Paint & Coating Industries

20.12.2018

Paint & Coating Industries: Trends, Innovations and New Technologies

1.2,3 Hybrid Paints and Coatings

After long years of studies of paint/coating specialist in the research labs, a new class of paints/coatings are formulated by chemical bonding of more than two paint / coating technologies which is broadly known as hybrid paints/coatings. The technologies 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 -which is also known as 2K polyurethane paint hardeners- with the amine polymeric compounds encountered in chemical resistant epoxy paints/coatings.

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

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

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, which is formed by reaction of Polyaspartic-esters with Urethane chemical groups.

Figure 2: Symbolic chemical formation of paints/coatings that has 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 / coating in the painting system) to provide the same level of corrosion, color and gloss resistance in the same atmospheric service conditions. (3 coats -> 2 coats)

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

Thanks to the paints / coatings with Polyaspartic technology, less material usage is used -and because of this- advantages such as less labor and lower solvent emissions can be provided.

1.2.3.3 Fluoropolymer

This technology is the result of chemically reacting the fluorinated polymers with the urethane groups. Polyvinylidene fluoride (PVDF) and Fluoroethylene-vinyl-ether (FEVE) technologies are the most outstanding Fluoropolymer paint and coating technologies. Products with this technology are available for both wet and powder coating.

Figure 4: Chemical structure of coatings and coatings with Polyaspartic technologies such as PVDF and FEVE.

This technology stands out with high gloss and high color retention features. Therefore, it is ideal for aesthetic protection of prestigious structures for that do not require any major maintenance for many years (20-25 or even over 30 years).

1.2.3.4 Polysiloxane

By the reaction of 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 brought to light.

Figure 5: Chemical structure of coatings and coatings with Polysiloxane technology.

The purpose herein is to provide more 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 paints-coatings.

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

Also, it is a well-known fact that the decrease in layer number and total film thicknesses yields to a noticeable labor and material costs decrease:

Figure 7: Polysiloxane paints provide 1 coat of paint saving in comparison with conventional paint system. For more information about the 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 between nanometer (one billionth of a meter, (1×10−9 m) to micrometer (one millionth of a meter, 1×10−6 m) in thickness are known in literature as thin film. Paints/coatings possessing this technology are being produced via nanotechnological manufacturing techniques like Sol-gel technology.

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

Main application areas are; optics, electric, batteries or photovoltaic industries where they can be applied via specialized techniques i.e. Physical Vapor Deposition or Chemical Vapor Deposition. The biggest difference in this technology is the resultant film thickness is the ultra-thin film thicknesses ranging from 300 nm – 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 technology is a paint technology that contains Silicate minerals as binders. Thanks to its minerals and silicate, it is chemically bonded to concrete surfaces. Therefore, in addition to the superficial adhesion of other concrete paints, it can be bonded 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 an accurate formulation.

2. Devices and Equipment

Perhaps the most striking developments in paint and coating technologies were the surface preparation tools, paint / coating application equipment, inspection gages and laboratory test instruments. Let’s take a closer look at these:

2.1 Surface Preparation Tools – New Technologies

In paint and coating applications projects in the intensive time, 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 of the example:

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 launched in recent years as a relatively new and niche technology. The adaptation to the industrial paint and coating industry is accelerating, especially after the successful removal of the organic materials has been proven at large majority.

Figure 10: Surface cleaning equipment using laser technology.

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

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 a mediocre cleaning quality far from abrasive blasting. However, the motorized power tools developed in recent years have been started to be launched on the market with almost equivalent outcomes in comparison with abrasive blasting. One of the most important of these is the technique known as Bristle Blaster, using the specially designed and tensioned metallic brush wires to rotate in the vertical direction, clean the surface almost close to the SA3 abrasive blasting level and also roughen the surface as required for the paint / coating before application.

Figure 11: Cleaning metal surfaces with motorized patented device with metallic brushed 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 this robotic systems technology developed for surface preparation and cleaning processes with both abrasive sandblasting and water (such as water jetting and water blasting), those handicaps of manual removal have been eliminated and the following advantages have been achieved: •Complete digital mapping of complex / grifting parts with sensors and multi-axis robots; thereby no surfaces left without surface cleaning / preparation on any part of the material in concern. •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 of 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 gained especially in repeating and close to 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 of the modern Industrial Paint / Coating chemical products are 2-component. That is, one can may include a component consisting of resin or binders, while other component 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, the two-component paints & coating products with different mixing ratios can be easily applied precisely in the correct proportions, as well as 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 / mobile / portable airless paint pumps that can be easily operated with one hand and can work with a charged battery or even with the 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, the printing varnishes and ink, wood and plastic used for the industry, this technology has been recently made suitable for metal surfaces; It is also being used in the coil coatings industry (for example, aluminum, galvanized steel, brass, magnesium and nickel can be applied successfully on metal surfaces.)

Figure 15: UV, IR and EB Curing Lamps

The most important advantages of this technology can be listed as;

•Faster drying and curing. •Volatile organic compounds (VOC) little or no (100% solids). •Better final performance.

2.2.4 Robotic Systems

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

Figure16: Automatic Painting with Robotic Systems

The following advantages gained by using this technology:

• Complete digital mapping of complex / grifting 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 operator (may be required only for touching / retouching).