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WO2006000036A1 - Panneau de signalisation en contreplaque et composition de revetement en poudre - Google Patents

Panneau de signalisation en contreplaque et composition de revetement en poudre Download PDF

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Publication number
WO2006000036A1
WO2006000036A1 PCT/AU2005/000920 AU2005000920W WO2006000036A1 WO 2006000036 A1 WO2006000036 A1 WO 2006000036A1 AU 2005000920 W AU2005000920 W AU 2005000920W WO 2006000036 A1 WO2006000036 A1 WO 2006000036A1
Authority
WO
WIPO (PCT)
Prior art keywords
plywood
powder
signage
mdf
powder coating
Prior art date
Application number
PCT/AU2005/000920
Other languages
English (en)
Inventor
David Murray James
Original Assignee
Orica Australia Pty. Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from AU2004903500A external-priority patent/AU2004903500A0/en
Application filed by Orica Australia Pty. Limited filed Critical Orica Australia Pty. Limited
Publication of WO2006000036A1 publication Critical patent/WO2006000036A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/03—Powdery paints
    • C09D5/033—Powdery paints characterised by the additives
    • G—PHYSICS
    • G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F19/00—Advertising or display means not otherwise provided for
    • G09F19/22—Advertising or display means on roads, walls or similar surfaces, e.g. illuminated
    • G—PHYSICS
    • G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F7/00—Signs, name or number plates, letters, numerals, or symbols; Panels or boards

