CA2351036A1 - Method for powder coating wood and composition for use therewith - Google Patents
Method for powder coating wood and composition for use therewith Download PDFInfo
- Publication number
- CA2351036A1 CA2351036A1 CA 2351036 CA2351036A CA2351036A1 CA 2351036 A1 CA2351036 A1 CA 2351036A1 CA 2351036 CA2351036 CA 2351036 CA 2351036 A CA2351036 A CA 2351036A CA 2351036 A1 CA2351036 A1 CA 2351036A1
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- CA
- Canada
- Prior art keywords
- article
- conductive
- epoxy
- powder coating
- composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
- B05D1/045—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field on non-conductive substrates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2203/00—Other substrates
- B05D2203/20—Wood or similar material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/002—Pretreatement
- B05D3/005—Pretreatment for allowing a non-conductive substrate to be electrostatically coated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
- B05D3/0263—After-treatment with IR heaters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
- B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
- B05D3/065—After-treatment
- B05D3/067—Curing or cross-linking the coating
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
The present invention provides a method of powder coating an article with a non-conductive surface. The method consists of the steps of applying a conductive composition that is a mixture of an epoxy polarity additive and an epoxy solvent to the non-conductive surface, allowing the conductive composition to dry, thereby forming a conductive layer on the non-conductive surface, electrostatically spraying a powder coating composition onto the conductive layer, and, heat curing the powder coating composition to form an overcoating layer.
Description
METHOD FOR POWDER COATING WOOD
The present invention relates to methods for powder coating articles, and in particular to methods for powdercoating articles made of non-conductive, heat sensitive materials such as wood.
Background Powder coating is a method of applying a finish to an article by applying a very fine dry powder to the article and then heat curing the article. Typically, the powder particles are electrostatically sprayed onto the article and are attracted to the article by electrostatic forces. When heated to a suitable temperature for an appropriate length of time, the powder on the article melts and fuses together, thereby forming a continuous coating on the surface of the article.
Powder coating is becoming an increasingly desirable method of applying a finish to articles. Powder coatings, unlike paint finishes, require no solvents, and they expel virtually no volatile compounds to the surrounding atmosphere once heat cured. Further, powder overspray is recyclable.
The present invention relates to methods for powder coating articles, and in particular to methods for powdercoating articles made of non-conductive, heat sensitive materials such as wood.
Background Powder coating is a method of applying a finish to an article by applying a very fine dry powder to the article and then heat curing the article. Typically, the powder particles are electrostatically sprayed onto the article and are attracted to the article by electrostatic forces. When heated to a suitable temperature for an appropriate length of time, the powder on the article melts and fuses together, thereby forming a continuous coating on the surface of the article.
Powder coating is becoming an increasingly desirable method of applying a finish to articles. Powder coatings, unlike paint finishes, require no solvents, and they expel virtually no volatile compounds to the surrounding atmosphere once heat cured. Further, powder overspray is recyclable.
Powder coating of electrically-conductive materials such as metals has long been known. It has only recently, however, become more commonplace to powder coat non-conductive, non-metallic materials.
Typically, non-conductive materials are powder coated by heating an article in an oven at a relatively high temperature, and then spraying it with powder material in the conventional manner. The heating of the article may cause it to electrostatically attract powder particles, and may cause the powder to melt slightly, causing the powder simply to stick to the article's surface. The article is then heat cured in the conventional manner.
While this method is somewhat successful when applied to many non-conductive materials, some heat sensitive materials such as wood are not easily powdercoated in this manner, since the process is very temperature-dependent. First, some materials can easily be damaged by the heat. Second, articles powdercoated in this manner need to be of a relatively uniform thickness to retain heat evenly over their surface. If heat is not retained evenly over the surface of the article, powder particles are not evenly attracted to the article, leading to a poor, patchy finish.
Typically, non-conductive materials are powder coated by heating an article in an oven at a relatively high temperature, and then spraying it with powder material in the conventional manner. The heating of the article may cause it to electrostatically attract powder particles, and may cause the powder to melt slightly, causing the powder simply to stick to the article's surface. The article is then heat cured in the conventional manner.
While this method is somewhat successful when applied to many non-conductive materials, some heat sensitive materials such as wood are not easily powdercoated in this manner, since the process is very temperature-dependent. First, some materials can easily be damaged by the heat. Second, articles powdercoated in this manner need to be of a relatively uniform thickness to retain heat evenly over their surface. If heat is not retained evenly over the surface of the article, powder particles are not evenly attracted to the article, leading to a poor, patchy finish.
