Вы находитесь на странице: 1из 16

A SUSTAINABLE APPROACH TO CAN AND COIL

MODERN COATING TECHNOLOGY


COATINGS
A Sustainable Approach to
Modern Coating Technology

Patcham FZC is a well-established manufacturer of specialty additives headquartered in the


United Arab Emirates. Since its inception, Patcham has steadily grown into a leading supplier
of specialty additives for the Paint & Coatings, Ink, PVC and Composite industries.

The companys Pat-Add range of coating additives includes wetting & dispersing agents,
defoamers, slip & leveling agents, rheology modifiers. Whilst keeping focus on environmental
sustainability, the company produces products using green raw materials that are APEO free
and have low or no VOC.

These products are multi functional and multi compatible, which simplifies the production
process, reduces the chance of errors and minimizes inventory thus improving cost effective-
ness.

Patcham has built a strong manufacturing and R&D infrastructure that enables the rapid
transition from concept to products. The company has strategically located technical service
laboratories, offices and representatives around the world to provide the most efficient
customer service. In addition, a well-developed robust supply chain network enables it to
deliver its products and services to customers around the globe with minimal lead-time.

www.patchamltd.com
Contents

Introduction 1
Patcham additive package 2
Primers and backcoats 3
Topcoats 5
Black topcoat 6
Red topcoat 7
Blue topcoat 8

www.patchamltd.com
Introduction

Coil coating is a continuous, automated process for coating metal before fabrication into end
products. A steel or aluminum substrate is delivered in coils from the rolling mills. The metal
coil is positioned at the beginning of the coating line and in one continuous process, the coil
is unwound, cleaned, treated, primed and painted before being coiled at the other end and
packaged for shipment to other industries to be fabricated into variety of end products. All
of this happens at up to 700 feet per minute!

The excellent top coat finishes in these coatings are directly influenced by the resins,
pigments and the additives used. Innovative additives from Patcham, designed to work with
pigments in various resins deliver the attributes necessary for the required topcoat
performance.

Entrance accumulator Prime Curing


coater oven

Dry
Exit accumulator

Uncoiler

Pretreatment Top Finish


(Cleaning and coater oven Water
quench Source: NCCA
conversion coating)
Cut-o

Figure 1: Typical coil coating line

The following steps take place on a modern coating line:

01. Stitching the strip to the previous coil 07. Curing (often only 15 to 60 seconds)
02. Cleaning the strip 08. Cooling the strip
03. Power brushing 09. Top coating on one or both sides
04. Pre-treating with chemicals 10. Second curing
05. Drying the strip 11. Cooling down to room temperature
06. Applying primer on one or both sides 12. Rewinding of the coated coil

www.patchamltd.com 1
Patcham additive package
Table 1: Patcham additives for coil coatings

Type of coating Additive Grade Dosage(%)

On SOP
White pigment : 1-5
Top Coat Low structured carbon black : 30 to 50
Dispersing PatAdd DA 947
Polyester : Melamine High structured carbon black : 50 to 120
additive High Molar Volume polymeric
Inorganic pigments : 10-20
dispersing agent
Organic blue/green : 40-60
Organic red/violet/yellow : 30-70
Grinding stage

Primer PatAdd DA 1801 On SOP


Dispersing Polyester anionic wetting and 1-5 (Inorganic and extenders)
Polyester : Melamine : Epoxy additive dispersing agents Grinding stage

Top coat and primer PatAdd AF 70 0.1 to 0.3


Defoamer Best for defoaming in solvent (On total formulation)
Polyester : Melamine
free high build coatings Letdown stage

Top coat and primer PatAdd AF 62 0.1 to 0.3


Polyester : Melamine Defoamer Silicone and fluoro free polymeric (On total formulation)
defoamer Letdown stage

Top coat Surface PatAdd LE 1070 0.2 to 0.5


Polyester : Melamine Solvent free, fluoro and silicone (On total formulation)
modifier
free polyester surface modifier Letdown stage

Figure 2: The painting system

Figure 3a: Adhesion test Figure 3b: Pencil hardness test

NB: Adhesion test is done as per ASTM D 3359-02 (tape test) and the pencil hardness test is done as per ASTM D 3363-00

www.patchamltd.com 2
Patcham additive package - Primers and backcoats

Wetting and dispersing additives

Primers and backcoats

The main role of primers is to provide good adhesion of the topcoat to the pre-treated
substrate. Primers have a crucial role in protecting the substrate from corrosion. Further-
more, primers are expected to be compatible with subsequent layers of coatings. Backcoats
on the other hand, have a dual function. They are formulated to have properties of both the
topcoat and a primer. Back coats are applied on the reverse of the metal sheet.

