short course: principles of parquet and furniture

Transcription

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
Industrial Wood Coatings
Global Market 2011: 1690 kt*
RoW
6,00 %
NAFTA
12,70 %
Region
Europe
30,10 %
L.-America
9,70 %
Asia
8,40 %
China
33,10 %
[kt]
Europe
509
China
560
NAFTA
215
L-America
164
Asia
142
RoW
101
Europe and China / Asia are the biggest market for Industrial Wood Coatings
Quelle: Bayer 2009, Irfab 2008/2009, KNG 2008, SRI-CEH 2009, Eastman 2010, DSM 2010, 3P 2013
* Deco/ Field applied Wood Flooring products are included
Industrial Wood Coatings 2012
European Market by Outlet (kt)
Industrial Wood Coatings (paints)
Flooring
6%
Joinery
23 %
Furniture
71 %
The Furniture market is the largest outlet for Industrial Wood Coatings in Europe
Source: Bayer 2009, Irfab 2008/2009, KNG 2008, SRI-CEH 2009, Asefapi, DSM 2010, Eastman 2010, 3P 2011
* Deco/ Field applied Wood Flooring products are included
European Coatings Market for Furniture
2011 by Technologies  325 kt
Technologie
Nitrocellulose
15%
2C-PU
34%
Radiation Waterbased
19%
Curing
23%
Acid Curing
5%
Unsaturated
Polyester
4%
Solventborne Polyurethan-Lacquers dominating
the Industrial Wood Coatings Market
Quelle: 3P 2013
[kt]
2C-PU-Lacquers
110
Radiation Curing-Lacquers
75
Nitrocellulose-Lacquers
49
Waterbased-Lacquers
62
Acid Curing-Lacquers
16
Unsaturated PolyesterLacquers
13
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-ityourselver or parquet flooring professional.
Furniture Coatings Market
Europe by Application (volume)
Wood Coatings market for Flooring (Paints)
Europe by Segment and Technology (2012)
Industrial
On-site (Field applied)
Paint formulations
Oil (oxidative curable)
0,7 %
1C water based (UV-curing) 0,2 %
Acid curing 3,5 %
2C PU
water based
19,1 %
Alkyd enamel
Oxidative
10 %
Polyurethanes
10,5 %
1C water based
56 %
Formulations contain
Acrylic and PUDŒ
s
•
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.
Ecofriendly Coating resins by technology
World Consumption* 2008 – 2016 (forecast)
Quelle: Bayer 2009, 3P
Curve of live of different wood coatings
technologies for industrial use
emergence
growth
1C- and 2CPolyurethane-Lacquers
maturity
age
Unsaturated-Polyester Lacquers
Acid Curing-Lacquers
CN-Lacqers
Radiation-Lacquers
Powder Coatings
(thermisch- und
UV-härtend)
Waterborne-Lacquers
Quelle: 3P 2011
Emission behaviour of different wood coatings technologies
based on 100 % clear-coat
Gehalt an organischen Lösemittel [%]
100
CN
Acid-Curing
2C-PU
UP
Radiation Curing
ingredients:
Formaldehyde
Isocyanate
Styrene
Monomers
80
70
Waterborne Lacquers
50
0
Quelle : J.Prieto, J. Keine, Holzbeischichtung
70
10
Solvent content [%]
10
5
Segmentation by end-use applications
Interior
Exterior
Joinery
Joinery
Window frames
Window frames
Doors / Panels
Doors / Panels
Furniture
Flooring
Assembled for
offices
Solid wood parquet
Assembled for
residential homes
Multilayer
hardwood flooring
Garden furniture
Cladding shutters
Skirting boards
Quelle: 3P 2011
Flat stock for self
assembled furniture
Kitchen and
bathroom cabinets
Coated Laminate
Raw materials for Stains (indoor)
Solvent- und waterborne wood stains
Organic
dyes
Pigments
Resins
Wood-Stains
thixotroping agent,
thickenerr,
neutralisation medium
Additivee
defoamer,
silicone oils,
dispersing agents
Typical roller coat application processes for wood stains
…..
