Emerging/Future Applica6ons for UV Cure Technologies

Transcription

1 Emerging/Future Applica6ons for UV Cure Technologies Michael J. Dvorchak Acknowledgements: Jo Ann Arceneaux, Marcus Hutchins, and Jonathan Shaw 1

2 Agenda Self Curing Resins High Func6onality Oligomers High Gloss UV Polyurethane Dispersions Acrylated Allophanate Oligomers Thick sec6on UV Cure Elastomers UV Cure Glass Coa6ngs 1K UV Dual Cure Conformal Coa6ngs 1K UV- A Auto Refinish Clear Coats UV- A Aerospace Coa6ngs Direct to Metal Applica6ons 2

3 Self Curing Resins - Low Extractable / Low Odor versus Standard Raw Materials selec6on Standard Technical Performance Self- Curing Resin Technical Performance Cost Purity Cost Produc6on ISO 9001 ISO 9001 Longer Stripping GMP Quality Control Physico- Chemical Physico- Chemical ImpuriIes GC- MS Mutagenicity NOT Evaluated NON Mutagenic

4 Self- Curing Resins - Migra6on (extrac6on) Tes6ng for Low Extractable/Low Odor versus Standard Products Formula6on: Product % TMPTA 70 Low extractable/low odor; 30 Flexo/OPV or Litho self- curing resin 100 Results (LC- MS): Product 95% Ethanol 5% water Test condi6ons 6 µm film (on PP) Cure dose: ~800 mj/cm² Direct contact: 10 days at 40 C Simulant: 95% Ethanol/5% water 50% Ethanol/50% water 50% Ethanol 50% water Low extractable/ low odor ; Flexo/OPV self- curing resin Low extractable/ low odor; Litho self- curing resin Not Detected DetecIon limit = 50 ppb Not Detected DetecIon limit = 50 ppb Not Detected DetecIon limit = 10 ppb Not Detected DetecIon limit = 10 ppb Both self- curing resins are compliant with Nestlé guidance note & Swiss Ordinance B- list (leber)

5 Highly Func6onal (f = 9 & 10) Oligomer Proper6es Characteris6c Bravo 1 Bravo 2 Appearance Clear liquid Clear liquid Density (g/cm³) Viscosity at 60 C (mpa.s) C stability 10 days 10 days Color, APHA Max 100 Max 100 FuncIonality 9 10 End applicaion Hardcoat on Flexible/rigid substrates Hardcoat for rigid substrate or at low coat weight on filmic substrates 5

6 Highly Func6onal (f=9 & 10) Low Coat Weight Applica6ons 3 to 5 g/m² (dry) 1100 mj/cm² 6f ALUA Bravo 1 9f Bravo 2 10f 100 acetone double rubs OK OK OK Cross hatch tape adhesion 100 % 100 % 100 % Visual inspecion (µscope) aier 10 double rubs with 00 grade steel wool Many scratches Some scratches Very few scratches uncoated PMMA 6f ALUA Bravo 1 9f Bravo 2 10f 1 mm

7 UV Cure PUD - High Gloss & Mirror Effect Op6cal Proper6es (UV PUD Charlie) Substrate: Black ABS Film thickness: 120µ wet Drying: 20 min, 40 C Curing: 5m/min 80W Hg lamp Gloss 20, expressed in Gloss Unit (GU) 83.3 DOI (%) 98.8 LogHaze 1.6 Rspec (GU) 79.3 DOI is the disinctness of Image = sharpness of a reflected image in a coaing surface. RSpec is the Peak specular reflectance. RSpec is very sensiive to any surface texture. When RSpec = Gloss, the surface is smooth. Haze describes the milky halo or bloom seen on the surface of high gloss surfaces. Haze is caused by microscopic surface texture which diffuses light adjacent to the main component of the reflected surface. 7

8 UV Cure PUDs - Coa6ng Performance Scratch Resistance Picture of scratched high gloss coa6ngs 120µ wet - dried 20 min at 40 C - cured at 5m/min under a 80W Hg UV lamp Linear Taber Abraser - 500g load - Steelwool DR - 20 r/min Scratched Zone 8

9 Acrylated Allophanate Oligomers Idealized structure Based on aliphaic allophanate polyisocyanate (HDI- type) Low viscosity High amount of urethane/ allophanate structures Outdoor perfomance March 14, 15 9

