Paint & Coating Industries

Paint & Coating Industries: Trends, Innovations and New Technologies

 

1.2.3 Hybrid Paints and Coatings

After years of research by paint and coating specialists in research laboratories, a new class of paints and coatings has been formulated through chemical bonding of more than two paint and coating technologies, broadly known as hybrid paints and coatings. The technologies that stand out in recent years are:

1.2.3.1 Polyurea

Paint & coating products of this technological class are produced by the reaction of the polymeric isocyanate component—also known as 2K polyurethane paint hardeners—with the amine polymeric compounds found in chemical-resistant epoxy paints and coatings.

Figure 1: Symbolic representation of chemical formation of Polyurea generic type paints and coatings

In particular, some of the prominent features are applicability in very high thicknesses and very quickly (between several hundred microns to thousands of microns). Very fast drying and curing (within minutes, even seconds), high chemical resistance, impact resistance along with corrosion resistance and better elasticity compared to competitors. Wastewater pools, chemical tank floors, overflow pools, underground and aboveground pipelines and roof coverings are some application areas.

1.2.3.2 Polyaspartic

This technology is also known in the literature as Polyaspartic Urethane (PAS). In fact, this technology is based on Aliphatic Polyurea technology and is a new hybrid technology formed by reaction of Polyaspartic esters with Urethane chemical groups.

Figure 2: Symbolic chemical formation of paints and coatings with Polyaspartic technology

Because of Polyaspartic type paints, just 2 coats of paint may be adequate instead of 3 coats normally needed (1 coat less paint and coating in the painting system) to provide the same level of corrosion, color and gloss resistance under the same atmospheric conditions. (3 coats → 2 coats)

Figure 3: The same protection performance with 2 layers instead of 3 layers thanks to Polyaspartic technology

Thanks to paints and coatings with Polyaspartic technology, less material usage is required—and because of this—advantages such as less labor and lower solvent emissions can be achieved.

1.2.3.3 Fluoropolymer

This technology results from chemically reacting fluorinated polymers with urethane groups. Polyvinylidene fluoride (PVDF) and Fluoroethylene-vinyl-ether (FEVE) technologies are the most prominent Fluoropolymer paint and coating technologies. Products with this technology are available for both liquid and powder coating.

Figure 4: Chemical structure of coatings with Polyaspartic, PVDF and FEVE technologies

This technology stands out with high gloss and high color retention features. Therefore, it is ideal for aesthetic protection of prestigious structures that require no major maintenance for many years (20-25 or even over 30 years).

1.2.3.4 Polysiloxane

By reacting a silicon-based skeleton chemical structure (inorganic component) with organic chemical groups used in alkyd, acrylic and epoxy paints, this inorganic-organic hybrid Polysiloxane technology has been developed.

Figure 5: Chemical structure of coatings with Polysiloxane technology

The purpose is to provide greater resistance to outdoor exposure with silicon groups and flexibility, corrosion and chemical resistance with the help of organic groups in the formulation of this type of paint and coating.

Figure 6: The contributions of organic and inorganic parts of Polysiloxane technology

Also, it is a well-known fact that the decrease in layer number and total film thicknesses results in noticeable labor and material cost reductions: Figure 7: Polysiloxane paints provide 1 coat savings in comparison with conventional paint systems. For more information about Polysiloxane technology, you can visit the link at the end of this article.

1.2.3.5 Thin-Film Technology

Paint and coating films having thicknesses between nanometer (one billionth of a meter, 1×10−9 m) and micrometer (one millionth of a meter, 1×10−6 m) are known in literature as thin film. Paints and coatings possessing this technology are produced via nanotechnological manufacturing techniques such as Sol-gel technology.

Figure 8: What is SOL-GEL technology? What are the products?

Main application areas are optics, electrical, batteries and photovoltaic industries, where they can be applied via specialized techniques such as Physical Vapor Deposition or Chemical Vapor Deposition. The biggest difference in this technology is the resultant film thickness—ultra-thin film thicknesses ranging from 300 nm to 10 microns—which are much thinner than conventional paints and coatings commonly known.

1.2.3.6 Mineral Paints

Particularly related to the construction sector, this paint technology contains Silicate minerals as binders. Thanks to its minerals and silicates, it is chemically bonded to concrete surfaces. Therefore, in addition to the superficial adhesion of other concrete paints, it can bond to concrete surfaces by penetrating the concrete surface.

Figure 9: Microscopic view of Silicate Mineral paints

Thanks to its high breathability and chemical resistance, it provides better adhesion than other conventional paints and much better protection against external factors (sun, rain, etc.). (It can withstand acid rain.) It is environmentally friendly with its non-toxic structure. This technology can also be used in the Fire-Retardant sector with correct formulation.

2. Devices and Equipment

Perhaps the most striking developments in paint and coating technologies have been in surface preparation tools, paint and coating application equipment, inspection gauges and laboratory test instruments. Let's take a closer look at these:

2.1 Surface Preparation Tools – New Technologies

In paint and coating application projects with intensive timelines, labor and supplies are usually required during surface preparation operations. For this reason, time, labor and consumable savings as well as occupational safety and greener technologies are constantly being developed. Following are some examples:

2.1.2 Surface Cleaning by Laser

Although laser technology has been known for many years in welding, drilling and cutting processes, laser surface cleaning has been introduced in recent years as a relatively new and niche technology. Adoption by the industrial paint and coating industry is accelerating, especially after successful removal of organic materials has been proven in the large majority of applications.