This problem is exacerbated in the case of wood articles, in which moisture is also a concern, since different areas of the wood have different moisture levels. Moisture is important since a high level of moisture can cause "moisture bubbles" in the final finish.
The above-described currently-popular method of powder coating non-conductive surfaces relies on the heating of the article to make it conductive. Another known method for rendering the surface of non-conductive articles conductive is to pre-treat the articles with a conductive coating. The following patents disclose a composition or process for powder coating non-conductive articles:
United States Patent No. 5,721,052, which issued 24 February, 1998 to Muthiah et al. discloses certain epoxy-based powder coating compositions and a method whereby wood can be electrostatically spray coated with these compositions by using a grounded conveyor line on which the wood is placed. The invention of this patent is, primarily, the coating substance, which appears to have a use somewhat limited to pieces of wood with a fairly uniform thickness.
The above-described currently-popular method of powder coating non-conductive surfaces relies on the heating of the article to make it conductive. Another known method for rendering the surface of non-conductive articles conductive is to pre-treat the articles with a conductive coating. The following patents disclose a composition or process for powder coating non-conductive articles:
United States Patent No. 5,721,052, which issued 24 February, 1998 to Muthiah et al. discloses certain epoxy-based powder coating compositions and a method whereby wood can be electrostatically spray coated with these compositions by using a grounded conveyor line on which the wood is placed. The invention of this patent is, primarily, the coating substance, which appears to have a use somewhat limited to pieces of wood with a fairly uniform thickness.
United States Patent No. 5,792,558, which issued 11 August, 1998 to Jonas et al. discloses a process for the electrostatic lacquering of non-conductive surfaces that uses organic, electrically conductive polymers to pre-coat a surface that is to be lacquered.
United States Patent No. 6.077,610, which issued 20 June, 2000 to Correll et al. discloses a method for powder coating that may be used to coat a "porous particleboard, pre-coated with a conductive liquid composition". This patent is primarily directed toward the coating substance, not the conductive liquid composition.
United States Patent No. 6,146,710, which issued 14 November, 2000 to Symons discloses a method of powder coating a substance such as wood that has an initial pre-treating step where the substance is impregnated with a dicarboxylic anhydride, a tricarboxylic anhydride, an isocyanate thermosetting resin, or a combination thereof.
Despite these advances, powdercoating of articles made of non-conductive, heat sensitive materials such as wood is still difficult, and there continues to exist a need for a method for powdercoating such articles, and a composition for use with that method.
One aspect of the present invention provides a method of powder coating an article with a non-conductive surface. The method comprises the steps of applying a conductive composition to the non-conductive surface, allowing the conductive composition to dry, thereby forming a conductive layer on the non-conductive surface, electrostatically spraying a powder coating composition onto the conductive layer, and, heat curing the powder coating composition to form an overcoating layer.
The conductive composition used in the present method is preferably an epoxy polarity additive, and may also include a solvent.
The epoxy polarity additive is preferably comprised of approximately 30-40% (by weight) aromatic naphtha, 20-30% 2-propoxyethanol (glycol ether), 13-20% trimethylbenzene, 1, 2, 4 isomer, 1.5-4% N-butanol, 1.5-4% xylene isomers, and, 0-1 % ethyl benzene. A product having these characteristics is sold by Lily Industries, Inc. of Indianapolis, IN under the Product Code "2600RX", which is also known as "RX2600".
Brief Description of Drawings Figure 1 is a block diagram of the method of the present invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may in some instances be practised without these specific details. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
The method of the present invention comprises a first step of pre-treating a surface of an article desired to be powder coated with a conductive composition. Following this, the second step in the new method comprises allowing the conductive composition to dry to form a conductive layer on the article.
United States Patent No. 6.077,610, which issued 20 June, 2000 to Correll et al. discloses a method for powder coating that may be used to coat a "porous particleboard, pre-coated with a conductive liquid composition". This patent is primarily directed toward the coating substance, not the conductive liquid composition.
United States Patent No. 6,146,710, which issued 14 November, 2000 to Symons discloses a method of powder coating a substance such as wood that has an initial pre-treating step where the substance is impregnated with a dicarboxylic anhydride, a tricarboxylic anhydride, an isocyanate thermosetting resin, or a combination thereof.
Despite these advances, powdercoating of articles made of non-conductive, heat sensitive materials such as wood is still difficult, and there continues to exist a need for a method for powdercoating such articles, and a composition for use with that method.
One aspect of the present invention provides a method of powder coating an article with a non-conductive surface. The method comprises the steps of applying a conductive composition to the non-conductive surface, allowing the conductive composition to dry, thereby forming a conductive layer on the non-conductive surface, electrostatically spraying a powder coating composition onto the conductive layer, and, heat curing the powder coating composition to form an overcoating layer.