A
1
2
3
…..
B
1
2
4
3
C
…..
1
2
5
2
5
3
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
D
…..
3
E
…..
6
2
7
8
9
2
5
3
Typical roller coat application processes for wood stains
Foamed rubber roller
General composition of cellulose nitrate wood lacquers
Cellulose nitrate
Resins
plasticizer
CN-Lacquers
Pigments /
filling material
Additives
Solvents
Molecular structure of cellulose and cellulose nitrate
OH
CH2OH
O
OH
O
O
OH
OH
O
O
OH
CH2OH
OH
CH2OH
O
O
OH
OH
O
O
OH
CH2OH
OH
CH2OH
O
OH
O
O
OH
CH2OH
O
General composition of acid curing lacquer
(AC-Lacquer)
Resins
Alkyd resins
Cellulose nitrate
Amino resins
Urea- und
Melamine resins
AC-Lacquers
Organic solvents
Esters, Ketones,
Aromatics, Alcoholes
Acid
Para-Toluenesulfoneacid
Base Lacquer
Hardener
Pigments, Filling materials,
Matting agenst,
Thixotroping agents
Additives
Anti foaming agents,
Silicone oils,
Amines, plasticizer
Renewable Raw Materials – oxidative curable
Structure of long oil alkyd resins
Triglycerids
fatty acid
phthalic acid
Renewable Raw Materials – oxidative curable
Source: P-Marie Baudoin, Vandeputte Oleochemicals, Industrial applications of linseed oil and industry outlook
Renewable Raw Materials
Quelle: P-Marie Baudoin, Vandeputte Oleochemicals, Industrial applications of linseed oil and industry outlook
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
„Antique-like effects upon solid oak“
trends 2013/2014
colouring trends
oak natural
Quelle Bilder: 3P
bright
medium
dark
General composition of UP-Lacquers (unsaturated Polyester)
Unsaturated
polyester resins
Reactive thinner
Styrene,
Vinyltoluen
Pigments, filling materials,
matting agents,
thixotroping agents
Paraffine wax
melting range
between 50 – 60 ˚C
UP-Lacquers
Initiator
Peroxide
Base coat
Hardner
Accelerators
e.g. Cobalt salts
Accelerator
Additives
Silicone oils,
inhibitors
Principle polycondensation to produce unsaturated Polyester
HOOC
COOH
- H2O
O
O
+
HO
OH
+
O
Maleinsäure
Propylenglykol-1,3
o-Phthalsäure
O
O
O
R
O
O
O
O
O
R
O
O
O
O
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/m 2 (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
Cobalt paint
RT
1. Active base coat process
80-450 g/m2
ca. 15 g/m2
Co- paint Peroxid-paint
2. Double head - (1:1) process
Cobalt- paint Peroxide- paint
Per unit 125 g/m2
Approx.. 15 Min
RT
per unit 125 g/m2
Co-paint
3. Sandwich-process
Co- paint Peroxid-paint
RT
200 g/m2 100 g/m2
4. Reverse- (4:1) process
Co- paint, Peroxid-paint
400 g/m2
100 g/m2
10-20 Min.
200 g/m2
RIM-Process (Reaction Injection Molding)
depot
depot
dosing machine
mixing chamber
tool
moulding
Quelle: BayerMaterial Scienes
General compositon of 2C-PU-Lacquers
Resins
Polyacrylate
Polyester
Alkyd resins
Organic solvent
Ester, Ketone,
Aromatics
matting agents,
thixotroping agents
Cellulose acetobutyrate
Cellulose nitrate
Base coat
Hardner
2-C-PU
Lacquer
Polyisocyanates
Additives
Silicone oils, catalysts
Amines, plasticizer,
water scavengers
Examples of different polyisocyanates
Polyaddition to produce polyurethane lacquers
Allgemeine Zusammensetzung von 2K-PUR Holzlacken
+
NCO
OCN
OH
HO
Diol
Diisocyanate
O
O
O
N
O
H
H
Polyurethane
O
N
O
High-gloss Lacquer  Base coat withe 2C-UP or 2C-PU-Filler
Top-Coat  pigmented 2C-PU (Spraying process)
Optional :
Isolation and stabilisation of the milled edges and interior
2-C-PU-Isolation
profile
2-C-UP-Filler white (styrene)
300 – 500 g/m² wet application in different working steps
2-C-PU-Filler white alternative
150 – 500 g/m² 1 – 3 working steps
to 2-C-UP-Filler white
Drying / chemical curing at
23˚C und 50 % rel. air humidity
room temperature
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
At least 24 – 48 hours at 23˚C and 50 % rel. Humidity
room temperature
Post-treatment
Depending of the quality requirement 
Sanding and polishing of the surface
Application line for High-gloss 2C-PU-Lacquers (pigmented)
7.
