EP1563916A2 - Apparat und Methode zum Pulverbeschichten von Substrat auf Basis von Holz mit Hilfe von Infrarotstrahlung - Google Patents

Apparat und Methode zum Pulverbeschichten von Substrat auf Basis von Holz mit Hilfe von Infrarotstrahlung Download PDF

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Publication number
EP1563916A2
EP1563916A2 EP20050250341 EP05250341A EP1563916A2 EP 1563916 A2 EP1563916 A2 EP 1563916A2 EP 20050250341 EP20050250341 EP 20050250341 EP 05250341 A EP05250341 A EP 05250341A EP 1563916 A2 EP1563916 A2 EP 1563916A2
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EP
European Patent Office
Prior art keywords
infrared radiation
side wall
source
zone
junction
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
EP20050250341
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English (en)
French (fr)
Inventor
William Peter Miller
David Francis Miller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MILLER Dolores Mary
Original Assignee
MILLER Dolores Mary
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
Application filed by MILLER Dolores Mary filed Critical MILLER Dolores Mary
Publication of EP1563916A2 publication Critical patent/EP1563916A2/de
Withdrawn legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0218Pretreatment, e.g. heating the substrate
    • B05D3/0227Pretreatment, e.g. heating the substrate with IR heaters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254After-treatment
    • B05D3/0263After-treatment with IR heaters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/06Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2401/00Form of the coating product, e.g. solution, water dispersion, powders or the like
    • B05D2401/30Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant
    • B05D2401/32Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant applied as powders

