{"id":11788,"date":"2021-05-14T06:05:46","date_gmt":"2021-05-14T12:05:46","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=11788"},"modified":"2021-05-28T09:19:29","modified_gmt":"2021-05-28T15:19:29","slug":"pc-the-basics-of-powder-coatings","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/11788\/pc-the-basics-of-powder-coatings\/","title":{"rendered":"The Basics of Powder Coatings"},"content":{"rendered":"

Introduction<\/h2>\n

Industries are searching for coating systems that contain a lower amount of organic solvents<\/a><\/strong>. A variety of approaches are used to achieve this. The switch from solvent-based to water-based<\/strong> systems has been made in several applications. Also, liquid systems that contain less solvent (high-solids coatings<\/a>) or no solvent at all (solvent-free coatings<\/a>) are being used. Powder coatings<\/a> are a winning technology for specific industrial applications.<\/p>\n

Powder paint<\/h2>\n

A powder paint<\/a> consists of solid particles. Each particle contains the key ingredients of the system.<\/p>\n

\"Powder<\/p>\n

The core of a powder paint is the binder system<\/a>, that may consist of more than one component. Both resin(s)<\/a> and crosslinker(s)<\/a> are present in a thermosetting binder system. Most powder paints contain solid particles, being pigments<\/a> and\/or fillers<\/a>. Finally, the system contains a low percentage of additives<\/a>. These can be components that accelerate the crosslink reaction of resin and crosslinker, assure the escape of air or improve flow and levelling, see the Film Formation section of this article<\/em>.<\/p>\n

A powder paint is storage stable when the glass transition temperature (Tg<\/sub><\/strong>) of the binder system is high enough. At temperatures below Tg<\/sub> , the powder particles are in the glass<\/strong> state, thus preventing that the particles melt together during storage and transport. Preferably, the Tg<\/sub> of a powder paint is above 50 \u00b0C.<\/p>\n

Production<\/h2>\n

Powder paint is produced in a few steps. The raw materials, which are solid at room temperature, are mixed on macroscopic level in a mixer. This mixture is fed into a kneader, called extruder<\/strong>.<\/p>\n

\"Single<\/p>\n

The core of a single-screw extruder is a screw that rotates in a heated shaft. The material is transported through the extruder because the screw rotates. The shaft of the extruder is heated in steps to a temperature between 70 and 120 \u00b0C. The binder system and the additives melt in the Melting<\/em> zone. Mixing of the molten raw materials up to molecular level takes place in the last part of the extruder. Also, wetting and dispersion<\/strong> of the pigments and fillers takes place in the Mixing & Dispersion<\/em> zone. The homogeneous melt that comes out of the extruder is cooled and becomes solid. The material is then flaked and ground into solid particles of the desired size.<\/p>\n

Application<\/h2>\n

Most powder paints are applied on metal<\/strong> objects by spray application. An airflow transports the powder through the spray gun and the powder particles are electrostatically charged within the spray gun. The particles adhere to the metal surface because of the charge difference between the paint and the substrate.<\/p>\n

\"Discover
Electrostatic spray application of powder paint on metal objects<\/figcaption><\/figure>\n

Film formation<\/h2>\n

During film formation, the solid powder paint particles transform into a strong and smooth coating. Several phenomena play an important role during film formation.<\/p>\n

\"Film<\/p>\n

The object, that is covered with powder, goes into an oven. The particles melt<\/strong> and merge<\/strong> to form a uniform and smooth layer. A critical aspect is that air, that is present between the solid particles, must be able to escape during film formation. De-aeration is assured by using a degassing agent<\/strong> as one of the additives in the powder paint formulation.<\/p>\n

A chemical reaction of resin and crosslinker, called cure<\/strong> or crosslinking<\/strong>, takes place during film formation of a thermosetting system.<\/p>\n

A thermoplastic powder coating, on the other hand, does not contain crosslinker. The resin of a thermoplastic system only melts, flows and levels during film formation. The film becomes hard upon cooling.<\/p>\n

The future<\/h2>\n

Many powder paints are thermal curing systems, implying that they cure at elevated temperatures. A key challenge in powder coating technology is the development and improvement of systems that can be applied on heat-sensitive substrates<\/strong> like wood, Medium Density Fiberboard (MDF) and plastics1,2<\/sup>.<\/p>\n

Radiation cure, by using ultraviolet (UV) or electron beam (EB<\/strong>) radiation is more and more used to arrange film formation of powder paints3,4<\/sup>.<\/p>\n

A relative thin coating layer is sufficient for many applications. Regular powder paint, with particle diameter between 20 and 70 \u00b5m, results in a coating layer thickness of 50-100 \u00b5m. So-called thin film<\/strong> powder coatings, having a layer thickness that can be as low as 25 \u00b5m, require powder paints that consist of only small particles. Both production and application of fine powders is challenging, but it is already done in powder coating industry.<\/p>\n

References<\/h2>\n
    \n
  1. Article Considerations for Developing Wood Coatings<\/em><\/a>, Ron Lewarchik, 20 March 2015, Prospector Knowledge Center.<\/li>\n
  2. Article Powder Coatings for Heat-Sensitive Substrates<\/em><\/a>, Jochum Beetsma, 2 September 2016, Prospector Knowledge Center.<\/li>\n
  3. Article Using UV\/EB Resins in Coatings<\/em><\/a>, Marc Hirsch, 21 October 2016, Prospector Knowledge Center.<\/li>\n
  4. Article\u00a0 Radiation Cure Coatings \u2013 The Ultimate in Rapid Cure Technology<\/em><\/a>, Ron Lewarchik, 2 April 2021, Prospector Knowledge Center.\u00a0<\/span><\/li>\n<\/ol>\n","protected":false},"excerpt":{"rendered":"

    Introduction Industries are searching for coating systems that contain a lower amount of organic solvents. A variety of approaches are used to achieve this. The switch from solvent-based to water-based systems has been made in several applications. Also, liquid systems … Continued<\/a><\/p>\n","protected":false},"author":11,"featured_media":11789,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[],"ppma_author":[1235],"class_list":{"0":"post-11788","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"entry"},"yoast_head":"\nThe Basics of Powder Coatings - Prospector Knowledge Center<\/title>\n<meta name=\"description\" content=\"Discover a coating system that contains a lower amount of organic solvents. 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