Introduction into powder coatings
DSM Coating Resins
Powder Coating - February 05 -
Introduction into powder coatings 1
• Polymerisation
• Chemistries
• chemical reaction
• advantage/disadvantages
• Application
• Melting/Curing process
• Matting
DSM Coating Resins
Powder Coating - February 05 -
Two types of Polymerisation processes 2
· Addition polymerisation
-A polymerization in which the growth of polymer chains
proceeds by addition reactions between molecules of
all degrees of polymerization (e.g. acrylics)
· Condensation polymerisation
- A polymerization in which the growth of polymer chains
proceeds by condenstation reactions between molecules of
all degrees of polymerization with loss of small molecules
like water. (e.g. polyesters)
DSM Coating Resins
Powder Coating - February 05 -
Raw materials 3
· Diols (glycols) · Dicarboxylic acids
·Neopentylglycol ·terephthalic acid
·Ethyleneglycol ·isophthalic acid
·propyleneglycol-1,2
· Polyalcohols · Polycarboxylic acids
·Trimethylolpropane ·trimellitic anhydride
·glycerol
DSM Coating Resins
Powder Coating - February 05 -
Esterification 4
· Esterification:
· Acid + Alcohol Ester + Water
· Polyacid + Polyalcohol Polyester + Water
· Hydrolysis:
· Polyester + Water Polyacid + Polyalcohol
· Overall:
· Polyacid + Polyalcohol Polyester + Water
DSM Coating Resins
Powder Coating - February 05 -
Main reaction 5
Excess of OH OH-functional polyester
Excess of COOH COOH-functional polyester
DSM Coating Resins
Powder Coating - February 05 -
Powder Coating Formulation 6
· Resin (polyester)
· Crosslinker
· Pigments / Fillers
· Flow agents
· Degassing agents
· Catalysts
DSM Coating Resins
Powder Coating - February 05 -
Chemistries (Binder systems) 7
• Interior • bisphenol A epoxies • Carboxylic polyester
(hybrid)
• Exterior • Araldite PT 810 (TGIC) • Carboxylic polyester
• Primid XL 552 / QM 1260
• Araldite PT 910
• Mix crosslinker
• Uranox
• (blocked) Isocyanates • Hydroxyl polyester
• glycoluril
DSM Coating Resins
Powder Coating - February 05 -
Overview of the characteristics of binder
8
systems
Polyester Polyester Polyester Polyester Uranox Uranox/ Polyester/
/ Epoxy / TGIC / Primid / Primid Isocyanate
PT 910 no split-off
Flexibility ++ ++ ++ ++ ++ ++ ++
Flow ++ ++ ++ ++ + ++ ++
adjustability
Exterior -- ++ ++ ++ + ++ ++
durability
Powder ++ + + +/± ± + +
stability
Colour stability
- overbake + ++ + ++ ± ± +
- direct gas + ++ ± ++ + + +
oven
Processing ++ ++ + + ++ ++ +/++
Split-off ++ ++ - ++ ++ + ++
products
Blister-free ++ ++ - ++ ++ + +
layer thickness
Labelling ++ -- ++ ± ++ ++ ++
DSM Coating Resins
Powder Coating - February 05 -
Hybrids 9
CH3 CH3
O O
OH + CH CH2 O C O OH O C O
O
CH2
CH3 CH2 HC CH3 CH2 HC
CH2
CH3
OH
O OH
Carboxylated + Bisphenol A diglycidyl ethers
Polyester
O
R2
R1 O
OH
DSM Coating Resins
Powder Coating - February 05 -
Hybrids 10
+ Advantages - Disadvantage
• Price/performance • Outdoor durability
• Flexibility
• Large curing window
• Ease of processing
• Powder stability
• Chemical resistance
DSM Coating Resins
Powder Coating - February 05 -
Carboxyl Polyesters for Hybrids 11
Crosslinker: bisphenol A epoxies
• 50/50 systems • Acid value 70-85
• 60/40 systems • Acid value 48-55
• 70/30 systems • Acid value 32-38
DSM Coating Resins
Powder Coating - February 05 -