Definitions

  • the present invention relates to an apparatus and process for coating a substrate with a coating material, in particular to an apparatus and process for powder coating a substrate such as a wood based substrate (eg medium density fibreboard (MDF)), and to a method for processing a product.
  • a substrate such as a wood based substrate (eg medium density fibreboard (MDF))
  • MDF medium density fibreboard
  • MDF board is manufactured from wood fibres which when mixed with binders and other additives are compressed and cured to provide a solid board which may be used inter alia in the building industry.
  • the quality of MDF board varies considerably even amongst premium quality board. Inconsistencies in quality may become apparent during the various heating steps involved in powder coating. Some boards are more tolerant to heat than others but generally speaking improper heat treatment may lead to poor powder coating, gassing or cracking.
  • conventional heating systems such as hot air or electric systems are used to condition MDF and/or for melting and curing the powder, a number of drawbacks exist and the method is generally considerably unstable and unpredictable. Direct irradiation by catalytic heaters reduces but does not eliminate these drawbacks.
  • EP-A-0933140 One conventional method for powder coating MDF is largely described in EP-A-0933140. This firstly involves preheating raw board with catalytic heaters to bring moisture to the surface where it assists in electrostatic transfer of powder from an application gun onto the surface of the board to create a generally satisfactory condition to assist powder adhesion (whilst generally minimising complete dry out).
  • the catalytic heaters are placed in a frame inside a metallic tunnel structure which resembles a hexagonal shaped enclosure which can vary in height, width and length.
  • the heaters are fitted into recesses in stainless steel sheeting separated in the horizontal and vertical plane by gaps of various sizes dependent on their design, type, size and number.
  • the heaters emit long wave infrared radiation and are fitted in a manner such that the heat is directed onto both sides of the MDF board as it travels down the tunnel.
  • the stainless steel in the gaps between the heaters reflect back the infrared radiation towards the opposite side of the tunnel.
  • underheating or overheating can prevent the powder from adhering properly to even the highest quality board. This is particularly true for a routed board or a board into which a design has been cut. In such cases, the areas in which the board has been routed or cut are thinner than the remainder of the board and can dry out excessively during heating.
  • the board After then carrying out powder application (eg spraying) in a non-heated zone, the board is moved by conveyor into a hotter zone where the powder melts.
  • This step requires considerable heat penetration into the powder/substrate to effect a change in the powder from a dry state to a hot wet state and is usually carried out by a series of catalytic heaters to directly irradiate the board from both sides. Catalytic heaters flow the powder more easily and evenly than other heating means.
  • the board After the powder melts, the board is then passed through a curing tunnel which stabilises the temperature of the powder/board and cures the flowed powder by direct irradiation using catalytic heaters. This gives reasonable results but not without drawbacks. In particular, difficulties in controlling all of the heaters in the curing section may make it troublesome to satisfy the requirements of different boards and powder colours/types and lead to an inconsistent finished quality.
  • the present invention seeks to improve coating of substrates such as wood based substrates by irradiating the substrate exclusively with reflected infrared radiation.
  • the present invention provides an apparatus for coating a substrate with a coating material comprising:
  • the present invention advantageously makes it possible to avoid heat shock (and therefore cracking) and to achieve a consistent and uniform coating of all currently available powder formulations irrespective of the characteristics of the substrate.
  • the substrate may be natural or synthetic.
  • the substrate may be a wood-based substrate such as medium density fibreboard (MDF), high density fibreboard (HDF), chipboard, hardboard, blackboard or timber board.
  • MDF medium density fibreboard
  • HDF high density fibreboard
  • chipboard chipboard
  • hardboard hardboard
  • blackboard blackboard or timber board.
  • Other suitable substrates are paper based, card based, metallic or plastic substrates. Even vulnerable or heat sensitive substrates such as light gauge metals and wet paint and powder coated plastics may be coated by the apparatus of the invention.
  • the substrate may be clay and the coating material may be a glaze.
  • the substrate is a wood-based substrate.
  • the present invention in this embodiment serves advantageously to eliminate heat shock and dry out even where the wood-based substrate is routed, recessed or cut.
  • the coating material may be a solvent (eg water) based or solid ( eg powdered) coating material.
  • a preferred coating material is a powder, particularly preferably a flowable powder.
  • the coating material may be a paint ( eg a GRP paint), lacquer, sealant, stain, varnish, ink, rubber or glue.
  • the coating may be decorative and/or protective.
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate
  • the apparatus comprises:
  • Irradiating the wood based substrate substantially exclusively with reflected infrared radiation in the conditioning zone typically raises the wood based substrate to a preconditioning temperature in the range 60-80°C.
  • the conditioning zone may be further adapted to directly irradiate the wood based substrate with infrared irradiation to raise it to an elevated conditioning temperature (eg 160-180°C).
  • the elevated conditioning temperature may be sufficient to elevate the electrical conductivity at the surface of the substrate.
  • the apparatus may further comprise a powder distribution zone for distributing (eg spraying) powder onto the surface of the wood based substrate.
  • the powder distribution zone is generally unheated and on leaving the conditioning zone, the temperature of the wood based substrate may drop typically to 40-60°C.
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate
  • the apparatus comprises:
  • the curing zone includes:
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate
  • the apparatus comprises:
  • the first temperature is in the range 160-190°C.
  • the second temperature is in the range 130-140°C.
  • the or each zone may be a walled zone such an oven.
  • the substrate may be stationary or may move linearly or rotate.