Definitions

  • This invention relates to plywood signage intended for outdoor use.
  • Outdoor signage also needs to have good optical characteristics.
  • the signs should be able to present information clearly at a distance.
  • the substrate should provide or accept a suitable surface on which desired information can be presented.
  • the substrate should be scratch resistant insofar as it affects the presentation of information thereon.
  • Signage can have a number of other requirements depending on the intended use. Traffic and street signs are used in large numbers in western countries.
  • the substrate used in the signs and the sign blanks need to be capable of being worked and machine shaped and fastened to a support structures such as a pole or side of a building.
  • Wooden signs have been used for many years. Wood can be easily worked and shaped, either in a factory or on site by the use of saw. It may be used bare or unprotected when the substrate has satisfactory weathering characteristics or when the local environment provides suitable protection. More commonly, the wooden substrate will be protected from the elements by the application of paint. However, the paint degrades over time and the sign may require regular repainting to clearly present the information and to protect the substrate.
  • RWS Reconstituted wood substrate
  • MDF medium density fibreboard
  • Plywood is another engineered product and is a laminate formed from joining relatively thin layers of veneer together, with the grain of adjacent layers at right angles. Plywood may have a core of RWS.
  • Manufactured woods can provide significant cost advantages over nature timbers and also have the advantage of consistency, in that different batches of the same grade product should meet the same quality standards.
  • most manufactured woods, including plywood have a poor resistance to water and make it unadvisable to use such products as a substrate for outdoor signage. Even when protected with a paint layer, a manufactured wood substrate can quickly fail once exposed to the weather.
  • One of the problems with the use of manufactured woods is that once water gets in under the protective paint coating, the cellulose fibres can absorb the water and expand. This expansion can degrade the mechanical properties of the substrate and also lead to further water damage as cracks in the protective coating are widened.
  • metal substrates are suitable for powder coating as the powder is applied using electrodeposition techniques and the mechanical properties of the substrate metal are not affected during the heat curing of the powder coating.
  • metal substrates can significantly expand and contract during day and night cycles and can result in damage to the paint layer. Rust and electrolytic reactions with metal supports can also cause problems with metal substrates.
  • unlike wooden signs it can be difficult to rework the shape of a sheet metal sign on site.
  • a signage comprising a plywood or MDF core and a weather protective and water resistant powder coating on the core on which information may be presented.
  • the invention is predicated on the surprising discovery that it is possible to powder coat plywood and MDF and provide a coating capable of forming an effective water resistant barrier.
  • the coating has properties which enables the use of the powder coated substrate in outdoor signage.
  • the use of MDF or plywood provides an alternative low cost substrate which may be machine shaped and also shaped by hand on site.
  • the curing temperatures can also result in distortion or internal splitting (checking) of the sheets and outgassing resulting in surface defects such as pin holing and poor adhesion. These defects generally are as a result of the release of moisture and other volatiles from the substrate.
  • a further problem typically associated with the powder coating is poor coverage at the edges of the sheets.
  • the powder coating process involves applying a polymer powder to the substrate, typically by electrostatic coating techniques, and then fusing and temperature and / or UV curing the powder so that the particles melt, flow and fuse together and transform into a smooth, typically high gloss, coating. It is an environmentally friendly method of applying a coating as a solvent is not required and the overspray particles that are not bonded to a substrate can be collected and re-used in the next powder coating application. It is envisaged that a broad range of powder coating compositions and application methods could be used.
  • Another method for improving charge retention is to incorporate sufficient amounts of electrically conductive materials within the plywood or MDF composite.
  • the inclusion of metal fibres, the use of metal powders, inorganic salts such as sodium chloride, carbon black and other conductive materials as additives to the composite may significantly enhance charge retention.
  • the powder coating can be applied as a primer coat which is subsequently coated with top powder layer or, may include pigments for use as a single layer coating. As it is necessary to provide a water resistant, and more preferably water proof coating, then it is preferred to have multiple layers of the powder coating. This also can provide for smooth surface finish on the signage.
  • the use of a primer powder coating layer may significantly reduce the need to pre- sand the uncoated MDF or plywood and provide a good painted surface finish.
  • the primer layer includes significant amounts of a texture additive, such as Bentone, then the primer layer can be sanded smooth before the application of the top coat.
  • the powder coating may be applied to the plywood and MDF using techniques adapted from those used to coat other reconstituted cellulose containing substrates, such as particle board, as known to the art.
  • Two useful references are Volume 1 of Powder Coatings: The Technology, Formulation and Application of Powder Coatings by David M Howell, John Wiley & Sons Ltd, London, 2000 and The Technology of Powder Coatings by S.T.Harris, Portcullis Press Ltd, Surrey UK, 1976.
  • MDF and plywood will be damaged by the use of high temperatures or by the application of moderate heat over a prolonged period.
  • the moisture resistance of the coatings will be damaged due to vapour emissions from the substrate.
  • Preferred methods involve the use of UV curable powder coatings, powder coatings which cure at low temperatures, such as those including low temperature curing agents or a combination of both UV and low temperature curing coatings.
  • the powder coating process may also include other techniques used to avoid the application of excessive heat to the substrate. It can be useful to pre-heat the substrate for a short time at a moderate heat, for example, by 2 to 10 minutes (preferably 5 minute) at 60 to 80°C (preferably 70°C). The use of a burst of steam shortly before coating may also preheat the substrate and improve charge retention. Low temperature curing techniques can be enhanced by the use of localised heating with IR lamps which reduce the heat exposure of the underlying substrate. Hg containing lamps have been found to be effective for UV curing.
