Medium Density Fiberboard (MDF) Powder Coatings

Powder spraying of MDF (Medium Density Fiberboard) and other wood materials has attracted more and more attention of the wood processing industry. They want to change the traditional MDF coating system, such as PVC veneer or liquid paint into a powder coating spray.

Over the past decade or so, the advantages of MDF surface powder coating spray have been highly recognized just like metal surface powder coating. Powder coating spraying provides excellent scratch and stain resistance while providing a choice of colors and surface effects. In addition, powder coating spraying is an environmentally friendly production process that does not use solvents, heavy metals, and halogenated compounds. Powder utilization can reach almost 100% with the help of automatic spraying and powder recovery equipment. In addition, no hazardous waste treatment is required after powder coating is completed. The high efficiency of powder coating not only achieves environmental advantages but also brings an effective cost advantage.

Powder Coating In addition to its well-known advantages, the wood processing industry also appreciates some of the new opportunities presented by MDF powder coating. For example, furniture designers and interior architects have begun to take full advantage of the new design freedoms that powder spraying offers them. At all kinds of furniture trade shows, on modern and fashionable furniture samples and products that are powder coated, it is clear that the MDF that the powder coating is evenly sprayed on gives designers new freedom of design. The current technology has developed to apply the same powder coating to the front and back of the MDF, including the edges. Therefore, edge wrapping is no longer necessary. And powder coating can be packaged and shipped to customers immediately after curing. With the help of powder coating, the design of MDF panels and edges is almost unlimited: arcs, various live shapes, surface engravings, and some other shapes can be sprayed in the same way. See Figure 1 - Figure 4.

MDF Powder Coating Spraying Challenge China's fiberboard has an annual output of more than 100 million cubic meters. Among them, the annual output of MDF (medium density fiberboard) is about 30 million cubic meters. If calculated according to 16mm specifications, the optical MDF will have about 1.8 billion square meters. With the development of technology, fiber boards other than MDF, such as popcorn, can also be powder sprayed. It is expected to have a potential market for hundreds of thousands of tons of powder. In other words, the wood plate powder coating has a very broad prospect.

Since MDF powder coatings are painted with so many obvious advantages and large markets as mentioned above, there is no large-scale commercial operation in China. The reason is that MDF powder coating has a very high technical content and requires a certain amount of up-front investment and challenging problems. It is not an ordinary sprayer that can be operated with existing spray equipment and processes. To achieve high quality, especially to ensure that the edge does not crack for a long time, it is necessary to grasp the quality control of the medium-density wood board, the design and control of the spray line, the performance design of the powder coating, and the final quality test and guarantee technology in four aspects.

Here is a brief introduction to the most important MDF, powder coating, powder coating line and quality certification.

MDF: The painter should fully understand the performance of the MDF before spraying the MDF powder coating.

The spraying process of powder coatings on metal surfaces has been very mature, stable and has a good level of control. In order to understand why MDF powder coating is very different from metal surface powder coating, we must know the inherent characteristics of MDF. It is generally believed that the most important difference between metal and MDF is electrical conductivity. This may be true for absolute conductivity; however, that is not the most important factor for MDF powder coating.

In general, a surface resistance of 1010 ohms to 1011 ohms can provide sufficient conductivity for MDF powder coating spraying. A standard MDF at room temperature has a surface resistance of about 1012Ω. By adding a small amount of additives to the MDF, or preheating the MDF, or both methods, these can easily adjust the conductivity of the MDF to the required range.

However, a greater difference between metal and MDF is thermal conductivity. Table 1 shows the thermal conductivity of various materials. The thermal conductivity of MDF is only 0.07 [W/(m•K)]. This is much lower than the thermal conductivity of aluminum, which is the most commonly used substrate for powder coating spraying. This temperature distribution within the MDF substrate presents many difficulties for powder coating.

As can be seen from Table 1, the thermal conductivity of MDF is as low as that of an asbestos blanket, and asbestos blankets are the materials used to make fire-fighting equipment and high heat-resistant gloves. Therefore, MDF takes a long time to heat and cool. During heating and cooling, the surface temperature of the MDF and its center temperature will be different. If there is more heating in a certain part of the MDF surface than in other parts, the surface temperature and the edge temperature will be very different. This phenomenon is not obvious in aluminum spraying.

In addition, in order to obtain high-quality powder coating, we must carefully control the various properties of MDF, such as surface smoothness, sandability, exhaustability, cracking at a certain temperature, and some other properties. One of the key properties in the MDF specification is also easily influenced by the MDF manufacturing process, which is the internal bond strength of the MDF. This internal bond strength should be at a reasonably high level.