6.
5.
1.
2.
3.
4.
5.
6.
7.
4.
3.
Conveyer belt
Dust collection system
Conveyer belt (encapsulated area)
Dedusting unit with compressed air
Spraying robot (encapsulated area)
with 4 spraying guns
Drying rack (with 6 drying zones) approx. 25 – 30 °C
actual time approx. 45 minutes
Conveyer belt
2.
1.
General composition of water-borne lacquers
Resins
• Dispersions / Emulsions
Reactive thinner, hardner
• saturated and unsaturated Monomers/
Oligomers
• Polyisocyanates
Matting agents
Water-borne
Lacquer
Fotoinitiator and
Synergists for
UV-curing water-borne
lacquers
Additives
Anti foam agents,
Leveling agents,
Inhibitors,
Neutralisation medium,
Thickner,
Emulsifiers
The influence of added quantity (coalescing agents for
film forming of polyacrylic dispersion)
0 % addition of
solvent
1 % addition of
solvent
4 % addition of
solvent
5 % addition of
solvent
microscopic imaging
Stereomicroscope , 12,5 x magnification
2 % addition of
solvent
6 % addition of
solvent
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
B
A
C
D
Wasser
A
B
C
D
Initiator
Emulsifier
Protectiv colloid
Polymer
Structural parameter
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
Particle morphology of single- and
multi-phase aqueous emulsions
Individual particle
(hard)
Individual particle
(soft)
Core-shell particle
Hemispheric particle
Inverse Core-shell particle
Particle with
„Raspberry-Morphology“
Particle
producing through
gradient process
The influence of the polymer structure of polyacrylate dispersions
to the penetration depth in pine wood (optical microscope)
Grobteilige Acrylatdispersion
Feinteilige Acrylatdispersion ca. 50 nm
geringe Penetration (2 Zellschichten)
gute Penetration (3-6 Zellschichten)
coarse-particle polyacrylic dispersion
low penetration (2 cell layer)
fine-particle polyacrylic dispersion
good penetration (3 – 6 cell layer)
Structure of high molecular, acrylatefunctional Polyurethanedispersionen
O
+
NR3
O
O
R
H
H
N
N
H3C
O
COO
O
O
O
O
O
_
H
H
N
N
O
O
O
O
O
R
A
B
C
B
A
A = Polyester-/Epoxy-/Urethan-/Polyesteracrylat
B = Diisocyanat
C = Hydrophilierung (Carboxylat-, Ammonium- oder Sulphonatgruppen)
A = Polymeres oder monomeres Diol
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)
H
O
OCN
N
O
OCN
N
N
N
O
O
O
O
O
O
O
O
O
CH3
Structure of polyether modified polyisocyanates (HDI-trimeric)
(HDI trimeric / Allophanat-Type)
O
OCN
N
O
N
N
O
OCN
H
O
OCN
N
O
OCN
O
N
N
N
N
O
O
O
O
O
O
O
O
O
CH3
Structure of aminosulfone acid modified HDI-trimeric
H
O
OCN
N
O
OCN
N
N
N
N
- +
R
O
O
SO3
NR3H
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
Quelle : Bayer MaterialScience, „Toolbox for waterborne 2C Polyurethane coating systems“
influencing factors in the drying of water-borne lacquers
Air
• Temperature Tair (t)
• Humidity
• Air flow velocity
v
Paint film
• Temperature Tpaint (t)
• Thickness d (t)
• Formulation
v
Substrate
• Temperatur TSubstrate (t)
• Wood humidity F
• Absorption characteristics (t)
Quelle: Holzbeschichtung 2007, Jorge Prieto / Jürgen Kiene
The influence of the heating of the substrate before coated
to reduce the swelling of the wood fibre
without heating
High swelling
with heating 50 ˚C
low swelling
Example for an application line for pigmented
2C-PU-UV-curing waterborne lacquers
Spraying line with vertical dryer
cycle time approx. 25 – 50 minutes
The influence of the UV-curing
parameters on the coffee resistance
coffee-test
2C-PU-UV-Waterborne lacquer (structured,
pigmented) Base coat + 5 % hardner
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
Resins,
UV-curable
Reactive thinner,
Monomers
matting agents,
thixotroping agents
UV-Lacquers
Photoinitiators,
synergists
Additives
defoaming agent,
silicone oils,
inhibitors,
stabilisers
Why are the uv-curing lacquers
gaining in the last years in the market?