  • the powder coating utilised may be any suitable commercially available powder coating composition.
  • the powder coating will be based on polyester, epoxy, hybrid blends of polyester / epoxy, polyurethane and other suitable resins.
  • it will be UV curable and / or low temperature curable.
  • Polyester resin systems are preferred for external use as epoxy resins can exhibit significant colour and structure degradation with long term exposure to sunlight. However, epoxy resins may still be used for outdoor signage in locations which are not generally subjected to direct sunlight.
  • the coatings are generally prepared by adding the required amounts of the raw materials into a premixer in which the ingredients are mechanically mixed, usually with a metal blade, to form a homogeneous mixture.
  • This premix material passes through an extruding process. In this process the mixture is processed under heat (usually between 8O 0 C and 14O 0 C) and compounded using mechanical shear. This causes the powder coating composition to melt and act like a semi-liquid, and allows the ingredients to be intimately mixed into the powder coating composition.
  • After leaving the extruder the material is cooled, generally on a chiller belt. The cooled mixture is then milled (ground) to the required particle size distribution for good application.
  • a standard particle size distribution ranges from 2 to 200 microns, preferably 10 to 150 microns and typically around a medium size of 50 - 60 microns.
  • the resin may contain colour pigments, extender pigments, cross-linkers and other additives.
  • pigments and fillers include metal oxides, such as titanium oxide, iron oxide, zinc oxide and the like, metal hydroxides, metal powders, sulphides, sulphates, carbonates, silicates such as aluminium silicate, carbon black, talc, kaolins, barytes, iron blues, lead blues, organic reds, organic maroons and the like.
  • the pigment (including extender pigment) can comprise up to 40% of the formulation depending on colour.
  • a slip-enhancing additive may be included to improve coating wear characteristics such as that described in US 5,925,698.
  • Powder coating compositions may contain other coating modifiers such as polytetrafluoroethylene modified waxes, polyethylene waxes, polypropylene waxes, polyamide waxes, organosilicones and blends of the above.
  • Polytetrafluoroethylenes (PTFE) may be used as a slip-enhancer / coating modifier.
  • the inclusion of significant amounts (0.2% by weight or greater) of Telfon or other PTFEs such as Dyneon TF 1641 or Ceraflour 969 may also provide other benefits, not limited to scratch resistance. It is thought the inclusion of 1 or 2% by weight of PTFE may improve the bonding between the substrate and powder coating formulation.
  • Horizontal powder coating systems such as that described in US 2003/0211252, may be of particular use with longer lengths of the substrate than could be reasonably attached to a hanging conveying system and should permit the powder coating of the main contact face and edge faces.
  • Hanging systems allow the substrate to be entirely coated in a single pass with multiple electrostatic guns that apply the powder to all sides. Alternatively, electrostatic guns could be used to spray the powder on at least one face of a suspended substrate.
  • Horizontal systems can be used to provide a wholly coated substrate in sequential powder coating steps. Horizontal systems can also allow the use of alternative powder delivery techniques such as fluidised beds or allowing powder to fall onto the substrate, by using for example a vibratory hopper.
  • edge faces of the substrate should be coated in order to improve overall water resistance and thereby reducing or preventing contact between the underlying plywood or MDF core and environmental water.
  • the edge faces may be separately coated with a water proof sealant. This may also be done to the edges of a coated wood substrate, after it has been cut to a desired size.
  • the plywood or MDF may be coated as sheets or formed signage blanks or intermediate products. Whilst it is envisaged that the invention would be applied to provide street and traffic signs, it may also be used in the production of other types of outdoor signage, including irregularly shaped signs and signs having non-planar surfaces.
  • the size and dimensions of plywood or MDF sheets can vary widely.
  • the length of each sheet may be from 100 mm to 3500 mm.
  • the width may vary from 30 mm to 2000 mm.
  • the thickness may be, for example, from 2 mm to 50 mm.
  • the coating powder is typically applied to achieve a cured thickness of 0.04 to 0.6 mm, and preferably less than 0.1 mm.
  • the powder is typically applied at a thickness of from 0.08 mm to 0.13 mm.
  • the substrate could be coated with multiple layers to increase the thickness of the coating.
  • the powder coating can be applied by any suitable electrostatic technique.
  • the two major techniques used are the corona electrostatic technique and the triboelectrostatic technique.
  • the corona electrostatic technique the powder particles are given an electric charge as they come out of the end of a powder coating corona gun by electrodes located at the end of the gun tube.
  • the electrodes are powered by a power-pack which can generate up to 100,000 V (100 KV).
  • the usual working range for voltage is 50 to 100 KV.
  • the powder is sprayed (powder is carried in a stream of air) at the earthed composite panel. The charge on the powder particles allows the powder particles to adhere to the substrate.
  • the triboelectrostatic technique involves a tribogun which also works by charging the powder particles towards an earthed panel. The charge in this case is not generated by a power pack.
  • the tribogun is generally a long polytetrafluoroethylene tube. Friction is generated between the powder coating and the PTFE tube and a charge on the powder is generated by electron removal.
  • the powder coating process provides an environmentally friendly method of applying a coating as a solvent is not required and the overspray particles that are not bonded to a substrate can be collected and re-used in the next powder coating application.
  • a technique for powder coating the substrate of the invention involves the use of UV curable powder coatings. With such coatings, the powder is applied to the substrate and heated to and above the melting point of the powder coating composition. The temperature achieved in the melting phase is usually between 9O 0 C and 16O 0 C. The melting phase is conducted by either infrared (IR) heating oven or convection gas or electric heating oven, or a combination of the two systems. After melting and flow out of the powder stage the coated panel is then passed under a UV cure oven. At this stage the coating is irradiated with UV light. The UV light phase is generated by either a mercury lamp or a gallium doped mercury lamp with wavelengths of between 205 and 405 nm.
  • IR infrared