In summary, MDF should have heat resistance, slight electrical conductivity, and good grindability. Fortunately, MDF manufacturers are now able to produce these types of panels. In fact, some MDF manufacturers have begun to market MDF that can be used for powder coating spraying.

Powder Coatings: At first glance, powder coatings themselves are considered to be the most important factor in the MDF powder coating process. However, as noted above, the powder coating provided to the MDF is only one of several factors that must be combined with other factors in order to produce a high quality powder coated MDF.

When we analyzed the powder coating chemistry, we found that there are two curing methods that can be used as the MDF powder coating curing method. One of the first is the traditional heat curing. The second is ultraviolet (UV) curing. The powder is first heated to a molten state and then cured by UV light. Both of these technologies have advantages and disadvantages. The question of which curing technology is the most successful method for MDF powder coating has been intensely discussed.

Regardless of the method of curing, the first step is the melting of the powder. A particular powder coating needs to melt within a specific temperature range. In order to achieve the same final surface characteristics, such as surface texture, gloss range, scratch resistance, chemical resistance, etc., the melting temperature and curing temperature must be controlled to the minimum range.

The melting and curing temperature of the MDF sprayed powder must be the same on all surfaces. This means that the edge cure temperature should be the same as the front and back temperatures. Unfortunately, most curing lines so far, regardless of the curing method used, the temperature in the curing oven did not meet this requirement. This is an important reason for the failure of MDF powder coating in most cases. A more detailed discussion follows.

Only when the powder reaches a certain temperature does it start to melt and flow to form a powder-specific surface effect. When the melting temperature is too low, a rough, sandpaper-like surface structure results; when the melting temperature is too high, the color changes. Irrespective of the powder chemistry, both UV-curable and thermosetting powders produce the same effect.

For heat-curing powders, it is not only necessary to control the proper melting temperature, but also to control the curing temperature-time window, which is determined by the reaction speed of the particular powder. Recently, powders capable of sufficiently curing at a low temperature of 130°C to 140°C in a short time of 4-5 minutes have been developed. The lower the temperature in the curing oven, the more time it takes to fully cure, and vice versa.

When powder spraying, the most critical part is to find out when the powder is fully cured. Only fully cured powders give the best performance in terms of chemical resistance, scratch resistance, abrasion resistance, flexibility, and more. You cannot visually see if the UV-curable powder and the heat-cured powder are fully cured. When we see the appearance is very beautiful, you may think that the powder has been fully cured. Then the destructive test found its unqualified quality. Therefore, every powder coating company must establish a strict process and quality control to ensure that the required curing parameters of the powder itself are controlled within a strict range. This includes monitoring and adjusting the baking temperature of the melting and curing oven, and in the case of a UV curing oven, adjusting the intensity and dose of ultraviolet light in the ultraviolet region.

Although these should seem to be standard procedures for powder coating by any powder coating manufacturer, it is surprising that most MDF powder coating companies do not know what is happening in the oven, nor have they measured the precise temperature distribution and UV distribution. If the coating line can ensure that the powder gets the conditions it needs to melt and fully cure, the end customer will get a good surface finish.

Spray line. Powder spray line technology has proven to be the most important factor in obtaining high quality MDF powder coating. Unfortunately, for those small metal surface powder coating companies, it is impossible to obtain high-quality MDF powder coating through the old metal powder coating line.

The most important part of the spraying line is the baking oven technology, where baking ovens melt. If the heat-curing powder is also chemically cured. It is important to remember that the thermal conductivity of MDF is very low. Therefore, the design of the oven needs to enable its temperature to be evenly distributed; otherwise, the heat will not be distributed throughout the surface of the substrate like aluminum. However, heating on the MDF must ensure an even surface temperature distribution, as shown in Figure 5.

Due to the low thermal conductivity of MDF, we have taken advantage of this advantage. As discussed earlier, the powder needs to be melted and cured at a suitable temperature. This temperature is often higher than MDF can afford. However, when the powder is heated by infrared rays, the powder and the surface of the plate rapidly reach a temperature that can be melted and solidified. Due to the slow heat conduction of the plate, the temperature in the center of the plate is still relatively low, which is much lower than the temperature during the complete melting and solidification of the powder. Therefore, the thermal stress on the MDF board is minimized so as not to be damaged.

We can see that the two ovens described above melt-cured, ie, heat-cured and UV-cured, and are currently not suitable for MDF powder coating. Because conventional thermal curing heats the entire powder and MDF, it takes a relatively long time to reach 150-160 degrees due to the low thermal conductivity of MDF. As a result, the powder has not completely cured and MDF has been damaged. The other is UV curing. It has been very difficult to achieve uniform distribution of UV intensity and dose so far. At the same time, different colors and different spray thicknesses are different. Therefore, UV curing has not been successfully used for MDF powder coating. However, the ultraviolet rays can be used for the curing of the transparent powder glazing layer after MDF powder coating (this is not specifically described here).