  • the substrate may be agitated or turned over to assist coating.
  • the or each zone typically takes the form of an elongate tunnel (eg a hexagonal or box-like tunnel) or an essentially box-like enclosure ( ie with entry and exit doors) into which the substrate may be introduced or through which the substrate may be conveyed by conventional conveyor means ( eg flat bed or monorail).
  • conventional box oven enclosures, semi enclosures and drying rooms could be readily adapted into a zone according to the apparatus of the invention.
  • the air in the elongate tunnel may be recirculatory.
  • the substrate may be irradiated substantially exclusively with reflected infrared radiation by judiciously siting and fixing one or more sources of infrared radiation in the zone.
  • the one or more sources of infrared radiation may be one or more heaters such as catalytic heaters, naked flame infrared sources or electric infrared sources.
  • the one or more heaters may be adapted to provide flash heating.
  • the one or more sources of infrared radiation emit long wave infrared radiation.
  • the one or more sources of infrared radiation are one or more catalytic heaters (eg Bruest catalytic heaters available from the applicants Miller, Miller and Miller for the present application).
  • the one or more sources of infrared radiation may have the same or different output.
  • the conditioning zone it may be useful to have a plurality of sources of infrared radiation with a ramped output ( eg to create a gradual or stepped increase in temperature along the zone).
  • the one or more sources of infrared radiation are mounted such that the radiative face of each source of infrared radiation is adjacent to and faces one or more discrete reflective surfaces.
  • the or each source of infrared radiation is preferably mounted such that the infrared radiation with which the substrate is substantially exclusively irradiated is reflected substantially only from the nearest (and optionally the second nearest) discrete reflective surface.
  • the or each discrete reflective surface may adopt any convenient regular or irregular shape ( eg angled, flat, rounded, convex or concave shape).
  • the discrete reflective surface may be a reflective wall.
  • the one or more sources of infrared radiation are mounted such that the radiative face of each source of infrared radiation is adjacent to and faces one or more ( eg two) reflective walls ( eg adjacent to and facing a side wall, the floor or the ceiling or adjacent to and facing a side wall and the ceiling or a side wall and the floor).
  • the or each source of infrared radiation is preferably mounted such that the infrared radiation with which the substrate is substantially exclusively irradiated is reflected substantially only from the nearest (and optionally the second nearest) reflective wall.
  • one or more walls of a walled zone may be at least partially (preferably wholly) composed of or lined with a reflective material such as a reflective metal, metal alloy or metal composite.
  • a reflective material such as a reflective metal, metal alloy or metal composite.
  • each reflective wall is wholly composed of or lined with a reflective material.
  • each reflective wall is composed of or lined with a reflective metal, particularly preferably stainless steel.
  • the precise angle at which the radiative face is disposed to a discrete reflective surface (eg reflective wall), the precise distance from the discrete reflective surface ( eg reflective wall) and the separation of the sources of infrared radiation may be readily empirically determined for optimum effect by the skilled person.
  • the angle, distance and separation may depend inter alia on the type and size of the substrate and the heating temperature required. For example, if there is too great a distance between sources of infrared radiation, a long region of substantially exclusively reflected infrared radiation zone exists with a greater likelihood of cold spots.
  • Other influential factors such as temperature, output and the gas pressure and flow to catalytic heaters may equally be readily optimised by the skilled person.
  • the one or more sources of infrared radiation are mounted such that the radiative face of each source of infrared radiation faces a discrete reflective surface in a manner such as to aggregate a substantially linear region of substantially exclusively reflected infrared radiation zone (a "reflective region") to the rear of the radiative face of each source of infrared radiation.
  • a substantially linear region of substantially exclusively reflected infrared radiation zone a "reflective region”
  • the radiative face of the or each source of infrared radiation is at a distance of between 6 and 24 inches from the reflective wall to create a stable and uniform reflective region.
  • the one or more sources of infrared radiation may be wall mounted.
  • one or more sources of infrared radiation may be mounted on both side faces of the zone.
  • the one or more sources of infrared irradiation are mounted at the upper and lower ends of the side faces of the zone.
  • the one or more sources of infrared radiation may be mounted at or near to the junction of two surfaces (for example a side wall and a floor or a side wall and a ceiling).
  • first source of infrared radiation mounted at or near to the junction of a side wall and the ceiling
  • second source of infrared radiation mounted at or near to the junction of the side wall and the floor
  • third source of infrared radiation mounted at or near to the junction of the opposing side wall and the ceiling
  • fourth source of infrared radiation mounted at or near to the junction of the opposing side wall and the floor.
  • first source of infrared radiation mounted at or near to the junction of a first side wall and the ceiling
  • second source of infrared radiation mounted at or near to the junction of the second side wall opposite the first side wall and the ceiling
  • third source of infrared radiation mounted at or near to the junction of a third side wall and the ceiling
  • fourth source of infrared radiation mounted at or near to the junction of the fourth side wall opposite to the third side wall and the ceiling.
  • first source of infrared radiation mounted at or near to the junction of a first side wall and the ceiling
  • second source of infrared radiation mounted at or near to the junction of the second side wall opposite the first side wall and the ceiling
  • third source of infrared radiation mounted at or near to the junction of a third side wall and the ceiling
  • fourth source of infrared radiation mounted at or near to the junction of the fourth side wall opposite to the third side wall and the ceiling
  • a fifth source of infrared radiation mounted at or near to the junction of the first side wall and the floor