• 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
History of the uv-curable lacquers
 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
Styrene (Reactive thinner
Benzoinisopropylether (Photoinitiator)
Highly dispersed silica (thickner)
Paraffin wax melting point 42-58 ˚C
79,00 %
16,15 %
4,00 %
0,75 %
0,10 %
------------100,00 %
Benzoinisopropylether
UV-hardening methods for paraffin based,
unsaturated polyester lacquers
Mercury low pressure lamps
UV-Paraffin-Polyester
„UV-Angelierung“
floating of the
paraffin wax
to the surface
500 µm
Substrate
Substrate
Mercury high pressure lamps
cured paint film
UV-curing
Substrate
Substrate
Unsaturated polyester acrylates
OH
O
HO
R 1 C O n R 2 OH
+
OH-functionell Polyester
O
Acrylic acid
O
O
O
O
C O nR 2 O
R1
2
+
2 H2O
Unsaturated polyester acrylate
- hardness/elasticity
 Hard or elastic are possible
 Hard and elastic is limited
Pendel hardness (König) in [s]
Unsaturated polyester acrylates
• 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.
Polyether acrylates
reaction equation to produce polyether acrylates
HO
O
Polyether
OH
+
3
O
H
OH
- 3 H 2O
acrylic acid
O
O
Polyether
O
O
O
O
Polyether acrylatee
Amine modified polyether acrylates (Michael-Addition)
O
O
O
Polyether
O
O
Polyether
O
+
H
O
O
O
O
O
N
H
O
R
O
O
Polyether
O
O
O
N
O
R
O
Polyether
O
O
O
O
O
Polyether acrylates
• 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
Epoxy acrylates
Synthesis of epoxy acrylates
OH
O
+
R
O
O
Epoxid
O
2
HO
OH
O
R
O
Acrylic acid
O
Epoxidacrylat
wobei R beispielsweise =
O
O
n
OH
O
O
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
Range of properties  aromatic epoxy acrylates
hardness
uv reactivity
Reaktivität
Härte
elasticity
10
8
Elastizität
6
Chemical resistance
Chemikalienbeständigkeit
4
toughness
2
Zähigkeit
0
Viscosity spectrum
Viskositätsspektrum
Abriebfestigkeit
Haftung
abrasion-resistance
Adhesive strenght
Urethane acrylatee
O
NCO
HO R OH
+
+
2
2
HO
O
NCO
Toluylendiisocyanat TDI
Polyol
O
O
Hydroxyethylacrylat
H
N
O
H
N
O
O
O
HN
O R O
O
NH
O
O
O
Urethane acrylates
• a wide range of properties
• very good toughness, chemicalresistance 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)
Formulation of an UV-Topcoat for parquet (roller coater)
Formulation
57,5
20,0
10,0
6,0
2,0
1,5
3,0
clear coat:
Polyester acrylate
Polyurethane acrylate
Reactive thinner
Matting agent
Wax
Additives
Photoinitiator
Formulation of an uv base coat for parquet (roller coater)
Formulation
60,0
20,0
5,0
6,0
4,0
2,0
3,0
UV-base coat:
Polyester acrylate
Polyurethane acrylate
