Paints and Coatings Industries

Paints and Coatings Industries: Trends, Innovation and New Technologies

 

1.2.3 Hybrid Technology Paints/Coatings

As a result of many years of laboratory work by paints and coatings specialists, the chemical combination of multiple paint/coating technologies to create a hybrid paint/coating is referred to as Hybrid Technology Paints/Coatings. The technologies that have stood out in recent years are as follows:

1.2.3.1 Polyurea

Paint and coating products in this technological class result from the chemical reaction between polymeric isocyanate components of different structures, also known as 2K polyurethane hardener, and amine polymeric components of different structures, particularly those found in chemically resistant epoxies.

Image 1: Symbolic chemical composition of paints and coatings with polyurea technology

Notable characteristics include the ability to be applied at very high thicknesses and very rapidly (ranging from several hundred microns to thousands of microns), the capability to cure very quickly (within minutes or even seconds), high chemical resistance, impact resistance along with corrosion protection, and better elastomeric flexibility compared to competitors. Wastewater treatment ponds, chemical tank floors, overflow basins, underground and above-ground pipelines, and roof coatings are among the 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 the reaction of polyaspartic ester with urethane chemical groups.

Image 2: Symbolic chemical composition of paints and coatings with polyaspartic technology

Due to their corrosion resistance and gloss and color retention properties, paints with this technology achieve the atmospheric protection normally provided in 3 coats with just 2 coats by using 1 less paint/coating layer. (3 coats → 2 coats)

Image 3: Achieving the same protection performance with 2 coats instead of 3 thanks to polyaspartic technology.

Through the use of paints and coatings with polyaspartic technology, less material is consumed and, as a result, advantages such as reduced labor and lower solvent emissions can be achieved.

1.2.3.3 Fluoropolymer

This is a technology created by chemically reacting fluorinated polymers with urethane groups. Polyvinylidene fluoride (PVDF) and fluoroethylene vinyl ether (FEVE) technologies are the prominent fluoropolymer paint and coating technologies today. Products with this technology exist for both liquid and powder paints.

Image 4: Chemical structure of paints and coatings with polyaspartic technology such as PVDF and FEVE.

This is a technology that stands out for its high gloss and superior color retention. For this reason, it is ideal for prestigious structures where aesthetic protection is desired for many years (20-25, even 30+ years) without requiring significant maintenance.

1.2.3.4 Polysiloxane

The inorganic-organic hybrid polysiloxane technology results from the reaction between a silicon-based skeletal chemical structure (inorganic component) and organic chemical groups used in alkyd, acrylic or epoxy paints.

Image 5: Chemical structure of paints and coatings with polysiloxane technology.

The aim here is to impart to the formulated paint/coating product the resistance of silicon groups to external factors combined with properties such as flexibility, corrosion and chemical resistance derived from the chemical groups used in the organic portion.

Image 6: Contributions of organic and inorganic portions to polysiloxane technology.

Additionally, it is a known fact that with this technology, the number of paint/coating layers and total film thicknesses are reduced, thereby reducing labor and material consumption: Image 7: Polysiloxane paints provide 1 coat savings compared to conventional paint systems. For more detailed information regarding polysiloxane technology, please refer to the references section at the end of this article.

1.2.3.5 Thin-Film Coating Technology

Paint or coating films ranging in thickness from nanometers (one billionth of a meter, 1×10−9 m) to micrometers (1×10−6 m) are referred to in the literature as Thin Films. Paint and coating materials with this technology are produced using nanotechnological production technologies such as sol-gel technology.

Image 8: What is SOL-GEL technology? What are its products?

The main application areas include the optical, electrical, battery or photovoltaic industries, and application methods include different deposition technologies such as Physical Vapor Deposition or Chemical Vapor Deposition. The greatest distinction of this technology is that the final product film thickness is generally measured in nanometers (nm) and as a result is significantly thinner than the paints and coatings we know (300 nm – 10 micrometers).

1.2.3.6 Silicate Mineral Paints

This technology, which particularly concerns the construction sector, is a paint technology that contains silicate minerals as a binder. Due to the minerals and silicates it contains, it bonds chemically to concrete surfaces. For this reason, in addition to the superficial adhesion of other concrete paints, it can penetrate the concrete surface and bond very strongly to concrete surfaces.

Image 9: Microscopic view of silicate mineral paints

Due to its high breathability and chemical resistance, it provides better adhesion and significantly better protection against external factors (sun, rain, etc.) compared to other conventional paints (even resistant to acid rain). Its non-toxic nature also makes it environmentally friendly. With proper formulation, this technology can also be used in the fire retardant sector.