  • Photo-initiators suitable for inclusion in UV powders include aromatic carbonyl compounds, such as benzophenone and alkylated or halogenated derivatives, anthraquinone and its derivatives, thioxanthone and its derivatives, benzoin ethers, aromatic or non-aromatic alphadiones, benzol dialkyl acetals, acetophenone derivatives and phosphine oxides.
  • aromatic carbonyl compounds such as benzophenone and alkylated or halogenated derivatives, anthraquinone and its derivatives, thioxanthone and its derivatives, benzoin ethers, aromatic or non-aromatic alphadiones, benzol dialkyl acetals, acetophenone derivatives and phosphine oxides.
  • UV cure powder coatings can be applied to the substrate using similar techniques to standard coatings which require baking.
  • Low bake powder coatings are designed to cure at temperatures between 9O 0 C (or less) and 16O 0 C for between 10 and 40 minutes total oven time (in a conventional gas or electric fired oven). IR cure of low bake powder will be much faster (from 30 seconds to 5 minutes). Epoxy and acrylic resins are commonly used.
  • All formulations should contain degassing agent.
  • the degassing agent should be present in an amount of from 0.2 to 4% by weight.
  • the Powdermate 542DG and Benzoin products are preferred as they generally provide good results, although others such as Oxymelt may be used.
  • the Benzoin product is preferably present in an amount of from 0.3% to 1%, more preferably about 0.5%.
  • the Powdermate product is preferably present in an amount of from 1% to 3%, more preferably about 1% by weight.
  • the formulations may optionally include a texture additive such as Bentone.
  • a texture additive such as Bentone.
  • the inclusion of a significant amount (2 to 15%, preferably 5 to 13%, most preferably 8 to 10% by weight) of texture additive is useful in formulations intended for use a primer coating.
  • the coating can be sanded flat before the application of a top coat.
  • the UV cured resin will generally have the following properties:
  • the UV curing resin is generally an amorphous resin that can be cross-linked by a free radical polymerisation mechanism.
  • the coating resin may contain unsaturated functional groups including methacrylic and acrylic unsaturated groups.
  • the UV curing resin may be polyester resin such as those commercially available as Uvecoat.
  • Uvecoat A range of Uvecoat products are available including the 3002 product, which provide good weathering characteristics and some flexibility.
  • the UV initiators are added to start the free radical polymerisation mechanism, upon absorption of the UV irradiation energy.
  • These can include but are not exclusive to ⁇ - hydroxyketone types such as l-(4-(2-Hydroxyethoxy)-phenyl)-2-hydroxy-2-methyl-l- propane-1-one and BAPO bis cyclophoshinoxide types such as Bis (2,4,6-trimethylbenzoyl)- phenylphosphineoxide).
  • Example UV initiators include Irgacure 2959 and 819.
  • the polyester resin usually has the following properties:
  • a flow additive may be present in any of the compositions in an amount from 0 - 3%, typically 1%.
  • the mixtures were prepared by combining the ingredients (resins, initiators, colour pigments, extenders, flow additives and other minor additives). The mixture was then agitated and then heated and extruded at 100 0 C to provide a homogenous sheet. The sheet was cooled, granulated and then milled and sieved to provide particles having a particle size less than 125 micrometers (average particle size of 40 microns) to provide the powder coating composition. All amounts are parts by weight.
  • the powder coating compositions was applied electrostatically to the substrate material and cured.
  • UV curing used Hg (Mercury) and Hg/Ga (Gallium Doped Mercury) UV lamps. Heat curing involved the use of an IR oven or a convection oven.
  • Coating formulation 1 was applied to plywood which had been preheated for 5 minutes at 7O 0 C, then cured by IR for 2 minutes at IR setting of 200 0 C and with 3 passes of UV.
  • the coated plywood panel was examined and found to provide a hard (no marring) and smooth surface without voids or dimple effects.
  • the coated surface of the panel was water tested with steam for 3 minutes and examined. No water damage was noted.
  • Coating formulation 2 was applied to plywood which had been preheated for 5 minutes at 7O 0 C, then cured by IR for 2 minutes at IR setting of 200 0 C and with 3 passes of UV.
  • the coated plywood panel was examined and found to provide a hard (no marring) and smooth surface without voids or dimple effects.
  • the coated surface of the panel was water tested with steam for 3 minutes and examined. No water damage was noted.
  • the formulations 3-5 were used as a primer coat for plywood.
  • the plywood was preheated for 5 minutes at 7O 0 C, before the powder formulation was applied.
  • the coatings were then cured by heating for 2 minutes at IR setting of 200 0 C and subjected to two passes of UV.
  • the primer coatings were lightly sanded in preparation for a subsequent top coat.
  • UV Primer formulations All formulations were considered to be good UV Primer formulations. The appearance was good after sanding with no signs of pin holing from volatile or oil emissions from the plywood surface.
  • Coating formulation 6 was applied to and cured on plywood that had been primed and sanded with coating formula's 3-5 respectively.
  • the primed plywood was preheated for 5 minutes at 7O 0 C, then by IR for 2 minutes at IR setting of 200 0 C and with 3 passes of UV.
  • All of the coated plywood panels were examined and found to provide a hard (no marring) and smooth surface without voids or dimple effects.
  • the coated surface of each of the panels was water tested with steam for 3 minutes and examined. No water damage was noted.
  • Coating formulations 7 and 8 were cured for 20 minutes at 15O 0 C.
  • the coated substrates were examined and found to provide satisfactory results.
  • the coated plywood panel was examined and found to provide a hard (no marring) and smooth surface without voids or dimple effects.
  • the coated surface of the panel was water tested with steam for 3 minutes and examined. No water damage was noted.
  • the coating formulations 9, 10 and 11 were applied to preheated plywood test panels (8 minutes at 9O 0 C) and heated for 20 minutes at 15O 0 C. The coating was then sanded to a smooth finish and top coated with coating formulation 12 and heated at 20 minutes at 15O 0 C. The coated substrates were examined and found to provide satisfactory results.
  • the coated plywood panel was examined and found to provide a hard (no marring) and smooth surface without voids or dimple effects.
  • the coated surface of the panel was water tested with steam for 3 minutes and examined. No water damage was noted.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Theoretical Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Business, Economics & Management (AREA)
  • Accounting & Taxation (AREA)
  • Marketing (AREA)
  • Organic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Paints Or Removers (AREA)

