LED UV 固化涂料應用簡介 - 客戶案例研究.pdf

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1、UV Coatings for High Volume Production:Faster.Smaller.Cleaner.IntroductionMy Name:Rich LeonardCurrent Role:Sales Director(U.S.based UV Coatings company)Experience:Thin film coatings and surface treatments-28 years.Education-Materials Science,Metallurgy,Applied TechnologyCareer-Production Manager,Pro

2、cess Manager,Product Manager,and Sales.Purpose at CTT Summit:Increase awareness of sustainable UV cured coatings for the U.S.manufacturing sector.HEATSUNLIGHTUV CUREHOSPITAL395 LEDUV Light/Energy Application DiagramWhat are UV Coatings?DefinitionUnique coatings which cure when exposed to UV light en

3、ergy(instead of heat energy).CompositionOligomers:pre-polymer resin.Monomers:low weight compounds that react with oligomers.Photoinitiators:absorb UV light which initiates reaction.Additives:enhance specific properties.Basic Mechanism1.UV energy penetrates the coating and activates photoinitiators.2

4、.Photoinitiators absorb UV energy and decompose to form reactive radicals or cations.3.The reactive species cause monomers and oligomers to link together forming long polymer chains(polymerization).4.The chain reaction continues until the coating has fully cured.LED or Microwave UV LampUV Coating in

5、 liquid form as applied byspray,vacuum,roller,dipping etc.Direction of ConveyerUV Irradiation Curing(fraction of a second!)UV Coating is now fully cured/drysolid cross-linked polymer chains.Nearly Instant UV Curing ProcessOligomerMonomerPhotoinitiaterAdditives(Epoxy,Urethane,Acrylic,Polyester)UV Coa

6、ting of Pipe-400ft/minuteUV Coating of Pipe-800ft/minuteBenefits of UV CoatingsInstant Curing:Reduced production time,no drying stage.Faster Line Speeds:Increased throughput.Small Footprint:Less equipment and less material.Cleaner:Non-volatile,non-flammable,less waste,noevaporation.Durability and Pe

7、rformance:Less corrosion,wear,andweathering.Cost-Effective:Reclaimable(99%efficient),lower energycosts,rapid ROI.Appearance:Glossy or matte,clear or opaque,metallic,wide variety of colors.Suitable Substrates for UV CoatingsSubstrates:Plastics,Metals,Wood,Glass,Paper,Textiles,Ceramics,CompositesSurfa

8、ce Preparation:Substrate and application dependent:o Scale/dust removal if needed.o Cleaning if needed.o Drying if needed.o Heating if processed in a cold environment.o Plasma etching for certain plastics.UV Coated Examples:Fiberglass Bottle,Aluminum Cans,PlasticU.S.A.is Leading the World in UV Inno

9、vationTraditional Industries for UVInclude:PrintingWood FinishingMedical DevicesConsumer GoodsOptical WearElectronicsU.S.Industries leading the charge for UVInnovation:Renewable Energy(Solar Tube)Beverage Containers(LED UV)Building/Construction(sprinkler pipe,conduit,fencing,sewer pipe,fiberglass re

10、bar)Health/Beauty(metallizing)Oil/Gas(Pipe)UV 0.5mil0 HoursBare G900 HoursASTM B117 Salt Fog Test G90 4X4 Solar TubeCompare:Bare G90 vs.UV 0.5 mil thickUV Performance vs.Galvanized Steel-CorrosionUV 0.5mil384 HoursBare G90360 HoursBare G90720 HoursUV 0.5mil792 HoursWATER-BASED COATING22%SOLIDS 4.0 M

11、ilsevaporatesinto the air Solvent/WaterUV COATING100%SOLIDSWFT 1.0 MILSDFT 1.0 MILSNO EVAPORATIONComparison UV vs.Water-based CoatingUV wet film thickness to dry film thickness is 1:1Water-based WFT to DFT is about 4:1WFT4.0 to 5.0MILSDFT 1.0 MILSUV vs.Water/Solvent based coatingsWater-based coating

12、s contain 2.2lbsof VOCs/gal.Based on usage of 700/gal permonth.VOC reduction of 55,440 lbs/yearwith UV coating.Note:Permits are often required to emitVOCs or HAPs which adds cost.Check with local environmentalauthorities for more information.UV Coating emits no VOCs and no HAPsUV vs.Water/Solvent ba

13、sed coating less waste/messWater-based excess waste.Same line after switch to UV.UV Implementation ProcessStep-by-Step Guide:1.Contact an experienced expert for a consultation.oCommunicate needs and specifications.2.Work in tandem with a UV Coating company and Equipment IntegratoroFrom early plannin

14、g through start of production and beyond.Your UV Coating company should offer:Customized Solutions:oTo match your specific needs.Support in choosing the right types of technology:oEquipment(LED vs.microwave,Spray vs.Vacuum etc.)EHS training:oEasy ways to avoid excessive skin contact etc.(UV Coating

15、is a skinirritant)QA training and instructions:oAdhesion checks,thickness checks,curing etc.Recommended practice instructions:oTo maximize your ROI and minimize downtime,quality issues.On-site startup support for your entire team.oIn tandem with equipment integrator.Ongoing process support after sta

16、rtup.oRegular visits to check coating quality and be an extra set of eyes.oTo be sure your expectations are met for you and your customers.CustomerUV EquipmentIntegratorUV CoatingTechnologyUV is a Process!UV Coating Summary Smaller Faster Cleaner High ROI Many attractive colors and finishes.Leading edge technology for U.S.manufacturing.Be sure to work with the right partners for a successful outcome.o UV Coating Companyo UV Equipment IntegratorQuestions?Thank you.