Reactive thinner
Corundum
Matting agent
Additives
Photoinitiator
Realtime-spectroscopic measurements
conversion rates of the double bonds  depending from the applied quantity
The influence through oxygen inhibition
depending from the applied quantity
Quelle: Eigene Messungen Jorge Prieto, 2009
„Sweat out“ of uncured monomers and low
molecular weight compounds from oak veneer
Chemical structure of the Isocyanato-Acrylate ICA 9000
Patentschrift: WO 00/39183
properties:
O
O
O
O
O
O
O
N
N
O
Quelle: BASF SE Ludwigshafen
15 %
2 mol/kg
800 g/mol
100 %
1200 mPas (23˚C)
< 0,5 %
sehr gering
O
H
H
OCN
NCO-Wert:
DB-Gehalt:
Molekulargewicht:
Festkörper (nfA):
Viskosität:
Rest HDI:
Geruch:
N
N
O
NCO
1,1
„Dual-Cure“Adhesion promoter on wood
OCN
OCN
R
OH
OH
R
OCN
R
OH
OCN
OH
UV-Angelierung
R
R
O
NH
O
O
NH
O
R
R
O
NH
O
O
NH
O
Extraction results of different UV-coatings with
and without Dual-Cure barrier-primer
Extrakt TPGDA
[mg/m2]
2500
2250 mg/m2
2000
1300 mg/m2
1500
1000
500
160 mg/m2
5 mg/m2
0
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
Adhesive strenght problems between a not full cured uv base coat
and a 2C-PUR-Top-Coat (white pigmented)
under cured
UV-clear coat on MDF-substrate
adhesion problems between
the two layers
Quelle: Jorg Prieto, 3P
Cleavage products of photoinitiator
(alpha-Hydroxyketones)
O
O
.
hv
.
HO
.
+
HO
- H.
1-Hydroxy-cyclohexyl-phenyl-ketone
Hydroxy-cyclohexyl-Radikal
O
.
HO
+H
Cyclohexanon
O
O
H
O
Benzil
Benzaldehyd
Geruch nach Bittermandelöl
Cleavage products of photoinitiator
(alpha-Hydroxyketones)
O
O
OH
.
H3C CH3
.
OH
+
H3C CH3
1-phenyl-2-hydroxy-2-methyl-propan-1-on
OH
O
O
O
OH
H3C
+
H3C CH3
H3C
CH3
O
Benzil
Aceton
H3C
OH
CH3
CH3
Schematic figure  Matting of coatings
wet film
paint shrinkage thorught
solvent evaporation
dryed paint film
matt surface  uv coating
Querschnitt eines mattierten Lackfilms
Cross-section through a matting paint film
Quelle: Foto Degussa/Evonik
Effect of the application and curing process to quality and
gloss results (roller coater)
surface quality
(uniformity of the paint )
very good
not optimum
W/G/N/N
Gloss
high
N/N
W/G/W
W/G/N/N
N/N
W/G/W
W
low
W =
N/N =
G =
W
1 x roller coater
roller wet in wet w/w
„slightly cured “ (not full curing paint film))
Degree of gloss (100 % UV-Lacquer) depending on the
temperature of the lacquer and roller coater process
60
Gloss 60˚
cold substrate
hot substrate
47
40
hot substrate + lacquer
39
39
38
35
34
29
26
24
25
25
23
20
0
roller coater
wet/wet
roll coater not full Walzen gelieren
curing wet/wet
Walzen
roller coater not
full curing a.