Abstract

L'invention concerne un panneau de signalisation extérieur comprenant un MDF ou contreplaqué revêtu de poudre. Le revêtement en poudre contient de préférence un agent de dégazage tel que Powdermate 542DG ou Benzoïne.
PCT/AU2005/000920 2004-06-25 2005-06-24 Panneau de signalisation en contreplaque et composition de revetement en poudre WO2006000036A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2004903500 2004-06-25
AU2004903500A AU2004903500A0 (en) 2004-06-25 Plywood signage and powder coat composition

Publications (1)

Publication Number Publication Date
WO2006000036A1 true WO2006000036A1 (fr) 2006-01-05

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PCT/AU2005/000920 WO2006000036A1 (fr) 2004-06-25 2005-06-24 Panneau de signalisation en contreplaque et composition de revetement en poudre

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WO (1) WO2006000036A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009035489A1 (fr) * 2007-09-14 2009-03-19 Dvuv, Llc Procédé pour la gravure au laser et/ou l'impression en relief au laser et la formation d'un revêtement en poudre sur un substrat

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5721052A (en) * 1996-05-06 1998-02-24 Morton International, Inc. Textured epoxy powder coating compositions for wood substrates and method of coating wood therewith
US5789039A (en) * 1994-09-06 1998-08-04 Herberts Powder Coatings, Inc. Radiation curing of powder coatings on heat sensitive substrates: chemical compositions and processes for obtaining coated workpieces
EP1043380A1 (fr) * 1997-11-12 2000-10-11 Showa Denko K K Matiere de revetement resistante a l'eau et article dote d'une surface resistante a l'eau
US6132883A (en) * 1997-05-02 2000-10-17 3M Innovative Properties Company Transparent powder coating compositions for protecting surfaces
JP2001342429A (ja) * 2000-05-31 2001-12-14 Nippon Paint Co Ltd 熱硬化性粉体塗料組成物
US6623793B2 (en) * 2000-08-16 2003-09-23 Litetech, Inc. Process for forming a reflective surface
US6683126B2 (en) * 2000-05-08 2004-01-27 Basf Aktiengesellschaft Compositions for producing difficult-to-wet surface
US20050070643A1 (en) * 2003-09-30 2005-03-31 General Electric Company Coating compositions, their preparation, and coated articles made therefrom

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5789039A (en) * 1994-09-06 1998-08-04 Herberts Powder Coatings, Inc. Radiation curing of powder coatings on heat sensitive substrates: chemical compositions and processes for obtaining coated workpieces
US5721052A (en) * 1996-05-06 1998-02-24 Morton International, Inc. Textured epoxy powder coating compositions for wood substrates and method of coating wood therewith
US6132883A (en) * 1997-05-02 2000-10-17 3M Innovative Properties Company Transparent powder coating compositions for protecting surfaces
EP1043380A1 (fr) * 1997-11-12 2000-10-11 Showa Denko K K Matiere de revetement resistante a l'eau et article dote d'une surface resistante a l'eau
US6683126B2 (en) * 2000-05-08 2004-01-27 Basf Aktiengesellschaft Compositions for producing difficult-to-wet surface
JP2001342429A (ja) * 2000-05-31 2001-12-14 Nippon Paint Co Ltd 熱硬化性粉体塗料組成物
US6623793B2 (en) * 2000-08-16 2003-09-23 Litetech, Inc. Process for forming a reflective surface
US20050070643A1 (en) * 2003-09-30 2005-03-31 General Electric Company Coating compositions, their preparation, and coated articles made therefrom

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009035489A1 (fr) * 2007-09-14 2009-03-19 Dvuv, Llc Procédé pour la gravure au laser et/ou l'impression en relief au laser et la formation d'un revêtement en poudre sur un substrat

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