WDMA TECHNICAL CONFERENCE JUNE 29, 2016 CHICAGO, IL

Transcription

1 WDMA TECHNICAL CONFERENCE JUNE 29, 2016 CHICAGO, IL

2 INTRODUCTIONS Doug Krusenklaus: Director, Building Products Market, Product Finishes Brian T Martin: Manager Color and Design, Product Finishes Eric Brandhorst: Manager of Technology, Product Finishes Don Cassil: Director Design Engineering Services

3 TODAY S DISCUSSION Changes Opportunity

4 SHIFT IN COLOR TRENDS How Millennials A re C ausing the Shift Brian T. Martin, Manager of Color and Design

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21 MOST FREQUENTLY ORDERED EXTERIOR COLORS IN 2015 Midwest Color Eastern Color Southeast Color Southwest Color #1 TRICORN BLACK #1 TRICORN BLACK #1 PURE WHITE #1 LATTE #2 DOVETAIL #2 MEADOWLARK #2 LATTE #2 TONY TAUPE #3 GAUNTLET GRAY #3 CEDAR BARK #3 TRICORN BLACK #3 KILIM BEIGE #4 PURE WHITE #4 PURE WHITE #4 TONY TAUPE #4 PURE WHITE #5 CEDAR BARK #5 DRIFTWOOD #5 DOVER WHITE #5 ACCESSIBLE BEIGE #6 TONY TAUPE #6 CEDAR #6 KILIM BEIGE #6 TRICORN BLACK

22 MOST FREQUENTLY ORDERED EXTERIOR COLORS 2015 USA Color Canada Color #1 #2 #3 #4 #5 #6 TRICORN BLACK PURE WHITE LATTE TONY TAUPE KILIM BEIGE SNOWBOUND #1 #2 #3 #4 #5 #6 TRICORN BLACK PEPPERCORN TONY TAUPE GAUNTLET GRAY CEDAR BARK CEDAR

23 PIGMENT SELECTION FOR HEAT MANAGEMENT Eric Brandhorst Group Leader, Building Products

24 OUTLINE Definitions Solar radiation spectrum How heat build is minimized IR reflective pigments used in solar reflective products

25 WHY HEAT MANAGEMENT? Energy savings Improved product life Enhanced beautification

26 HEAT ISLAND EFFECT Source: Berkeley National Lab

27 PREDICTING TEMPERATURE INCREASE How is a coating rated for resistance to increase in surface temperature when exposed to Solar Radiation?

28 PREDICTING TEMPERATURE INCREASE TSR (Total Solar Reflectance) - The percent of total solar energy reflected by a surface. Emissivity (IR Emittance) Ability of a surface to emit or release heat. ASTM C1371 SRI (Solar Reflective Index) Combined value of reflectance and emissivity. ASTM E1980

29 Source: The Shepherd Color Company

30 MAXIMIZING TSR Visible Spectrum: Contributes 45% of the total energy from the sun and ultimately controls the Solar Reflectance (SR) properties of a coating. NIR Spectrum: Slightly more than half of the sun's energy is transmitted at near IR wavelength. TSR is maximized by using NIR sensitive pigments engineered to reflect or transmit in these wavelengths.

31 SOLAR REFLECTIVE COATINGS

32 Traditional vs. Solar Reflective Pigmentation, Dark Blue 100% 90% Traditional vs. Solar Reflective Pigmentation, Blue SR 100% 80% 90% SR Hybrid % Reflectance % Reflectance 70% 80% 70% 60% 60% 50% 50% 40% 40% 30% 30% TSR=18.2% TSR=18.2% TSR=17.3% TSR=17.3% Hybrid Std Std 20% 20% 10% TSR=11.2 TSR= % 0% 0% Wavelenght of light in Nanometers Wavelenght of light in Nanometers

33 Traditional vs. Solar Reflective Pigmentation, Dark Grey 100% 90% Traditional vs. Solar Reflective Pigmentation, Dark Grey % Reflectance 80% 70% 60% % Reflectance 50% 40% 30% 20% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% TSR=18.2% TSR=18.2% TSR=24.5% TSR=24.5% TSR=24.2% TSR=24.2% SR Hybrid Std SR Hybrid Std 10% 0% 0% Wavelength of light in Nanometers Wavelength of light in Nanometers

34 MAXIMIZING TSR Transparent vs. IR Reflective Pigments TRANS REFLECT TRANS REFLECT TRANS REFLECT HBU Initial (ºF) Final (ºF) TSR (%) * All values recorded over white PVC at mils dry.

35 SUMMARY Solar reflective pigment technology in combination with a durable, weatherable resin system can provide a coating that will provide beauty and protection for years. Energy savings Improved product life Enhanced beautification

36 NOTES Berkeley National Laboratory, Heat Island Group, Climate Conservative Consumer, BASF, The Shepherd Color Company,

37 MANAGING COLOR CHANGE AND CURE FROM A MANUFACTURING PERSPECTIVE Don Cassil, Director Design Engineering Services

38 INFRARED CURING FOR LINEALS

39 COATING CURE TEMPERATURES Acrylic latex materials F Urethanes F Powders F Baking enamels F Fluorocarbons F

40 TIME AT TEMPERATURE Typically 3-5 minutes at optimum crosslink coating temperature is sufficient. Time requirement generally doubles for 10 C decrease in temperature from design and halves for each 10 C increase in temperature.

41 CURE CURVES Cure typical Urethane Polyester Powder Cure Time Time (min) Temperature F Time (Minutes) Temperature F

42 WHEN DOES A COATING GET TO TEMPERATURE? When substrate gets to temperature Steel (3 minutes in convection) Aluminum (2-2.5 minutes in convection) Insulative plastics (A really long time depending on thickness). Use 3-5 minutes as the coating and the surface of the substrate will come to temperature even if the middle of the substrate does not

43 WHY IS IR FASTER THAN CONVECTION? The substrate is not required to get to temperature (saves 3-5 minutes) The effective temperature is C higher than the measured temperature due to radiant heat absorption

44 CHALLENGES OF IR CURING Identifying temperature set points and proper dwell time (DataPaq are not as helpful without an IR probe). Solar reflective pigments lower coating temperature which results in longer dwell times which will be color dependent. Conveyor stops can lead to Overbake Conditions.

45 CHALLENGES OF IR CURING Energy Costs Electricity $.06/kwh = $ 17.57/MM-BTU Propane $2.36/Gallon = $ 17.61/MM BTU Natural Gas = $ 2.12/MM Btu Capital Costs (higher than convection)

46 CHALLENGES OF IR CURING 3 Dimensional Parts 46

47 CHALLENGES OF CONVECTION CURING Floor Space

48 CHALLENGES OF CONVECTION CURING Heating of adjacent spaces Heat up time 48

49 DESIGN CONSIDERATIONS Design for % additional capacity Work with coating supplier and equipment supplier Verify substrate and coating compatibility

50 COLOR CHANGE CONSIDERATIONS Changing from stock color inventory to paint to order

51 SELECTION CRITERIA Number of color changes Volume of each run Capital available Cup guns Manual color change valves Auto color change valves Lines run from paint kitchen $250/gun $300 per line $1000 per color $2500 per color

52 VOLUME OF RUN Cup guns typically cc s per fill Equivalent to square TE Pressure fed equipment can run unlimited Changeover time Cup guns (Instantly with 2) Pressure set up (instantly if all colors in line) seconds if using a color changer valve

53 Colors? Technologies? Processing?

54 THANK YOU Sherwin- Williams Product Finishes Division