10 Acrylated Allophanate Oligomers Applica6on on PC plas6c and outdoor stability Formula6on Func6on % by weight UV- curing allophanate resin 80 HDDA react. thinner 80 Irgacure 184 UV- iniiator 4.9 BYK 306 leveling agent 1.6 Hostavin 3206 UV- absorber 3.8 Hoatavin 3058 HALS- amine 1.7 Curing mj/cm² (Hg spectrum) DFT ca. 25 µm Substrate Makrolon AL 2647 Weathering data Urethane Acrylate ISO11341 Xenon Test CAM 180 UV - B Echo > 5000 h 5000 h 2500 h Fox Trot h 3250 h 2500 h Alpha h 5000 h 2500 h Bravo h 5000 h 2500 h India h 3000 h 2500 h Test parameters: Chalking, adhesion, cracks, blisters

11 Thick Sec6on UV Cure Elastomers Ingredient A; Parts by weight B; Parts by weight C; Parts by weight Oligomer LS Oligomer LF Oligomer EF Oligomer MF Monomer PhotoiniIator D; Parts by Weight Tensile; PSI 10,395 9,615 7,314 1,677 % ElongaIon Tear Strength , Cure; V- H bulbs Yes Yes Yes Yes Line Speed; i./ min mils Yes Yes Yes yes 11

12 Glass Coa6ngs - Glass Bokle Line Simula6on Test Ingredient E; Parts by weight F; Parts by weight G; Parts by weight J; Parts by Weight Oligomer LS Oligomer LF PhotoiniIator Flow AddiIve PhotoiniIator Pigment Paste Butyl Acetate ReacIve Dil RaIo:Hard/Soi 95/5 85/15 75/25 70/30 Mic.H; N/mm Scribe Adh. Pass Pass Pass Pass Line SIM (min)

13 1K UV Cure - Dual Cure Conformal Coa6ngs Conformal CoaIngs were developed to miigate enviromental issues with the prinited circuit board Developments in this technology have led to a dual cure concept that uses the R- N=C=O and R- C=C as the funcional part of the system. Recent developments show extremely low VOC, 1K UV Cure systems with viscosiies less then 800 mpa s This 1K UV Cure; Dual Cure system have proven themselves by passing the Delphi Delco Q , Test CondiIon D Delphi Delco Q , Test CondiIon D = - 40 F to 125 F, and 1,000 cycles This tesing lasts 500 hours and dwell Ime was set at 12 min. for each temperature extreme 13

14 UV- A Auto Refinish - Innova6on in the Market for Clear Coats Concept of matching the Tg s of tradiional 2 K clear coat technology with a 1K UV- A cure clear coat 14 Resin C UA Resin A 10 UA Resin B 104 UA Blend UA Blend UA Blend UA Blend 4 84 UA Blend 5 74 Commercial UV Refinish 101 Commercial 2K Refinish 62 14

15 UV- A Auto Refinish - Concept of matching the Tg s of tradi6onal 2 K clear coat technology with a 1K UV A cure clear coat 14 Blend line Blend line Photo micrograph of a blend line for a commercially available 2K Clear Coat over a black base coat Photo micrograph of a blend line for a UV A Cure Clear Coat Aier matching Tg of a 2K Clear Coat over a black base coat 15

16 UV- A Aerospace Coa6ngs - Gloss Reduc6on Techniques in UV Large paricles Increased viscosity Produces a truly rough surface IncompaIble oligomers/monomers Curing with two high intensity lamps Xenon lamp (172 nm) cures surface Mercury lamp provides through cure Causes shrinkage and reduces gloss Requires full spectrum lamps and inert environment (ozone formaion)

17 UV- A Aerospace; Reducing Gloss and Oxygen Inhibi6on Gloss levels did not decrease with increasing flabener levels Decreased light intensity or resin content increases O 2 inhibiion Gloss proporional to degree of O 2 inhibiion Inhibited surface cures last Focused Light Flood Light Light Type 60 Gloss 85 Gloss Fusion Full Spectrum Light (Focused) H & S UV- A Light (Flood) Quantum UV- A Light (Flood) AddiIonal 10% Monomer (H &S)

18 Direct to Metal (DTM) Coa6ngs - Allophanate Modified Oligomers Salt spray results with Allophanate modified oligomers, pigmented FWO d FWO c FWO d FWO C XP 2666, PVK 17 ca. % FWO h C h Stop 120 h 240 h 120 h 240 h Stop 120 h 240 h Stop Conclusion: Combined with UV inert extenders allophanate acrylates perform much beber than epoxy- ester acrylates 18

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