal baby warmer.- Plastic

( all metal and plastic components colour matched,easy clean, no moulding rejects, tough suface.)

• End caps for partitions – Plastic ( colourmatched to the aluminium components)

• Electrical components – Plastic (decorativeface plates, mouldings, switches )

• Towel rail brackets – Plastic ( decorativeharder wearing, easy multi colours,)

• Ceiling fans and extractors – Plastic(fan blades, assembly housings, replaces metal)

Typical coating plant layout

Pre-heat zone

powder booth Convection

I.R. pre-gelCan be retro fittedto an existing Powder coating line

load

unload

UV cure( )

board stabilisation

Not always requireddepending on boardor substrate

Substrate considerations

• Major considerations to be taken into account when selecting a grade of MDF (or other engineered wood product) for Powder Coating are: – board stability at powder curing temperatures – fibre length / wood composition– core density– moisture content– resin content / type– machineability

Orica MDF resin technology• Orica Adhesives & Resins, in conjunction with

Orica Powder Coatings, have developed an MDF resin technology enhancing the properties of engineered wood products making them more suitable for powder coating

• The key benefits of the Trimatrx resin are;

– Increased powder attraction to the substrate

– Increased heat stability of the substrate

– Improved machineability of MDF etc

– Low E rating

Rating Results for each finishNo Exposure Chemicals Time Vinyl Wrap Melamine Urethane HPL LPL TrimatrxXienta

1 Vinegar 16 hrs 1A 1A 1A 1A 1A 1A 1A2 10% Citric acid in water 16 hrs 1A 1A 1A 1A 1A 1A 1A3 10% Sodium Carbonate in water 16 hrs 1A 1A 1A 1A 1A 1A 1A4 10% Ammonia in water 16 hrs 1A 1A 1A 1A 1A 1A 1A5 Ethanol 16 hrs 1A 1A 1A 1A 1A 1B 1A6 White wine, Red wine 16 hrs 1A 1A 1A 1A 1A 1A 1A7 Beer 16 hrs 1A 1A 1A 1A 1A 1A 1A8 Cola 16 hrs 1A 1A 1A 1A 1A 1A 1A9 Coffee 16 hrs 1A 1A 1A 1A 1A 1A 1A

10 Tea 16 hrs 1A 1A 1A 1A 1A 1A 1A11 Black currant 16 hrs 1A 1A 1A 1A 1A 1A 1A12 Milk 16 hrs 1A 1A 1A 1A 1A 1A 1A13 Water 16 hrs 1A 1A 1A 1A 1A 1A 1A14 Petrol 16 hrs 1A 1A 1A 1A 1A 1A 1A15 Acetone 10 secs 1B 1A 1C 1A 1A 1B 1A16 Butyl acetate 10 secs 1A 1A 1A 1A 1A 1B 1B17 Butter 16 hrs 1A 1A 1A 1A 1A 1A 1A18 Olive oil 16 hrs 1A 1A 1A 1A 1A 1A 1A19 Mustard 16 hrs 1A 1A 1A 1A 1A 1A 1A20 Salt 16 hrs 1A 1A 1A 1A 1A 1A 1A21 Onion 16 hrs 1A 1A 1A 1A 1A 1A 1A22 Lipstick 16 hrs 1F 1B 1A 1B 1C 1B 1A23 Disinfectant 16 hrs 1A 1A 1A 1A 1A 1A 1A24 Ball point pen 16 hrs 1F 1F 1F 1F 1F 1F 1F25 Stamping Ink 16 hrs 1F 1D 1B 1C 1E 1B 1B26 Detergent 16 hrs 1A 1A 1A 1A 1A 1A 1A27 Cleaning solution 16 hrs 1A 1A 1A 1A 1A 1A 1A

Test DIN 68861 Part 1-

Furniture Surfaces- Behaviour at Chemical Influence

Requirements:

Pass 1B rating Minimum for all materials (Rating from 1A to 1F, A is the highest)

1A= No visible stain or other effect

1B= Slight stain or other effect

1F= Severe stain or other effect

meeting the standards DIN 68930 - summary

Rating from A to F; A is the highest

Test method Standard LaminateChemical exposure 1C 1A 1B 1B 1B

Abrasion resistance 2E 2B 2C 2C 2B

Scratch resistance 4E 4A 4A 4B 4A

Glowing cigarette 6A 6A 6C 6C 6B

Dry Heat 7C 7A 7A 7A 7A

Wet heat 8B 8A 8A 8A 8A

GE Advanced Materials Noryl GTX® resinOrica Camel Customcoat® powder coatAdvanced Aesthetics

NORYL GTX® is a registered trademark of the General Electric Company

Dulux ® & Customcoat® are registered trademarks of Orica Australia Limited

> Noryl GTX resin is a high heat engineering thermoplastic optimised for primer less electrostatic powder coating and has high chemical resistance with excellent powder transfer efficiency and adhesion performance.

> Customcoat powder coat is a high performance powder optimised for use on parts made with NorylGTX resin, giving the applicator a broad processing window and the excellence in aesthetics, efficiency & coating performance.

Introduction

> Broad aesthetics range, of colours, effects, gloss and textures

> Very minimal VOC’s and Eco friendly> Excellent utilisation efficiency of coating> Very durable finish> Weld & flow lines no concern> Excellent UV and chemical resistance> Excellent edge wrapping> Colour parity of metal, wood & plastic components for life> Indoor & outdoor weathering options

Why Powder coat?

> Plastic parts need to have low moisture content prior to powder coating

> Use good part handling practice to prevent surface contamination

> Utilises traditional equipment and gives best results when good process control exists

Powder coat process considerations

> Do not use mold releases > Use good part handling practices to prevent

surface contamination> Use good injection molding practice to minimise

molded in stresses> Seek optimum surface quality

Plastic Processing Considerations

> Reduce working capital – all moldings are black > Efficient and environmentally friendly painting> Very durable finish> Aesthetic parity of metals, wood & plastics for life> Weld & flow lines no concern> Broad range of colours, effects, gloss levels & textures> Facilitates innovative product design

“Why powder coat plastics?”

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