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Powder coatings provide several advantages over traditional coatings: environmental friendliness, freedom of design, robustness and resistance of surfaces, possibility to seamlessly all-around coating, fast production process, cost-effectiveness. In the last years these benefits of the powder coating technology have been adopted from metal to heat-sensitive natural fibre/ wood based substrates (especially medium density fibre boards- MDF) used for interior furniture applications. Powder coated MDF furniture parts are gaining market share already in the classic furniture applications kitchen, bathroom, living and offices. The acceptance of this product is increasing as reflected by excellent growth rates and an increasing customer base. Current efforts of the powder coating industry to develop new powders with higher reactivity (i.e. lower curing temperatures and shorter curing times; e.g. 120°C/5min) will enable the powder coating of other heat-sensitive substrates like natural fibre composites, wood plastic composites, light weight panels and different plastics in the future. The coating could be applied and cured by the conventional powder coating process (electrostatic application, and melting and curing in an IR-oven) or by a new powder coating procedure based on the in-mould-coating (IMC) technique which is already established in the plastic industry. Extra value could be added in the future by the functional powder toner printing of powder coated substrates using the electrophotographic printing technology, meeting the future demand of both individualization of the furniture part surface by applying functional 3D textures and patterns and individually created coloured images and enabling shorter delivery times for these individualized parts. The paper describes the distinctiveness of powder coating on natural fibre/ wood based substrates, the requirements of the substrate and the coating powder.
The effect of hard segment content and diisocyanate structure on the transparency and mechanical properties of soft poly(dimethylsiloxane) (PDMS)-based urea elastomers (PSUs) was investigated. A series of PSU elastomers were synthesized from an aminopropyl-terminated PDMS (M¯n: 16,300 g·mol−1), which was prepared by ring chain equilibration of the monomers octamethylcyclotetrasiloxane (D4) and 1,3-bis(3-aminopropyl)-tetramethyldisiloxane (APTMDS). The hard segments (HSs) comprised diisocyanates of different symmetry, i.e., 4,4′-methylenebis(cyclohexyl isocyanate) (H12MDI), 4,4′-methylenebis(phenyl isocyanate) (MDI), isophorone diisocyanate (IPDI), and trans-1,4-cyclohexane diisocyanate (CHDI). The HS contents of the PSU elastomers based on H12MDI and IPDI were systematically varied between 5% and 20% by increasing the ratio of the diisocyanate and the chain extender APTMDS. PSU copolymers of very low urea HS contents (1.0–1.6%) were prepared without the chain extender. All PSU elastomers and copolymers exhibited good elastomeric properties and displayed elongation at break values between 600% and 1100%. The PSUs with HS contents below 10% were transparent and became increasingly translucent at HS contents of 15% and higher. The Young’s modulus (YM) and ultimate tensile strength values of the elastomers increased linearly with increasing HS content. The YM values differed significantly among the PSU copolymers depending on the symmetry of the diisocyanate. The softest elastomer was that based on the asymmetric IPDI. The elastomers synthesized from H12MDI and MDI both exhibited an intermediate YM, while the stiffest elastomer, i.e., that comprising the symmetric CHDI, had a YM three-times higher than that prepared with IPDI. The PSUs were subjected to load–unload cycles at 100% and 300% strain to study the influence of HS morphology on 10-cycle hysteresis behavior. At 100% strain, the first-cycle hysteresis values of the IPDI- and H12MDI-based elastomers first decreased to a minimum of approximately 9–10% at an HS content of 10% and increased again to 22–28% at an HS content of 20%. A similar, though less pronounced, trend was observed at 300% strain. First-cycle hysteresis among the PSU copolymers at 100% strain was lowest in the case of CHDI and highest in the IPDI-based elastomer. However, this effect was reversed at 300% strain, with CHDI displaying the highest hysteresis in the first cycle. In vitro cytotoxicity tests performed using HaCaT cells did not show any adverse effects, revealing their potential suitability for biomedical applications.
Silicones
(2014)
Silicones are found in a variety of applications with requirements that range from long life at elevated temperatures to fluidity at low temperatures. This chapter first considers silicone elastomers and their application in room temperature vulcanizing (RTV) and heat curing systems (HTV). Also, new technologies for UV curing are introduced. Coverage of RTVs includes both one-component and two-component systems and the different cure chemistries of each, and is followed by a separate discussion of silicone laminates. Due to the high importance of silicone fluids, they are also discussed. Fluids include polishes, release agents, surfactants, and dielectric fluids.
In the powder coating of veneered particle boards the highly reactive hybrid epoxy/polyester powder transparent Drylac 530 Series from TIGER Coatings GmbH & Co. KG, Wels, Austria was used. Curing is accelerated by a mixture of catalysts reaching curing times of 3 min at 150 °C or 5 min at 135 °C which allows for energy and time savings making Drylac Series 530 powder suitable for the coating of temperaturesensitive substrates such as MDF and wood.
Despite the significant potential offered by the powder coating process for finishing wood-based materials, until now it has been used almost exclusively for coating Medium Density Fiber Board (MDF). A research project aims to develop processes and substrate materials that will allow lightweight boards to be powder coated.
