Sirris 2016 04-12 towards succesfull coating application-sirris

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Roadshow Smart Coating Application Lab

12.04.161 sirris | www.sirris.be | [email protected] |

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Towards successful coating applicationDaan DewulfProject Engineer [email protected] sirris | www.sirris.be | [email protected] |

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Not very succesful12.04.164 sirris | www.sirris.be | [email protected] |

First of all I would like to start with a silde about coatings that didnt perform to wellI would like to show you this because you can have a very good coating, but if you neglect some crucial steps.

De coating mag zeer goede eigenschappen hebben op het finaal product, maar als deze coating slecht is aangebracht dan zal de coating ook slecht presteren

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Applying coatings succesfully : not as easy as it sounds12.04.165What are the expectations?FunctionalityIndoor/outdoor exposure

sirris | www.sirris.be | [email protected] |Even more so: limitations?Plastic, metal, wood, mineral,Surface/workpieceTemperature resistance?Applications technology?Curing conditions?

Further,Before application of a coating, we have to consider all aspects and circumstances of the to be coated parts.What are the expectation of the coating? Which kind of function does the coating need to provide?Where is the coating exposed to?

Even more so, what are the limition of the workobject? 5

How to apply coatings - Flowchart12.04.16 sirris | www.sirris.be | [email protected] |6

PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

All these questions need answering.TO do so we need to walk through the complex complete coating process

Coating process is een heel complex gebeuren..

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Cleaning and pretreatment12.04.16Cleaning & pretreatment leads to activation of the substrateIncrease wettabilityIncrease adhesion

sirris | www.sirris.be | [email protected] |8PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

No plasma

Adhesion of coating to substrate is an absolute prerequisite for the servicability of the coating.

The demo shows a treated and untreated atmospheric plasma on PMMA. After wards, water was sprayed to show you the effect of surface activation.Due to the plasma, the surface energy is increased by incorporatioin of polar groups.

Bron :http://www.polyu.edu.hk/edc/tdg/showcase/492F_ITC/asiia/inc-lamination-151af.html?page=lamination

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Removal of surface contaminantsDust, oils, rustPhysical/MechanicalSand blastingwipingIonized airAnti-staticChemicalDegreasingSolvent ultra sonic

PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGCleaning

Strictly speaking, pretreatment also includes cleaningThe pretreatment of the samples is surface dependant

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Pretreatment12.04.16 sirris | www.sirris.be | [email protected] |10PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGTreatment of surfaceChemicalPrimingEtchingPhysicalFlame/oxidative gasCorona/glow dischargePlasma

Source: http://www.vetaphone.com/technology/corona-treatment/10

Pretreatment12.04.16Flame treatmentSurface oxidation leads to increase in polarity

ContinuousSimpleEffective

Thermal stress on componentsNot really suited for heat sensitive surfacesVery short-term effect



Pretreatment12.04.16Corona treatmentAC voltage electrode in stead of a flameOxidizes the surface by high energy oxygen ionsAdding and deleting electrons (+,- sites)

ContinuousNo thermal stress

Limited reachPlane surfaces and films (1D-2D)Short-term effect sirris | www.sirris.be | [email protected] |12PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Source: http://www.vetaphone.com/technology/corona-treatment/

Verschil tussen plasma en coronaPlasma: langere duur activatieControle van gas3D stukken mogelijkEarth friendlyCostly

CoronaVorm van plasma ontlading bij atmosfersiche drukGoedkoopMakkelijkMinder surface chemistry selectivityLimiet aan keuze substraatvoorbehandelingEnkel voor 2D

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Pretreatment12.04.16Plasma treatmentLike corona, plasma is the electrical ionization of a gasPlasma discharge creates a smooth undifferentiated cloud of ionized gas with no visible electrical filaments

More effective than coronaEffect can last several weeksSuitable for difficult to activate substrates (3D)

smaller area of activation



Pretreatment @ Smart Coating Lab12.04.16 sirris | www.sirris.be | [email protected] |14PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING


Pretreatment12.04.16 sirris | www.sirris.be | [email protected] |15PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Source: http://www.vetaphone.com/technology/corona-treatment/Nogmaals aanhalen dat voorbehandleing nodig is15

Main differences12.04.1616Although there are numerous theories explaining the principles behind the process of corona treating, the most commonly accepted theory appears to be the theory of high-speed oxidation. This theory states that the energy of the high-charged electrical corona breaks the molecular bonds on the surface of the non-polar substrate. The broken bonds then recombine with the free radicals in the corona environment to form additional polar groups on the film surface. These polar groups have a strong chemical affinity to the polar inks and adhesives, which results in improved adhesion. Similarly, the polar surface results in an increased surface energy that correlates with improved wettability.Plasma treatment or "modified atmospheric plasma" treating is very similar to traditional corona treatments with the exception that gases are injected into the corona discharge to modify the reaction with the substrate. Some materials are less reactive to a traditional corona and require this special atmospheric plasma treatment. Additionally, semi-conductive gases such as helium can be utilized to lower the operating voltage at the corona to meet other particular application requirements.Flame treating is just that, the exposure of a given substrate to an oxygen rich flame plasma for the purpose of promoting adhesion. It can be beneficial in several ways. Due to the high temperatures achieved with flame treating, it is commonly used on paper or board stock to burn off dust and fibers cleaning the surface for printing, coating or extrusion coating and works very well in the removal of annealing oils from foil to promote coating/laminating. The oxygen rich portion of the flame, known as the secondary zone, promotes oxidation in a very similar way that corona does to plastic substrates. The benefit to flame lies in the intensity of the plasma enabling higher treat levels at faster speeds with no backside treatment. Additionally, flame is not limited by gauge of material.Corona treatment is still the most popular means of achieving better adhesion and will continue to be the dominant choice for years to come. Why? Because corona treatment is still the most economical and practical means of promoting adhesion.

sirris | www.sirris.be | [email protected] |



Welke aspecten worden beoordeeld?

