WDMA TECHNICAL CONFERENCE JUNE 29, 2016 CHICAGO, IL
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
TODAY S DISCUSSION Changes Opportunity
SHIFT IN COLOR TRENDS How Millennials A re C ausing the Shift Brian T. Martin, Manager of Color and Design
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
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
PIGMENT SELECTION FOR HEAT MANAGEMENT Eric Brandhorst Group Leader, Building Products
OUTLINE Definitions Solar radiation spectrum How heat build is minimized IR reflective pigments used in solar reflective products
WHY HEAT MANAGEMENT? Energy savings Improved product life Enhanced beautification
HEAT ISLAND EFFECT Source: Berkeley National Lab
PREDICTING TEMPERATURE INCREASE How is a coating rated for resistance to increase in surface temperature when exposed to Solar Radiation?
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
Source: The Shepherd Color Company
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.
SOLAR REFLECTIVE COATINGS
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=11.2 10% 0% 0% 400 500 400 500 600 600 700 700 800 800 1600 1500 1400 1300 1200 1100 1000 900 900 Wavelenght of light in Nanometers 1000 1100 1200 1300 1400 1500 1700 1600 1800 1700 1900 1800 2000 1900 2100 2000 2200 2100 2200 Wavelenght of light in Nanometers
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% 400 400 500 500 600 600 700 700 800 1600 1500 1400 1300 1200 1100 1000 900 800 900 1000 1100 1200 1300 1400 1500 Wavelength of light in Nanometers 1600 1700 1700 1800 1800 1900 1900 2000 2000 2100 2200 2100 2200 Wavelength of light in Nanometers
MAXIMIZING TSR Transparent vs. IR Reflective Pigments TRANS REFLECT TRANS REFLECT TRANS REFLECT HBU 46 64 57 70 58 62 Initial (ºF) 75 72.5 73.5 75.7 72.6 76 Final (ºF) 138.7 160 152 167.6 153.3 156.4 TSR (%) 52.7 35.2 43.9 34.85 43 33.12 * All values recorded over white PVC at 1.5-1.8 mils dry.
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
NOTES Berkeley National Laboratory, Heat Island Group, www.heatisland.lbl.gov Climate Conservative Consumer, www.c3headlines.com BASF, www.dispersion-pigments.basf.com The Shepherd Color Company, www.shepherdcolor.com
MANAGING COLOR CHANGE AND CURE FROM A MANUFACTURING PERSPECTIVE Don Cassil, Director Design Engineering Services
INFRARED CURING FOR LINEALS
COATING CURE TEMPERATURES Acrylic latex materials 60-140 F Urethanes 60-400 F Powders 200-600 F Baking enamels 280-400 F Fluorocarbons 140-600 F
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.
CURE CURVES Cure typical Urethane Polyester Powder Cure Time 30 25 25 20 Time (min) 20 15 10 5 0 75 125 175 225 275 325 375 425 Temperature F Time (Minutes) 15 10 5 0 300 320 340 360 380 400 420 440 Temperature F
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
WHY IS IR FASTER THAN CONVECTION? The substrate is not required to get to temperature (saves 3-5 minutes) The effective temperature is 10-20 C higher than the measured temperature due to radiant heat absorption
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.
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)
CHALLENGES OF IR CURING 3 Dimensional Parts 46
CHALLENGES OF CONVECTION CURING Floor Space
CHALLENGES OF CONVECTION CURING Heating of adjacent spaces Heat up time 48
DESIGN CONSIDERATIONS Design for 50-100% additional capacity Work with coating supplier and equipment supplier Verify substrate and coating compatibility
COLOR CHANGE CONSIDERATIONS Changing from stock color inventory to paint to order
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
VOLUME OF RUN Cup guns typically 100-800 cc s per fill Equivalent to 10-80 square feet @50% TE Pressure fed equipment can run unlimited Changeover time Cup guns (Instantly with 2) Pressure set up (instantly if all colors in line) 30-300 seconds if using a color changer valve
Colors? Technologies? Processing?
THANK YOU Sherwin- Williams Product Finishes Division