The conductive composition used in the present method is preferably an epoxy polarity additive, and may also include a solvent.
The epoxy polarity additive is preferably comprised of approximately 30-40% (by weight) aromatic naphtha, 20-30% 2-propoxyethanol (glycol ether), 13-20% trimethylbenzene, 1, 2, 4 isomer, 1.5-4% N-butanol, 1.5-4% xylene isomers, and, 0-1 % ethyl benzene. A product having these characteristics is sold by Lily Industries, Inc. of Indianapolis, IN under the Product Code "2600RX", which is also known as "RX2600".
Brief Description of Drawings Figure 1 is a block diagram of the method of the present invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may in some instances be practised without these specific details. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
The method of the present invention comprises a first step of pre-treating a surface of an article desired to be powder coated with a conductive composition. Following this, the second step in the new method comprises allowing the conductive composition to dry to form a conductive layer on the article.
As a third step in the method, a typical powder coating composition is ectrostatically sprayed onto the conductive layer, and the fourth step of the method comprises heat curing the article to form an overcoating layer.
This method allows assembled articles to be powder coated, even if the articles are heat-sensitive, and of varying dimen-sions. This provides a distinct advantage over methods which require coating the individual pieces of an article separately and then assembling the pieces.
In a preferred embodiment, where the article is made of wood, such as a cupboard or cabinet door, the first step of the method comprises spraying the article with a conductive composition, and preferably, with a composition known in the chemical arts as an epoxy polarity additive. The inventors have determined that a particularly effective composition usable in the inventive method is the epoxy polarity additive sold by Lily Industries, Inc. of Indianapolis, IN under the Product Code "2600RX", which is also known as "RX2600". This product is comprised of approximately 30-40% (by weight) aromatic naphtha, 20-30% 2-propoxyethanol (glycol ether), 13-20%
trimethylbenzene, 1, 2, 4 isomer, 1.5-4% N-butanol, 1.5-4% xylene isomers, and, 0-1 % ethyl benzene.
The epoxy polarity additive may be diluted with an epoxy solvent, forming a solution having between 0% and 80% by weight solvent. The solvent sold by Courterco Inc. of Elkhart IN, under the Product Number 2677A has been found to be an effective solvent.
Naphtha may also be an effective solvent.
The second step of allowing the conductive composition to dry is not altogether necessary but is desirable, especially if a solvent is added to the epoxy polarity additive. In particular, the present method is most effective when the article is "air-dried" after being sprayed, and not heated. The inventors have determined that the word "dry", for the purposes of this discussion, means that the article should be "dry to the touch" as determined by tactile and visual examination of the article.
It has been determined that a drying time of between about'/2 hour and 1 hour is usually effective before spraying the article with powder. If the article is left for too long to dry, then the powder will no longer be attracted to the article when sprayed.
_g_ In the fourth, heating, step, the inventors have determined that a heating time of between 5-20 minutes at a temperature of 400°F
will effectively cure the article without causing the polarity additive to "bubble out", and without causing any other "outgasses" from the wood. This curing can be done in any known manner, including in batch ovens, or by ultraviolet or infrared radiation.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of the invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
This method allows assembled articles to be powder coated, even if the articles are heat-sensitive, and of varying dimen-sions. This provides a distinct advantage over methods which require coating the individual pieces of an article separately and then assembling the pieces.
In a preferred embodiment, where the article is made of wood, such as a cupboard or cabinet door, the first step of the method comprises spraying the article with a conductive composition, and preferably, with a composition known in the chemical arts as an epoxy polarity additive. The inventors have determined that a particularly effective composition usable in the inventive method is the epoxy polarity additive sold by Lily Industries, Inc. of Indianapolis, IN under the Product Code "2600RX", which is also known as "RX2600". This product is comprised of approximately 30-40% (by weight) aromatic naphtha, 20-30% 2-propoxyethanol (glycol ether), 13-20%
trimethylbenzene, 1, 2, 4 isomer, 1.5-4% N-butanol, 1.5-4% xylene isomers, and, 0-1 % ethyl benzene.
The epoxy polarity additive may be diluted with an epoxy solvent, forming a solution having between 0% and 80% by weight solvent. The solvent sold by Courterco Inc. of Elkhart IN, under the Product Number 2677A has been found to be an effective solvent.
Naphtha may also be an effective solvent.