Outdoor durable Crosslinkers 12
Araldite PT 810 Huntsman
XL 552 / QM 1260 EMS
PT 910/PT 912 Huntsman
Uranox DSM Resins
BF 1540 / BF 1320 Creanova
LS 2147 Bayer
DSM Coating Resins
Powder Coating - February 05 -
TGIC 13
O O CH 2
+ CH O
O
OH
H 2C C CH 2
OH
N N HC CH 2
O OH
O
C C
O N O
Carboxylated + TGIC
Polyester (triglycidylisocyanurate)
CH 2
H 2C CH
O
R2
R1 O
OH
DSM Coating Resins
Powder Coating - February 05 -
TGIC 14
+ Advantages - Disadvantage
• Flexibility • Labeling
• Large curing window
• Outdoor durability
• Colour stability
• Processing
• Powder stability
DSM Coating Resins
Powder Coating - February 05 -
Primid (XL 552, QM 1260) 15
O OH
O
O
OH
+
HO N
OH N OH
O OH
O
Carboxylated + Primid XL-552, ex-EMS
OH
Polyester Primid
HO
O + H2O
N
R1 O R3
DSM Coating Resins
Powder Coating - February 05 -
Primid (XL 552, QM 1260) 16
+ Advantages - Disadvantage
• Label free • Yellowing tendency
• System cost • Low blister-free layer thickness
• Low curing temperatures • Water sensitivity
• Outdoor durability • Proces sensitivity
• Powder stability
DSM Coating Resins
Powder Coating - February 05 -
PT 910 (PT 912) 17
O O O
O
OH
+
OH
O OH O O 0<n<1
O
n
Carboxylated + O O O
Polyester Araldite PT 910 and PT 912, ex-
Vantico
O
R2
R1 O
OH
DSM Coating Resins
Powder Coating - February 05 -
PT 910 (PT 912) 18
+ Advantages - Disadvantage
• Well-known chemistry • Xi Labeling
• Excelent exterior durability • Lower cross-link density
• Thick layers • Processing sensitivity
• Colour stability
DSM Coating Resins
Powder Coating - February 05 -
Mixed cross linker 19
• Combination of carboxylated resin with 2 cross linkers
• e.g. PT 910/Primid
• Primid/Uranox
DSM Coating Resins
Powder Coating - February 05 -
Uranox 20
O O O
O H3C O
OH
+ CH2
OH
R
O OH O n
Carboxylated + Uranox, ex-DSM Coating
Polyester Resins
O
R2
R1 O
OH
DSM Coating Resins
Powder Coating - February 05 -
Uranox 21
+ Advantages - Disadvantage
• No Hazard labelling • Powder stability
• Processing properties (P7200 and P 7300)
• Pigment wetting • Yellowing under extreme test
conditions
DSM Coating Resins
Powder Coating - February 05 -
Polyurethanes 22
HO OH O
+
H O O H
R N N R N C O R O C N
OH
n
Hydroxylated polyester + Internally blocked
isocyanates
R1 O NH
R2
DSM Coating Resins
Powder Coating - February 05 -
Polyurethanes 23
+ Advantages - Disadvantage
• Outdoor durability • Price
• Powder stability • Caprolactam blocked types:
• Flow • Split-off products
• Chemical resistance
DSM Coating Resins
Powder Coating - February 05 -
Polyester/cross linker ratio (carboxylated
24
resins)
• Equivalent weight polyester • Example: AV= 35
• 56100 / AV = EW1 • 56100 / 35 = 1600
• Equivalent weight Cross-linker: • Primid XL 552: EW = 84
EW2
• Stoichiometric resin ratio:
• (EW1 / (EW1 + EW2))*100% • (1600 / (1600 + 84))*100% =
• 95% Polyester
• 5% Primid XL 552
DSM Coating Resins
Powder Coating - February 05 -
Polyester/cross linker ratio (Hydroxylated
25
resins)
• - Equivalent weight polyester • Example: HV= 42
• 56100 / HV = EW1 • 56100 / 42 = 1336
• - Equivalent weight Cross-linker: • BF 1540: EW = 280
EW2
• Stoichiometric resin ratio:
• (EW1 / (EW1 + EW2))*100% • (1336 / (1336 + 280))*100% =
• 82% Polyester
• 18% BF 1540
DSM Coating Resins
Powder Coating - February 05 -