  • a sixth source of infrared radiation mounted at or near to the junction of the second side wall and the floor
  • seventh source of infrared radiation mounted at or near to the junction of the third side wall and the floor
  • an eighth source of infrared radiation mounted at or near to the junction of the fourth side wall and the floor.
  • the present invention may use a fewer number of heaters than conventional heaters.
  • four heaters are used in each two metre section (minimum height 4ft, maximum height 12ft) whereas 12 heaters are used in each six foot long and eight foot high section of the conditioning zone of a conventional heater.
  • four heaters are used in each six foot long by twelve foot (or less) high section whereas 12 heaters are used in each six foot long and eight foot high section of the curing zone of a conventional heater.
  • the desirability of a fewer number of heaters is that heat control is more straightforward and reliable and that energy consumption may be reduced by 60-80% with lower emissions. Additionally there are less ancillary components such as electrical wiring, gas piping and gas solenoids.
  • the present invention provides a process for coating a substrate with a coating material comprising:
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate and the process comprises:
  • the process may further comprise:
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate and the process comprises:
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate and the process comprises:
  • the coating material is a flowable powder
  • the substrate is a wood-based substrate and the process comprises:
  • the first temperature is in the range 160-190°C.
  • the second temperature is in the range 130-140°C.
  • the present invention provides a coated substrate obtainable or obtained by a process as hereinbefore defined.
  • the present invention relates to a method for processing a product comprising:
  • the step of the method may be a conditioning, drying, curing, hardening, dehydration, moisture removal or solvent removal step.
  • the product may be a pharmaceutical product (eg in tablet form), rubber, building products (eg plaster), fabric, paper, clay, wood chips, sawdust, oat grain, vegetables, biscuits ( eg water biscuits or biscuit derived from flower or grain products ( eg rusk used for sausage making)).
  • the method may be used to condition clay (prior to entry into the kiln), to remove solvents/chemicals from wood chips, sawdust, oats grain, vegetables or biscuits, to condition biscuit derived from flower or grain products ( eg rusk used for sausage making), to condition, form or dry a pharmaceutical product or to cure or condition rubber.
  • the product is a composite product (eg a carbon fibre composite product).
  • the composite product is an aircraft product (eg a product used in the aircraft construction industry).
  • the step of the method is a curing step.
  • the step of the method is a low temperature curing step eg a temperature in the range 30 to 80°C, preferably 40 to 60°C.
  • the product is an aircraft product and the method further comprises:
  • Figure 1 illustrates schematically in cross-section an oven of an embodiment of the apparatus of the present invention.
  • FIG. 1 is illustrated schematically an oven of an embodiment of the present invention designated generally by reference numeral 1.
  • the oven 1 comprises side walls 3a, 3b spaced part by a ceiling 4b and floor 4a in the form of a walled, box-like enclosure 2.
  • Each of the side walls 3a and 3b, the end walls (not shown) and the ceiling 4b is lined with reflective stainless steel.
  • catalytic heaters 5a-d are mounted respectively near to each of the junctions of the side wall 3a and floor 4a, floor 4a and side wall 3b, side wall 3b and ceiling 4b and ceiling 4b and side wall 3a.
  • the angle of the heaters 5a-d to the nearby reflective surfaces is about 45° and the respective radiative faces 6a-6d are directed outwardly towards the nearby side wall and the radiation (as shown by the arrows X) reflects off the side walls 3a and 3b towards the centre of the enclosure 2 (as shown by arrows Y) where it aggregates into a reflective region.
  • a wood based board 8 passes through the reflective region by conventional conveyor means (not shown) where it is exposed on both faces 8a and 8b to uniform heating by totally reflected infrared radiation.
  • the oven 1 may be used as a conditioning zone, a curing zone or a flowing zone. Three such ovens 1 may be used in sequence to effect coating of the wood based board 8 with a powder and such an arrangement is described in the following Example.
  • the board arrives at a main conditioning oven at room temperature where it is subjected to direct IR radiation by catalytic heaters in order to raise the temperature to 160°-180°C.
  • the board arrives at the main conditioning oven at an elevated temperature in the range 60-80°C having been subjected to indirect IR irradiation in accordance with the invention by catalytic heaters in a preconditioning phase.
  • the board leaves the powder booth and enters the flow oven where the temperature is elevated by direct irradiation to 160-190°C.
  • the board leaves the flow oven causing the temperature to drop to 130-150°C.
  • the temperature of the board is maintained at 130-140°C by indirect irradiation in accordance with the invention.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Coating Apparatus (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP20050250341 2004-01-22 2005-01-24 Apparat und Methode zum Pulverbeschichten von Substrat auf Basis von Holz mit Hilfe von Infrarotstrahlung Withdrawn EP1563916A2 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0401328 2004-01-22
GB0401328A GB0401328D0 (en) 2004-01-22 2004-01-22 Heating system

Publications (1)

Publication Number Publication Date
EP1563916A2 true EP1563916A2 (de) 2005-08-17

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Application Number Title Priority Date Filing Date
EP20050250341 Withdrawn EP1563916A2 (de) 2004-01-22 2005-01-24 Apparat und Methode zum Pulverbeschichten von Substrat auf Basis von Holz mit Hilfe von Infrarotstrahlung

Country Status (2)

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EP (1) EP1563916A2 (de)
GB (1) GB0401328D0 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007134346A1 (de) * 2006-05-19 2007-11-29 Tigerwerk Lack-Und Farbenfabrik Gmbh & Co. Kg Wärmebehandlungsofen mit infrarotstrahlern

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007134346A1 (de) * 2006-05-19 2007-11-29 Tigerwerk Lack-Und Farbenfabrik Gmbh & Co. Kg Wärmebehandlungsofen mit infrarotstrahlern

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Publication number Publication date
GB0401328D0 (en) 2004-02-25

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