Unsaturated polyester resins (UPR) and vinyl ester resins (VER) are among the most commercially important thermosetting matrix materials for composites. Although comparatively low cost, their technological performance is suitable for a wide range of applications, such as fiber-reinforced plastics, artificial marble or onyx, polymer concrete, or gel coats. The main areas of UPR consumption include the wind energy, marine, pipe and tank, transportation, and construction industries. This chapter discusses basic UPR and VER chemistry and technology of manufacturing, and consequent applications. Some important properties and performance characteristics are discussed, such as shrinkage behavior, flame retardance, and property modification by nanoparticles. Also briefly introduced and described are the practical aspects of UPR and VER processing, with special emphasis on the most widely used technological approaches, such as hand and spray layup, resin infusion, resin transfer molding, sheet and bulk molding, pultrusion, winding, and centrifugal casting.
Crosslinked thermoplastics
(2014)
Cross-linked thermoplastics represent an important class of materials for numerous applications such as heat-shrinkable tubing, rotational molded parts, and polyolefin foams. By cross-linking olefins, their mechanical performance can be significantly enhanced. This chapter covers the three main methods for the cross-linking of thermoplastics: radiation cross-linking, chemical cross-linking with organic peroxides, and cross-linking using silane-grafting agents. It also considers the major effects of the cross-linking procedure on the performance of the thermoplastic materials discussed.
Allyls
(2014)
This chapter addresses the importance and usage of the commercially low volume thermoset plastics group known as allyls. The three significant sub-elements of this group are poly(diallylphthalates), poly(diallylisophthalates), and poly(allyldiglycol carbonate). Chemistry, processing, and properties are also described. Allyl polymers are synthesized by radical polymerizations of allyl monomers that usually do not produce high-molecular-mass macromolecules. Therefore, only a few specific monomers can produce thermosetting materials. Diallyldiglycolcarbonate (CR-39) and diallylphthalates are the most significant examples that have considerably improved our everyday life.
Three different polyols (soluble starch, sucrose, and glycerol) were tested for their potential in the chemical modification of melamine formaldehyde (MF) resins for paper impregnation. MF impregnated papers are widely used as finishing materials for engineered wood. These polyols were selected because the presence of multiple hydroxy groups in the molecules was suspected to facilitate cocondensation with the main MF framework. This should lead to good resin performance. Moreover, they are readily produced from natural feedstock. They are available in large quantities and may serve as economically feasible, environmentally harmless alternative co-monomers suitable to substitute a portion of fossil-based starting material. In the presented work, a number of model resins were synthesized and tested for covalent incorporation of the natural polyol into the MF Framework. Spectroscopic evidence of chemical incorporation of glycerol was found by applying by 1H, 13C, 1H/13C HSQC, 1H/13C HMBC, and 1H DOSY methods. It was furthermore found that covalent incorporation of glycerol in the network took place when glycerol was added at different stages during synthesis. Further, all resins were used to prepare decorative laminates and the performance of the novel resins as surface finishing was evaluated using standard technological tests. The technological performance of the various modified thermosetting resins was assessed by determining flow viscosity, molar mass distribution, the storage stability, and in a second step laminating impregnated paper to particle boards and testing the resulting surfaces according to standardized quality tests. In most cases, the average board surface properties were of acceptable quality. Our findings demonstrate the possibility to replace several percent of the petrol-based product melamine by compounds obtained from renewable resources.
Mass-customization is a megatrend that also affects the wood industry. To obtain individually designed laminates in batch size one efficient printing and processing technologies are required. Digital printing was envisaged as it does not depend on highly costly printing cylinders (as used in rotogravure printing) and allows rapid exchange of the printing designs. In the present work, two wellestablished digital printing approaches, the multi-pass and the single-pass technique, were investigated and evaluated for their applicability in decorating engineered wood and low-pressure melamine films. Three different possibilities of implementing digital printing in the decorative laminates manufacturing process were studied: (1) digital printing on coated chipboard and subsequently applying a lacquered top-coat or melamine overlay (designated as “direct printing”, since the LPM was the printing substrate), (2) digital printing on decorative paper which was subsequently impregnated before hot pressing (designated as “indirect printing, variant A”) and (3) digital printing on decorative paper with subsequent interlamination of the paper between impregnated under- and overlay paper layers during the pressing process (designated as “indirect printing, variant B”). Due to various advantages of the resulting cured melamine resin surfaces including a much better technological performance and flexibility in surface texture design, it was decided to industrially further pursue only the indirect digital printing process comprising interlamination and the direct printing process with a melamine overlay-finishing. Basis for the successful trials on production and laboratory scales were the identification of applicable inks (in terms of compatibility with melamine resin) and of appropriate printing paper quality (in terms of impregnation and imprinting ability). After selection and fine tuning of suitable materials, the next challenge to overcome was the initially insufficient bond strength between impregnated overlay and the ink layers which led to unsatisfactory quality of the print appearance and delamination effects. However, the optimization of the pressing program and the development of a modified impregnation procedure for the underlay and overlay papers allowed the successful implementation of digital printing in the production line of our industrial partner FunderMax.
