1. Liquid Paint System Design & Applications II Wednesday June 6, 2001 Considerations for Applying UV Coatings Presented by: John Owed ITW Ransburg Electrostatic Systems

2. Considerations for Applying UV Coatings n What are “UV” Coatings? n Where are “UV” Coatings used? n Advantages of “UV” Coatings?

3. n Evaluating Existing Application Equipment for use with UV –Fluid Delivery Equipment –Application Equipment n Testing UV Materials for Your Application –Application Testing –Performance Requirements Considerations for Applying UV Coatings

4. What are UV Coatings

5. n UV coatings are formulated with 100% reactive liquid vehicles such as: –Oligomers –Monomers –Photoinitiators –Additives What are “UV” Coatings? n Coatings which are cured using various wave lengths of ultraviolet light. - Resin - Solvent - Catalyst - Additives

6. Where are UV Coatings Used

7. Where are “UV” Coatings used? Wheel Cover Rims Brake Components Mirror Housings Door Handles Exterior Trim Headlamps Tail Lights Starter Motors Adhesives Sealant Electrical Potting Automotive Applications

8. Where are “UV” Coatings used?

9. Restaurant Seating Flooring Cabinet Frames and Doors

10. Advantageous of UV Coatings

11. Advantages of “UV” Coatings? n South Coast Air Quality Management District (SCAQMD) has recognized UV as an exempt process. –Eliminates need to wait months for permitting. –Minimizes cost associated with permitting. n Environmental friendly process –UV Coatings are available in 100% solid formulations, no solvents = no VOC.

12. Advantages of “UV” Coatings? n Instantaneous Cure Time –Once exposed to high intensity UV light, coating converts from liquid to plastic in a fraction of a second. –Minimizes opportunity for contamination by air borne dirt. –Reduces floor space requirements typically associated with thermal cure ovens. –Less inventory tied up in the manufacturing process.

13. n Reduced manufacturing cycle. –Utilizes and consumes less energy. Spray Area Cure Chamber Unload Load Advantages of “UV” Coatings?

14. n Low Temperature Process –Works well with products that are temperature sensitive. –Idea for large metallic parts which would typically require a long cool down time. –Final surface temperature will depend on length of exposure and mass of product cured. n High Abrasion and Stain Resistance

15. Evaluating Existing Application Equipment for use with UV

16. n Fluid Supply Options –Peristaltic pump –Diaphragm pump –Piston Pump Evaluating Application Equipment –Pressure pot \ fluid regulator

17. n Regardless of the system used, the following items must be considered: –All wetted components in the fluid stream must be stainless steel or Teflon. –All fluid supply lines and tubes should be opaque. –Minimize exposure of coating to all light sources (fluorescent and sunlight). –UV coatings are shear sensitive and are not compatible with piston or gear pumps. Evaluating Application Equipment

18. n Pressure pot \ fluid regulator –Basic system –Grounded for solvent borne coatings Variable Pneumatic Signal Pressure Pot 60 - 80 psi air pressure To Paint Applicator Coating Material Pressure Pot Fluid Regulator Evaluating Application Equipment

19. Non-conductive drive shaft Variable Speed Drive Motor Return From Three-way Valve To Applicator Solvent Flush To Applicator Pump Head Cover Gravity Feed Container Note: Used to feed a single applicator. Three-way Valve n Positive displacement pump Evaluating Application Equipment

20. Pump Drum Back Pressure Regulator Fluid Regulator Paint Filter Paint Heater (optional) Return From CCV Stack Solvent PaintAir To Applicators Solvent Flush To Applicators n Diaphragm or piston pump –Used for circulating systems and bulk supply Evaluating Application Equipment

21. n Effects of heat on coating –Heat will lower viscosity of coating material. n Effects of heat on product coated –A heated part cause UV material to flow –Part should be cured immediately after coating (note: any residual solvents must be “flashed-off”). –Aids in atomization of coatings. –Simplifies fluid handling. Evaluating Application Equipment

23. n Most end users start out using their existing equipment configuration. –Equipment can not properly atomize the coating material. –Solvents are used to reduce the material, defeating the original objective to eliminate solvents. Evaluating Application Equipment

24. n UV materials can be applied with a wide variety of spray application equipment. Evaluating Application Equipment

25. n Air atomization - air is used to atomize coating into fine particles. n Conventional air spray - high pressure, low volume n HVLP air spray - high volume low pressure n Works best with lower solids coatings Evaluating Application Equipment

26. n Hydraulic atomization - material is forced through a fixed orifice at high pressure. n Conventional Airless: 2000 - 3500 psi fluid pressure. n Air Assisted Airless: 300 - 1500 psi n High shear is induced on coatings with piston style pumps. Evaluating Application Equipment

27. n Rotary atomizer - centrifugal force is used to atomize coating material. –Ability to atomize high viscosity coatings. –Serrated edge “bell” cup aids in atomization process. –Electrostatic applicator yields high transfer efficiency Evaluating Application Equipment

28. n Unique feature of 100% solids material: wet film thickness = dry film thickness Dry Film = 1.0 mils 1.0 mil2.0 mil “wet” 4.0 mil “wet” 25% solids by volume material 50% solids by volume material 100% solids by volume material Dry Film = 1.0 milsDry \Wet Film Evaluating Application Equipment

29. n Regardless of the application equipment used, fluid delivery rate is one of the most critical parameters to control (very critical with pigmented systems, excessive film may not cure properly). n Positive displacement pump offers good control of fluid flow rate since delivery is based on rotation of pump drive mechanism. n With pressure pot or diaphragm pump system, a flow meter can be placed in the fluid stream and interfaced with a flow controller. Evaluating Application Equipment

30. n Closed Loop flow Control Flow Meter Fluid Regulator Fluid Inlet Fluid Outlet Flow Controller Transducer Electrical Signal Pneumatic Signal Compare Adjust Measure Evaluating Application Equipment

31. Testing UV Materials for Your Application

32. –Coating Supplier –Equipment Supplier –Lamp Supplier n Find a place to test the process. Testing UV for Your Application –Need to simulate proposed or existing process as closely as possible. –Conveyor system, application equipment, curing system. –Keep safety in mind n Form a team:

33. n Must confirm coating meets physical properties. Performance Requirements –Adhesion –Corrosion resistance –Hardness –Abrasion –Gloss n Coating supplier will make recommendations on type of lamps to use –Wave length of lamps must be matched to photoinitiators in coating to ensure proper Cure.

34. –Provides acceptable coverage on the product. –Able to obtain good overall appearance. Performance Requirements n Equipment Supplier –Achieves good atomization quality with equipment demonstrated. –Save coated samples. –Measure dry film thickness. –Document material usage \ parts per gallon.

35. Performance Requirements –Have them make recommendation on lamp configuration and quantity. –Lamps must be installed with safety in mind, lights must be interlocked and shielded to prevent operator exposure. n Lighting Supplier –Although lights can fit in a small footprint, keep maintenance and accessibility in mind.

36. ConclusionConclusion n UV Coatings can offer: –An environmentally friendly solution. –A more streamlined manufacturing process. n Existing fluid delivery and application equipment may be adapted to apply UV materials. n Assemble a team consisting of coating manufacture, equipment supplier and lamp supplier.

37. Thank-youThank-you If I can be of any additional assistance's Please contact me: John Owed ITW Ransburg Electrostatic Systems 320 Phillips Ave. Toledo, Ohio 43612 Phone: 419\470-2066 Fax: 419\470-2185 E-mail: johno@itwransburg.com