Coating system, development

Other Coatings Systems Developed to Reduce VOC Emissions... 

Typical of the temporary or manufacturing aid coating systems is the RISTON dry film photoresist for printed circuit (PC) board fabrication. This was the first of these systems developed. The RISTON product stmcture and the basic steps in its use are shown in Figure 2. It consists of a photopolymer sheet laminated between a Mylar cover sheet and a polyolefin separation sheet. It is manufactured as a continuous web (see Coating PROCESSES, survey), and is suppHed in roUs of varying width and photopolymer composition. 

A waterborne system for container coatings was developed based on a graft copolymerization of an advanced epoxy resin and an acryHc (52). The acryhc-vinyl monomers are grafted onto preformed epoxy resins in the presence of a free-radical initiator grafting occurs mainly at the methylene group of the aHphatic backbone on the epoxy resin. The polymeric product is a mixture of methacrylic acid—styrene copolymer, soHd epoxy resin, and graft copolymer of the unsaturated monomers onto the epoxy resin backbone. It is dispersible in water upon neutralization with an amine before cure with an amino—formaldehyde resin. 

Non-Metallic Materials Numerous engineering thermoplastics have been commercialised including materials such as polyetherether ketone (PEEK) and polyether sulphate (PES) with much improved thermal/chemical resistance. The usage of FRP equipment has increased, and fluoropolymer lining technology/applications have come of age. Of particular interest is the development of stoved, fluoropolymer coating systems for process industry equipment. 

Generally, systems developed in the USA favour a combination of polyethylene with either butyl-rubber or hot-applied mastic adhesives, the latter consisting of a blend of rubber, asphalt and high molecular weight resins. In European and Far East coating plants, epoxy type primers and hard ethylene copolymer adhesives have been successfully employed. 

Different technical developments have occurred in the coating industry which permit the use of a variety of raw materials. It is possible to formulate surface coatings that are suitable for each and every kind of material. In many cases a number of different coating systems may come into consideration for painting a particular substrate. 

At present, the major effort to develop anti-pollution coating systems is devoted to outside lithographic decorating materials for beverage and non-food containers. Water-based, clear varnishes and white coatings are increasingly available for specific end uses. Significant advances are... 

Firstly, there are technical reasons concerning catalyst and reactor requirements. In the chemical industry, catalyst performance is critical. Compared to conventional catalysts, they are relatively expensive and catalyst production and standardization lag behind. In practice, a robust, proven catalyst is needed. For a specific application, an extended catalyst and washcoat development program is unavoidable, and in particular, for the fine chemistry in-house development is a burden. For coated systems, catalyst loading is low, making them unsuited for reactions occurring in the kinetic regime, which is particularly important for bulk chemistry and refineries. In that case, incorporated monolithic catalysts are the logical choice. Catalyst stability is crucial. It determines the amount of catalyst required for a batch process, the number of times the catalyst can be reused, and for a continuous process, the run time. 

Figure 7 illustrates the use of HPGPC to aid a resin chemist in developing an in-house isocyanate crosslinker for a powder coating system. Isocyanate crosslinker X-02 gave desired properties and is considered the standard. At the early stage of the development, resin X-03 was initially made. By changing the types of reactants, molar ratio of reactants and reaction conditions, resin X-36 was the next iteration in the resin synthesis process. Finally, X-36 was fine-tuned to produce X-38 which matched X-02 in both its chemical reaction properties and its MWD. 

Another specialty area is coil coating, which involves coating metal coils by continuous operation. Modern roller systems afford speeds of up to 200 m/min. Most coils are made of cold-rolled and surface treated steel, aluminum, or alloys of the latter with manganese or magnesium. Coating systems are based on alkyd or acrylic resins, oil-free polyester, silicone-modified polyester or acrylic resin, poly(vinylidene fluoride), or poly(vinyl fluoride). Water-reducible systems, mainly based on acrylic resins, have been developed for aluminum as well as for steel coils [21-24], Drying is carried out by continuous operation in gas- or oil-heated multichamber ovens. 

Manson (72,) expanded the concept to the solid state by observing that the strength of composite materials also depended upon the acid-base interaction between continuous and dispersed phases. More directly, Vanderhoff et al. (21) addressed the issue of adhesion of polymeric materials to corroded steel. They synthesized eight corrosion products of iron, and used the interaction scheme developed by Fowkes and Manson first to characterize the iron corrosion products as Lewis acids or bases and then to select polymer vehicles for practical coating systems. Such results were employed to enhance the adhesion of epoxy systems to substrates which were predominantly iron oxide in nature. A good overview of these Issues was presented by Fowkes in 1983 (74). ... 

Accelerated Corrosion Tests. There are as many as a dozen methods (salt fog, Kesternich, etc.) that are currently being used to investigate corrosion resistance of coating systems and a need to develop a better and more dependable method to predict in-use service. A severe drawback of all these tests is that their results often compare unsatisfactorily with practical experience. One reason for the discrepancies is assumed to be the variability of natural exposure conditions. Accordingly, cyclic testing procedures have been developed with which exposure conditions, especially temperature and humidity. 

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