Druipers (te dik)Visogen (bij slechte voorbehandeling)Dekkinggraad (ev te dun)

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Coating application12.04.1618 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGCoating is sprayed (atomized)(1D-2D-3D)Coating not sprayed(1D-2D)Pneumatic high pressureBrush, roll, wipePneumatic low pressure (HVLP)DippingHydraulic (pressure feed, HVLP)FlowingRotation (bel)Bar coating/Meyer barElectrostatically assistedElectrodeposition

Just as diverse as the various substrates that can be coated, is the choice of methods by which the coating can be applied to these usually pretreated surfaces.18

DipcoatingFlow coatingBar coating/Meyer bar

1D-2D coating application12.04.1619 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Bron:http://www.spraygunworld.com/Information2/AAA/Airless%20vs%20AAA.htmlFrom small to medium sized coating capacities.The maximum output can be increased by dipping more than one panel in the same time. Depanding on the product withdrawal and drying will limit the maximum output capacity.However up to 150 panels per hour arepossible.Uniform coating thickness 1m.Coating thickness can be variedsimple and clearly(e.g.7m to 12m) just by changing the withdrawal velocity.To get reliable and continously good qualityonly very few and easy to handle parameters need to be controlled. (Viskosity, temperature, withdrawal velocity).No coating tool is required!To cover or to fill holes or gapswithin a well defined range is not a big challenge using an adequate resist. (State of the technology)Coating electrolytic galvanized 3-D structures is possible. (State of the technology)Thin panels can be coated without limitation. (State of the technology)Flexible boards which ar not planar a100%can be coated without any quality loss.If specified even thick panels (e.g. 4 mm)can be coated. ( five sides)Basicly dust and aerosols can be reduced to a minimum by the right machine concept and well selected coating and drying modules.Especially for laser direct imaging (LDI) with highly collimated laser light it is a must.Suiteable resists are made to be used and kept indipping systems formonth without any cleaning efforts.Compared to roller coaters costs for maintenance and usage are very low.The compact construction reduces the required spot.

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Pneumatic low pressure/HVLPHydraulic pressure feed/HVLP

Manual 1D-2D-3D Application12.04.1620

sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Bron:http://www.spraygunworld.com/Information2/AAA/Airless%20vs%20AAA.html

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Programming knowledgeHigher investment costProfound knowledge of different parameters

Automated 1D-2D-3D application12.04.1621 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

High flexibilityReliabilityReproducibilityParameter optimization

ParametersNozzle diameterCoating viscosityAir pressure

Influences onOverspraySurface qualityCoating speed


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Automated application12.04.1622 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGProgramming tool: Simplified Robot Programming (SRP)


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Wat kan er misgaan bij bij aanvang van iedere nieuw onderdeel? Aanhalen met eventueel visueel materlaail

Te snel gedroogd?Kromtrekken van substraatVerkleuren coating? verbranden coating?

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Drying and curing/hardening12.04.1624DryingElimination of solventsDensification

ReactionsCondensationPolymerizationOxidation/reductionChemical modification2K systems


It is a physical and chemical pro24

Drying and curing12.04.1625Thermal curingHot (circulating) airIR curing

Radiation curingUV curingUV-LED curing(Electron beam)(Microwave)(laser)


Bron: http://www.honleuv.com/news/2014/5/28/fundamental-principles-of-uv-reactive-manufacturing-processe.html25

Drying and curing @ Smart Coating Lab12.04.1626 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Bron: http://www.honleuv.com/news/2014/5/28/fundamental-principles-of-uv-reactive-manufacturing-processe.html26

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sirris | www.sirris.be | [email protected] |

PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGDrying and curing @ Smart Coating Lab

Drying and curing12.04.1628IR drying


Bron:http://infohouse.p2ric.org/ref/29/28130.pdf

Coated workpiece is heate by absorpation of IR radiationEnergy or intensity of IR radiation depends on wavelegnthrange and hence on the temperature of the emmiteing elements28

Drying and curing12.04.1629UV curing sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Drying and curing12.04.1630 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANINGHot airIRUVThick/pigmented coatings++++-Coating complexity/Cost--++Drying/Curing times--+++Energy consumption/Ecological footprint--++Maintenance cost+++-+-Investment cost+-+--Throughput-+++

Hot airIRUVHeat transfer+++/Installation size++--Flexible technology++--Line-of-sight effect/shadowing++---Thermal stress--+++Heat sensitive substrates--+++VOC--++Health issues++--

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Control & testing12.04.1632 sirris | www.sirris.be | [email protected] |PRETREATMENTAPPLICATIONDRYING & CURINGCONTROL & TESTINGCLEANING

Scratch resistanceCross-cutUV-degradationAbrasion resistanceThickness ( on metal)GlossContact angleSurface topography


+32 472 38 11 [email protected] Dewulf Project Engineer Smart Coatings12.04.16 sirris | www.sirris.be | [email protected] |

Sirris 2016 04-12 towards succesfull coating application-sirris

Technology

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