Figure 10: Surface cleaning equipment using laser technology

The main advantages of this technology are: contactless surface preparation without abrasives, thereby reducing waste considerably. As a result, laser surface preparation technology stands out as a more environmentally friendly and safer method for surface cleaning and preparation.

2.1.3 Near Abrasive Blasting Cleaning by Power Tools

Surface cleaning tools such as grinding and sanding used in the paint and coating industry offer mediocre cleaning quality far from abrasive blasting. However, motorized power tools developed in recent years have begun to be launched on the market with almost equivalent outcomes compared with abrasive blasting. One of the most important of these is the technique known as Bristle Blaster, which uses specially designed and tensioned metallic brush wires rotating in the vertical direction to clean the surface almost to the SA3 abrasive blasting level and also roughen the surface as required for paint and coating application.

Figure 11: Cleaning metal surfaces with motorized patented device with metallic brush wires

In this way, a rough surface (100 microns and over) can be obtained close to abrasive blasting cleaning on metallic surfaces without using any abrasive.

2.1.4 Robotic Systems

Thanks to robotic systems technology developed for surface preparation and cleaning processes using both abrasive sandblasting and water (such as water jetting and water blasting), the handicaps of manual removal have been eliminated and the following advantages have been achieved: • Complete digital mapping of complex or grifted parts with sensors and multi-axis robots; thereby no surfaces are left without surface cleaning and preparation on any part of the material in question. • Thanks to sensors and multi-axis robots, more optimal surface roughness; thereby less water and/or abrasive consumption. • Minimization of occupational health and safety risks due to less need for operators in the environment (only for monitoring the robotic system and touch-ups if necessary). In addition, by using Robotic Surface Preparation and Blasting Systems, large material and labor gains can be achieved especially in repetitive and near mass production jobs.

Figure 12: Automatic Surface Cleaning with Robotic Systems

2.2 Paint/Coating Applications – New Technologies 2.2.1 Spray Systems with Electronic Proportioner

Most modern industrial paint and coating chemical products are 2-component. That is, one container may include a component consisting of resin or binders, while the other container may contain hardener and other additives in a metallic can or box.

Figure 13: Multi-component Paint Spraying Application with Electronic Proportioner Systems

Thanks to this technology, two-component paint and coating products with different mixing ratios can be easily applied in the correct proportions, and the amount of unnecessary and unused waste materials for the application is minimized.

2.2.2 Miniature Portable Airless Spray Systems

Also known as the Airless Paint Pump, the equipment is traditionally quite large and cannot be lifted with one hand. However, in recent years, some spray equipment manufacturers have produced portable and mobile airless paint pumps that can be easily operated with one hand and can work with a charged battery or even with mains electricity.

Figure 14: Portable Miniature Airless Spray Systems

2.2.3 Radiation-Energy Curing

Radiation energy Curing (or briefly radiation curing) is the drying and curing technology of paints and coatings specially designed by devices emitting special radiation energy such as Ultraviolet (UV), Infrared (IR) or Electron Beam (EB). Previously used in graphic design, printing varnishes, inks, wood and plastic industries, this technology has recently been adapted for metal surfaces; it is also being used in the coil coatings industry (for example, aluminum, galvanized steel, brass, magnesium and nickel can be successfully applied on metal surfaces).

Figure 15: UV, IR and EB Curing Lamps

The most important advantages of this technology are:

• Faster drying and curing. • Little or no Volatile Organic Compounds (VOC) (100% solids). • Better final performance.

2.2.4 Robotic Systems

Robotic painting systems, which have been used in the automotive industry since the 1980s, is a technology used in the industrial and powder coating industry for the last decade due to developments in sensor and robotics systems.

Figure 16: Automatic Painting with Robotic Systems

The following advantages are gained by using this technology:

• Complete digital mapping of complex or grifted parts with sensors and multi-axis robots; in this way there is no area that is not painted on the piece. • Thanks to sensors and multi-axis robots, more optimal paint film thicknesses; therefore less paint consumption. • Minimization of occupational health and safety risks for the environment where there is little or no need for paint operators (may be required only for touching/retouching). PCS. Tolga Dıraz Chemical Engineer / Protective Coating Specialist TUCSA TK-4 Surface Protection Committee Chair    

References 1. Corrosion Prevention by Protective Coatings – Charles G. Munger & Louis D. Vincent – NACE International 2. The Protective Coating User's Handbook – Louis D. Vincent 3. BASF Coatings' Global Trend Book - BASF's Coatings division 4. Selecting Coatings for Industrial and Marine Structures – SSPC publications 5. ASM Handbook, Volume 5B: Protective Organic Coatings 6. Paint and Surface Coatings – Theory and Practice - R Lambourne T A Strivens – Woodhead Publishing 7. https://www.vocabulary.com/dictionary/trend 8. http://www.turkceanlaminedir.com/trend-62082 9. https://www.coatingsworld.com/knowledge-center/coatings-markets-amp-technologies/market-trends-amp-forecast 10. https://www.merriam-webster.com/dictionary/innovation 12. https://www.academia.edu/36712021/INORGANIC_ORGANIC_HYBRID_POLYSILOXANE_PAINTS_PCS._Tolga_DIRAZ