Pat-Add DA 1801

An additive for dispersion of inorganic pigments, extenders and matting agents

An anionic polyester additive, where substrate adhesion is not affected due to


its chemical nature
The optimum benefit of the additive is to provide reduction of settling of pigment
and extenders, thus preventing syneresis

It is recommended for resin systems i.e., epoxy, alkyd, HMMM, PU

Figure 4: Application of primers

www.patchamltd.com 3
Patcham additive package - Primers and backcoats
Table 2: Guide formulation of Pat-Add DA 1801 for coil coat primers/backcoats

Raw materials Weight (%) Raw materials Weight (%)

Millbase Letdown
Saturated polyester 25.50 Melamine formaldehyde 13.00
Pat-Add DA 1801 0.75 Saturated polyester 10.00
Titanium dioxide 12.00 Epoxy resin 4.00
Barytes 5.50 Solvesso 150 5.35
Zinc phosphate 8.00 Acid catalyst 0.60
Talc 1250 5.00 Total 100.00
Fumed silica 0.30
Solvesso 150 10.00

SOP dispersant 1.50%


Resin ratio (PE:MM) 60:40
Peak metal temperature 2320C
Bar coater 10m

Figure 5: Coil coating primer actual paint sample

Table 3: Viscosity and stability

Stability study Pat-Add DA1801

Initial viscosity, cP 638


Viscosity after storage,
695
500C x 1 month, cP

Settling No settling observed

www.patchamltd.com 4
Patcham additive package - Topcoats

The ultimate goal of the multi step coil coating processes is to provide a fast, durable, cost
effective and a sustainable product with an exceptional topcoat finish to meet the approval of
the end use product manufacturers. The top coat is often required to be glossy or matt,
colored, flexible, particularly UV-resistant or have a combination of many different functions.

The additives highlighted below have been designed to work with the pigments and resins to
provide the desired topcoat finish

Pat-Add DA 947

High Molar Volume technology polymeric dispersant for solvent-based


industrial coatings
Enhances color strength and hue of pigment in paints and pigment
concentrates
Equally charges pigments to prevent possible co-flocculation in
cross-tinting of paints
Improves wetting and prevents thixotrophy
Highly recommended for acid-catalyzed polyester/melamine
topcoats and PVDF systems such as coil coatings, automotive
finishes and general industrial coatings

Pat-Add LE 1070

Silicone and fluoro-free surface modifier


Most efficient levelling agent in solventborne systems, notably industrial
coatings, including stoving enamels and can coatings
Unlike most polysiloxane based levelling agents, Pat-Add LE 1070 does
not affect surface slip or intercoat adhesion
Additive is allowed to be used in main coating and ink formulations for
food contact applications

Pat-Add AF 62

Efficient silicone free defoamer for solventborne coatings


Recommended for clear system resin system i.e., 2K PU, TPA, Epoxy
and saturated polyester
Suitable for various application procedures, such as brushing,
airless spraying, roller and curtain coating

www.patchamltd.com 5
Patcham additive package - Black topcoat
Table 4: Guide formulation for black topcoat

Raw materials Weight (%)

Mill base
Saturated polyester 20.00
Pat-Add DA 947 1.33
Black pigment 2.00
Solvesso 150 16.17
Fumed silica 0.50
Letdown
Saturated polyester 27.00
Melamine formaldehyde 18.50
Pat-Add LE 1070 0.30
Pat-Add AF 62 0.20
Acid catalyst 0.50
Solvesso 150 13.50
Total 100.00

SOP dispersant 40.00% Figure 6: Saturated polyester : melamine formaldehyde


coil coating system
Resin ratio (PE:MM) 60:40

Peak metal temperature 2320C

Bar coater 36m

DFT of primer 5m

CIE lab measurement Gloss value


90 86 84

80
12
70
10
60
53 52
Gloss Values

8 50
Color Values

6 40
4 30 25
20 21
2 20 18

0 10
DA 947 Ref A Ref B DA 947 Ref A Ref B 3 4
2 3
-2 Initial After stability 0
DA 947 Ref A Ref B DA 947 Ref A Ref B
L* 2.17 8.39 4.92 2.19 10.7 5.84 Initial After stability
b* 0.28 1.89 -0.16 0.0 2.53 1.05 Gloss values 20
o o
Gloss values 60