roller coater
cold substate (Gloss in relation to roller wet/wet)
100%
ca. 80 %
ca. 50 % - 55 %
ca. 50% - 60%
Application processes to coat wood pieces
• Dipping process
• Flow coater
• Drum process
• Spraying
• Curtain coater
• Roller coater
• Vacuum process
Quelle: Prieto/Kiene “Holzbeschichtung”
Spraying processes in the wood coatings industry
• 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 )
Automatic surface spraying systems
Trommeln / drum process
Coatings drum to coat
small pieces
Walther Trowal
GmbH & Co. KG
Rheinische Straße 3537
D-42781 Haan
Trommeln / drum process
Lab drum
Quelle: Jorge Prieto 3P
Prinzip der Gießmaschine
Principle of the curtain coater machine
Depositing
Gießkopf
Paint
supply
Lackzufuhr
Paint curtain
Lackvorhang
Feed direction
Vorschubrichtung
Transportband
Conveyer belt
aufgegossener
Applied paint
Lackfilm
Holzwerkstück
Wood substrate
Paint collectors
Lackauffangrinne
Lackpumpe
pump
Paint reservoir
Lackbehälter
head
Roller coater (unidirectional principle)
Application roller
Blade
Dosing roller
Paint
Substrate
Counter roller
Feed direction
Roller coater (unidirectional principle)
Blade
Application roller
Dosing roller
Paint
Feed direction
Substrate
Counter roller
Application process for furniture
- Roller coater process Sanding
Wood stain
UV-base coat
UV-base coat
UV-top coat
Sanding machine for wood
Längsaggregat / Queraggregat /
Queraggregat / Längsaggregat / Bürstenwalzen
Anwendung: Flexible Konfiguration für furnierte Platten
mit Längs- und Querfurnieren
Quelle: Karl Heesemann Maschinenfabrik
cross and longitudinal sanding
UV-roller coater line for furniture
Line speed 20 – 25 m/min
maple, beech, oak, cherry veneer
1
2
3
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
5
6
7
8
9
10
Conveyer belt
Sanding machine
Dust cleaner unit
Roller coater (smooth roller ), UV base coat approx. 8 – 10 g/m 2
UV-tunnel with 2 mercury lamps 80 W/cm, (not full cured)
Roller coater (smooth roller), UV base coat approx. 8 g/m 2
UV-tunnel with 3 mercury lamps 80 W/cm („full curing“)
Sanding machine
Dust cleaner unit
Roller coater (smooth roller), UV top coat
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/m 2)
UV-tunnel with 4 mercury lamps 80 W/cm („full curng“)
Conveyer belt
11
12
13
UV-roller coater line for wooden parquet
Line speed 30 – 40 m/min
Parquet flooring like maple, beech, oak
5
1
2
3
5.
6.
7.
8.
9.
10.
11.
7
8
9
10
11
4
21
1.
2.
3.
4.
6
20
Conveyer belt
Sanding machine
Dust cleaner unit
Roller coater (smooth rubber roller)
UV-Primer (water based) approx. 10 g/m2
Jet dryer 80 – 90 ˚C
Filling roller coater for UV-Filler, approx. 25 – 30 g/m2
UV-tunnel with 2 mercury lamps 80 W/cm
(„not full curing“)
UV base coat (Anti-abrasiv coat) approx. 10 – 12 g/m2
UV-tunnel with 2 mercury lamps 80 W/cm
UV base coat (Anti-abrasive coat) approx. 10 – 12 g/m2
UV tunnel with 2 mercury lamps 80 W/cm
19
18
17
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
16
15
14
Transport unit (curve)
UV base coat (sanding base coat) approx. 10 g/m2
(„full curing“)
Sanding machine
Dust cleaner unit
Roller coater (smooth ruber roller) for UV top coat, approx. 5 – 8 g/m2
Roller coater (smooth ruber roller) for UV top coat, approx. 5 – 8 g/m2
(„full curing“)
Conveyer belt
13
12
Testing of furniture surfaces
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
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:
Fire classification of construction products and building elements – Part1
2010-01
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
Thank you!
3P International Coating Consulting
Kreisstraße 68 – 44532 Lünen
Tel.: 02306-927000 - Mobil: 01632930778
E-Mail: [email protected] – www.3P-ICC.com
Copyright Pagnosoft© - 3P Lünen

short course: principles of parquet and furniture

Transcription

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