Melt-cure that can be successfully used for MDF powder coating is an infrared oven. The challenge is to provide infrared rays that can be uniformly illuminated on the surface of the MDF, including the edges. Fortunately, modern infrared ovens have a very high level of uniform illumination. Figure 6 is a temperature profile showing the top, middle, and bottom surface temperatures of MDF measured in an infrared oven by a temperature sensor. There is a very small change in the temperature of the MDF surface distribution, and the temperature range is less than 15°F.

A well-designed infrared curing oven shows a temperature change of less than 15°F from the top of the MDF substrate to the bottom. For good powder coating, the temperature distribution in the oven must be measured before starting powder coating. Measurements and monitoring are done not only at one surface location, but also around the MDF surface, including its edges. The temperature of the oven should be adjusted to avoid temperature differences in different locations where the temperature exceeds a limit, for example, less than 15°F. Figure 7 shows two temperature profiles a and b. Figure 7a is performed in a well-tuned infrared oven; the sensors are fixed at various locations on the surface of the MDF, including the edges. We can see that the surface temperature distribution on the MDF is very uniform. Figure 7b shows similar measurements in the oven before proper adjustment.

The oven temperature profile contains a well-controlled oven with a small range of measured temperature distribution on the four edges of the MDF.

The range of temperature distribution is too large and poorly controlled ovens. Obviously, the temperature profile in Figure 7b proves that, when the oven temperature setting change of the MDF surface is greater than 75°F, uniform powder coating cannot be obtained. In some cases, even distribution of temperature cannot be achieved due to technical defects of the oven. In other cases, a well-designed oven operates at an unsuitable temperature setting. These conditions will lead to the production of powder coating that should not be used. In many cases, it will lead to the failure of MDF powder coating.

At a given substrate size (including edges), the maximum temperature change in the melt-cure oven needs to be well discussed and strictly regulated by the manufacturer before making any decisions. Once the oven is installed, the production line settings must be optimized by measuring the temperature distribution during the production process and monitoring the continuous temperature distribution. This will ensure that the quality of powder coating meets specifications.

Quality Certification:. The level of quality required for MDF powder coating is ultimately customer-determined. The customer's various requirements are important for MDF powder coating. The MDF coating used to produce TV cabinets, displays, bathroom furniture or cabinet doors is very different. Before deciding which powder to use, what quality of MDF to use, and the design of the spray line, it is important to understand the quality requirements of the customer.

When it is required to achieve high quality MDF powder coating, we must use the most active and high-performance powders. We can only finish this work with very good quality MDF and the most complete curing conditions. In this case, no compromise can be accepted, and if the powder coating company strictly adheres to these principles, MDF powder coating will be successful.

In some cases, the performance of the paint and the quality of the edges of the MDF are not as important as the productivity and cost. In these cases, low-reaction-rate powders, low-quality MDF, and coating lines with incomplete curing conditions may still produce acceptable powder spray products.

Obviously, the customer's product specifications may determine the success or failure of powder coating. Therefore, before making any decision to push MDF powder coating to commercial use, it is important to discuss as much as possible the quality level required by the relevant parties.

Quality assurance plays a crucial role in the powder coating of MDF. The most difficult problem with MDF powder coating is to ensure that the edges of the sprayed MDF do not crack. However, we cannot judge from the freshly painted MDF that it will not crack or crack over a period of time. Tiger powder coating company after more than 10 years of research and development, summed up a set of quality certification system. Through the quality control of the MDF itself, the design requirements for the spray line, the design requirements for the infrared oven, the performance requirements for the powder coating itself, and the assessment of the entire coating line, a test evaluation is performed on the sprayed MDF at the same time. Then give the entire system certification. Tiger Powder Coatings has successfully cooperated with several spraying companies in Europe for the commercial operation of MDF powder coating. In the promising market of MDF powder coating, we hope to have a high starting point in China. Together, we will include MDF manufacturers, spray equipment suppliers, infrared furnace suppliers, and powder coating production companies to achieve the quality of MDF powder coating. And stable at a high level.

Workstation Sink

A Workstation sink is a sink with a mechanism built in to the front and back sides of the bowl to allow accessories to sit on the step or ledge, affording the user to prepare meals on the sink instead of on the countertop. The intent behind the design is to speed up the process of food preparation and clean-up.

Workstation Sink,Farmhouse Workstation Sink,Work Station Kitchen Sink,Workstation Farmhouse Sink

JIANGMEN MEIAO KITCHEN AND BATH CO.,LTD , https://www.jmmeiaogroup.com