2. Equipment, Instruments and Systems

Perhaps the most striking developments within paints and coatings technology have occurred in the areas of surface preparation equipment, paint/coating application systems, inspection equipment, and laboratory test instruments. Let us examine these in turn:

2.1 Surface Preparation Equipment - New Technologies

In paint and coating application projects, the most intensive time, labor, and consumables are typically required during surface preparation operations. For this reason, technologies that provide time, labor and material savings along with improved workplace safety and more environmentally friendly methods are continuously being developed. Some of these include:

2.1.2 Laser Surface Cleaning

Although laser technology has been known for many years in welding, drilling, and cutting operations, laser surface cleaning is a relatively new and niche technology that has been introduced to the market in recent years. Its adaptation to the industrial paints and coatings sector has accelerated in recent years, especially after its success in removing organic materials from surfaces has been proven.

Image 10: Surface cleaning equipment using laser technology.

The main advantages of this technology include non-contact operation, absence of abrasive materials, and significant waste reduction. As a result, surface cleaning and preparation operations represent a more environmentally friendly and safer technology.

2.1.3 Motorized Equipment Achieving Sandblasting Quality Surface Cleaning

Tools such as stone and sandpaper used for surface cleaning in the paints and coatings industry provide cleaning quality far inferior to abrasive sandblasting. However, in recent years, motorized equipment manufacturers have introduced technologies with nearly equivalent capabilities to sandblasting. Perhaps the most important of these is a technology known as Bristle Blasting, which uses specially designed and tensioned metallic brush wires to strike the surface in vertical rotation, achieving cleaning quality approaching SA3 sandblasting levels while simultaneously providing surface roughness suitable for paint and coating materials.

Image 11: Cleaning metal surfaces with motorized patented equipment featuring metallic brush wires.

Thus, without using any abrasive material, it is possible to achieve a surface on metal surfaces that is close to abrasive sandblasting cleaning quality and provides significant roughness (100 microns and above).

2.1.4 Robotic Systems

This robot technology developed for surface preparation and cleaning operations using both abrasive sandblasting and water-based methods (such as water jetting and wet blasting) eliminates certain handicaps of manual operation and provides the following advantages: • Through sensors and multi-axis robots, creating complete digital mapping of complex parts; ensuring no area is left unprepared on the component • Again through sensors and multi-axis robots, achieving more optimal surface roughness; resulting in reduced water and/or abrasive consumption • Minimizing occupational health and safety risks, as fewer operators are needed in the environment (only to monitor the robotic system and perform touch-up work when needed) Additionally, using robotic blasting systems can yield significant material and labor savings, especially in highly repetitive and serial manufacturing operations.

Image 12: Automatic surface cleaning with robotic systems

2.2 Paint/Coating Applications - New Technologies 2.2.1 Electronically Proportioned Spray Systems

Most modern industrial paint and coating chemical products are two-component. That is, one component/can contains resin and binder, while the other component/can contains hardener and other additives.

Image 13: Multi-component paint spraying application with electronically proportioned systems

This technology provides flexibility in both two-component paints and paint/coating applications, allowing paint and coating products with different mixing ratios to be easily applied with precision in correct proportions, while also minimizing waste material from over-mixing and unused portions.

2.2.2 Portable Miniature Airless Spray Systems

Equipment also known as Airless Paint Pumps are traditionally quite large in design and cannot be carried with one hand. However, in recent years, some spray equipment manufacturers have developed portable/mobile/handheld airless paint pumps that can be easily operated with one hand and can operate on rechargeable batteries or standard electrical power.

Image 14: Portable miniature airless spray systems.

2.2.3 Radiation Energy Curing

Radiation energy curing (or briefly, radiation curing) is a drying and curing technology for specially designed paints and coatings using devices emitting special radiation energy such as ultraviolet (UV), infrared (IR), or electron beam (EB). Initially used in graphic design printing varnishes and inks, this technology, which was used in the wood and plastic sectors, has in recent years been adapted for metal surfaces; It has also begun to be used in the Coil Coatings sector (for example, it can be successfully applied to metal surfaces such as aluminum, galvanized steel, brass, magnesium, and nickel).

Image 15: UV, IR and EB Curing Lamps

The most important advantages of this technology are;

• Faster drying and curing. • Low or zero volatile organic compounds (VOC) (100% solids systems). • Better final performance.

2.2.4 Robotic Systems

Robotic painting systems used in the automotive industry since the 1980s have emerged in the past 5 years as a technology used in the industrial wet and powder paint industry, depending on advances in sensors and robotic systems.

Image 16: Automatic painting with robotic systems

The following advantages have been achieved through this technology:

• Through sensors and multi-axis robots, creating complete digital mapping of complex parts; ensuring no area on the component remains unpainted. • Again through sensors and multi-axis robots, achieving more optimal paint film thicknesses; resulting in reduced paint consumption. • Minimizing occupational health and safety risks, as there will be no paint operators in the environment or very few will be needed (touch-up work may only be required).   PCS. Tolga Dıraz Chemical Engineer / Protective Paints and Coatings Specialist Head, TUCSA TK-4 Surface Protection Committee    

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/ INORGAN%C4%B0KORGAN%C4%B0K_HYBR%C4%B0T_ POLYS%C4%B0LOKSAN_BOYALAR_PCS._Tolga_DIRAZ