Polyester / crosslinker ratio several Acid
26
values
Ratio Polyester / crosslinker
EW AV
20 28 35 53 80
Araldite GT 7004 700 80/20 75/25 70/30 60/40 50/50
Araldite PT 810 110 96/4 95/5 93/7
(TGIC)
Primid XL 552 84 97/3 96/4 95/5 93/7
Primid QM 1260 100 97/3 95/5 94/6 91/9
Araldite PT 910 150 93/7 91/9
DSM Coating Resins
Powder Coating - February 05 -
Application 27
Air + powder Corona
High voltage
supply
Air + powder Tribo
DSM Coating Resins
Powder Coating - February 05 -
Corona Packaging 28
DSM Coating Resins
Powder Coating - February 05 -
Corona Faraday cage 29
DSM Coating Resins
Powder Coating - February 05 -
Corona Back ionisation 30
DSM Coating Resins
Powder Coating - February 05 -
Tribo 31
DSM Coating Resins
Powder Coating - February 05 -
Melting / curing proces melt cure stages 32
25°C 100°C 150°C 200°C
high viscosity start melting start reaction high viscosity
decrease viscosity increase viscosity flow stops
increase flowing decrease flow x-linked film
DSM Coating Resins
Powder Coating - February 05 -
Viscosity curves 33
10000 250
200
1000
150
100
100
10
50
1 0
0 100 200 300 400 500 600
high reactive low reactive
non reacting temperature profile
DSM Coating Resins
Powder Coating - February 05 -
Influence of melting rate on viscosity 34
4 5 0 0
4 0 0 0
3 5 0 0
3 0 0 0
viscosity
2 5 0 0 20°C/min
2 0 0 0
40°C/min
1 5 0 0
1 0 0 0
80°C/min
5 0 0
0 1 2 3 4 5 6 7 8 9 10
Time (min)
DSM Coating Resins
Powder Coating - February 05 -
Simplified DSC curve 35
DSM Coating Resins
Powder Coating - February 05 -
Influence of particle size 36
DSM Coating Resins
Powder Coating - February 05 -
Tg versus physical stability 37
10
9
8
Physical stability
7
6
5
4
3
2
1
0
20 30 40 50 60 70
Powder Tg
DSM Coating Resins
Powder Coating - February 05 -
Influence % cross-linker on Tg
(only TGIC and PT 910, Primid XL 552 and Epoxy resin Powder Tg 38
not (hardly) influenced)
Influence % cross-linker on Tg
12 70
68
10 66
64 %TGIC
Powder Tg (C)
% cross-linker
8
62
6 60 %PT 910
58
4 56 Resin Tg 64
icw TGIC
2 54
Resin Tg 68
52
icw PT 910
0 50
5 10 15 20 25 30 35 40
Acid Value
DSM Coating Resins
Powder Coating - February 05 -
Relation viscosity and resin Tg 39
1600
1400
1200
Viscosity dPas
1000
800
600
400
200
0
20 40 60 80
resin Tg
DSM Coating Resins
Powder Coating - February 05 -
Matting 40
• Powders are more difficult to matt than wet paints
• Techniques
• matting agents
• dry blend
DSM Coating Resins
Powder Coating - February 05 -
Mat powder coatings (Dry blend systems) 41
• fast with slow,different AV or different chemistries
• In generally wheatherability and mechanical properties
are OK
• Sparkling effect
• Extra processing step involved
• TGIC
E.g. P2220/P4800 with wax
• Freedom of formulation
• TGIC/PUR
• Freedom of formulation
DSM Coating Resins
Powder Coating - February 05 -
Mat powder coatings 42
• Primid
E.g. P870/P833, P873/P835 (optional with DT3329 )
+ gloss setting, mechanical properties
• water split off can give disturbances, gloss variations per layer thickness,
very low gloss is difficult
• PT910
E.g. P2240/P3487 with wax (DT 3329)
+ no splitt off
• moderate mechanicals, powder stability, not very low gloss
• PT910/Primid
+ low gloss possible
• bad mechanicals
DSM Coating Resins
Powder Coating - February 05 -