The second step of allowing the conductive composition to dry is not altogether necessary but is desirable, especially if a solvent is added to the epoxy polarity additive. In particular, the present method is most effective when the article is "air-dried" after being sprayed, and not heated. The inventors have determined that the word "dry", for the purposes of this discussion, means that the article should be "dry to the touch" as determined by tactile and visual examination of the article.
It has been determined that a drying time of between about'/2 hour and 1 hour is usually effective before spraying the article with powder. If the article is left for too long to dry, then the powder will no longer be attracted to the article when sprayed.
_g_ In the fourth, heating, step, the inventors have determined that a heating time of between 5-20 minutes at a temperature of 400°F
will effectively cure the article without causing the polarity additive to "bubble out", and without causing any other "outgasses" from the wood. This curing can be done in any known manner, including in batch ovens, or by ultraviolet or infrared radiation.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of the invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
Claims (14)
1. A method of powder coating an article having a non-conductive surface, the method comprising the steps of:
(a) applying a conductive composition to said non-conductive surface of said article, said conductive composition comprising an epoxy polarity additive;
(b) allowing said conductive composition to dry for a period of time, thereby forming a conductive layer on said non-conductive surface;
(c) electrostatically spraying a powder coating composition onto said conductive layer; and (d) heat curing said powder coating composition to form an overcoating layer.
(a) applying a conductive composition to said non-conductive surface of said article, said conductive composition comprising an epoxy polarity additive;
(b) allowing said conductive composition to dry for a period of time, thereby forming a conductive layer on said non-conductive surface;
(c) electrostatically spraying a powder coating composition onto said conductive layer; and (d) heat curing said powder coating composition to form an overcoating layer.
2. The method of claim 1 wherein the conductive composition further comprises a solvent.
3. The method of claim 2 wherein the solvent forms 1-80% of said conductive composition, by weight.
4. The method of claim 1 wherein the epoxy polarity additive is comprised of:
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanol(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanol(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
5. The method of claim 3 wherein the epoxy polarity additive is comprised of:
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanol(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanol(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
6. The method of either of claims 4 or 5 wherein the epoxy polarity additive is the product sold by Lily Industries, Inc. of Indianapo-lis, IN under the Product Code "2600RX".
7. The method of claim 2 wherein the solvent is the product sold by Courterco Inc. of Elkhart IN, under the Product Number 2677A.
8. The method of claim 2 wherein the solvent is naphtha.
9. The use of an epoxy polarity additive for pre-treating a non-conductive surface to prepare said non-conductive surface for electrostatic spraying with a powder coating.
10. The use claimed in claim 9, wherein the epoxy polarity additive is comprised of:
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanal(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
(a) 30-40% (by weight) aromatic naphtha;
(b) 20-30% 2-propoxyethanal(glycol ether);
(c) 13-20% trimethylbenzene, 1, 2, 4 isomer;
(d) 1.5-4% N-butanol;
(e) 1.5-4% xylene isomers; and (f) 0-1 % ethyl benzene.
11. The method claimed in claim 1 wherein the step of applying said conductive composition comprises spraying onto the article a solution comprised of an epoxy polarity additive and solvent.
12. The method claimed in claim 11 wherein the step of allowing the article to dry comprises allowing the article to air-dry for a period of time between 1/2 hour and 1 hour.
13. The method claimed in claim 12 wherein the step of heat curing the article comprises heating the article at a temperature of approximately 400°F for a period of time between 5 minutes and 20 minutes.
14. The method claimed in claim 12 wherein the step of heat curing the article comprises treating the article with either ultraviolet or infrared radiation for a period of time suitable to fuse together the particles of said powder coating composition.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2351036 CA2351036A1 (en) | 2001-06-15 | 2001-06-15 | Method for powder coating wood and composition for use therewith |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2351036 CA2351036A1 (en) | 2001-06-15 | 2001-06-15 | Method for powder coating wood and composition for use therewith |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2351036A1 true CA2351036A1 (en) | 2002-12-15 |
Family
ID=4169314
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2351036 Abandoned CA2351036A1 (en) | 2001-06-15 | 2001-06-15 | Method for powder coating wood and composition for use therewith |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2351036A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108296138A (en) * | 2018-04-13 | 2018-07-20 | 广东葫芦堡文化科技股份有限公司 | A kind of electrostatic dusting technique on furniture board surface |
-
2001
- 2001-06-15 CA CA 2351036 patent/CA2351036A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108296138A (en) * | 2018-04-13 | 2018-07-20 | 广东葫芦堡文化科技股份有限公司 | A kind of electrostatic dusting technique on furniture board surface |
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| EEER | Examination request | ||
| FZDE | Dead |