Figure 7 : Colour values of black topcoat Figure 8: Gloss values of black topcoat

www.patchamltd.com 6
Patcham additive package - Red topcoat
Table 5 : Starting formulation coil coating red topcoat

Raw materials Weight (%)

Mill base
Saturated polyester 20.00
Pat-Add DA 947 3.38
Pigment red 254 4.50
Solvesso 150 13.37
Letdown

Saturated polyester 28.00


Melamine formaldehyde 19.00
Pat-Add LE 1070 0.30
Pat-Add AF 62 0.20

Acid catalyst 0.50

Solvesso 150 10.75


Total 100.00
SOP dispersant 45.00%
Figure 9: Saturated polyester : melamine
Resin ratio (PE:MM) 60:40 formaldehyde coil coating system

Peak metal temperature 2320 C


Bar coater #36
DFT of primer 5m

CIE lab measurement Gloss values


56.5 8
100
7 90
88
86
56.08 80
6 74
56 70
55.88 5 63
Gloss values

60
a* values

4 51
50
E

3 40
55.5 55.45
30 30
2
20

1 10

0
55 0
DA 947 Ref A Ref B
DA 947 Ref A Ref B
Initial

a* Rub out test, dE Gloss Value 20


o o
Gloss value 60

Figure 10: Colour values of red topcoat Figure 11: Gloss values of red topcoat

www.patchamltd.com 7
Patcham additive package - Blue topcoat
Table 7: Starting formulation coil coating blue topcoat

Raw materials Weight (%)

Mill base
Saturated polyester 20.00
Pat-Add DA 947 2.63
PB 15:3 4.50
Solvesso 150 17.37
Organo clay thickener 0.50
Letdown
Saturated polyester 20.00
Melamine formaldehyde 20.00

Pat-Add LE 1070 0.30


Pat-Add AF 62 0.20

Acid catalyst 0.50

Solvesso 150 4.00

Total 100.00 Figure 12: Saturated polyester : melamine


formaldehyde coil coating system
SOP dispersant 45.00%
Resin ratio (PE:MM) 60:40
Peak metal temperature 2320 C
Bar coater #36
DFT of primer 5m

30 CIE lab measurements Gloss Values


.6

20 18.34 17.4 17.92 1.4 120

10 1.2 100 99 92 89

1
Gloss Values

0 80
L* and b* Values

72
E

0.8 61
60
-10 49

0.6 40
-20
0.4 20
-30 0.2 0

-40 DA 947 Ref A Ref B


-43.5 0
-45.1 -44.54 Initial

-50 DA 947 Ref A Ref B Gloss values 20


o
Gloss values 60
o

L* b* Rub-out test,dE

Figure 13: Colour values of blue topcoat Figure 14: Gloss values of blue topcoat

www.patchamltd.com 8
Rubout tests on panels

Rub out test of tinted topcoats

Reference Pat-Add DA 947 Reference Pat-Add DA 947


E = 0.55 E = 0.40 E = 0.74 E = 0.29

Reference Pat-Add DA 947 Reference Pat-Add DA 947


E = 1.33 E = 0.70 E = 1.92 E = 0.87

www.patchamltd.com 9
Coil coating panels

Coil coating primer

Coil coating topcoat

www.patchamltd.com 10
Notes

www.patchamltd.com
Notes

www.patchamltd.com
www.patchamltd.com

PATCHAM (FZC) PATCHAM INDIA

P.O. Box: 7753, B-52, Pravasi Industrial Estate


Saif Zone, Sharjah, UAE Vishweshwar Nagar, Off Aarey Road
Tel: +971-6-5570035 Goregoan (E), Mumbai - 400 063 (India)
Fax: +971-6-5570038 Tel: +91-22-29272471
Email: patcham@emirates.net.ae Email: india@patchamltd.com

PATCHAM EUROPE BV PATCHAM USA LLC

Klavermaten 65-1 10 Commerce Road


7472 DD Goor Fairfield, New Jersey 07004
Netherlands Tel: (201) 293-4282
Email: eu@patchamltd.com Fax: (201) 820-0818
Email: info@patchamusa.com

The information given in this booklet is intended for technical guidance without obligation. Ver. 1.0

Вам также может понравиться