This presentation will explain how the combination of a conductive primer, plasma treatment, and UV-curable powder coatings is a viable way to finish lightweight materials without causing thermal damage or deformation. It will describe plasma treating, operating conditions, and surface condition measurements before and after plasma treating. The second half of the presentation will describe adhesion results of UV-cured powder coating with and without plasma treating on various plastics and composites. It will conclude with an evaluation of suitable substrates for plasma treating, UV-cured powder coating, and UV-cured powder coating performance results specifically for the aerospace industry.

1. New Finishing Opportunities for
Lightweight Materials
Conductive Primers + Plasma Treatment + UV Curable Powder Coatings
Evan Knoblauch
Keyland Polymer UV Powder, LLC
March 19th, 2020

2. Presentation Agenda
Company Overview
Industry Opportunities
Why Are They Difficult to Coat?
UV Curable Powder Coatings
Adherence
Adhesion
Plasma Treating
Additional Testing and Results
Conclusions
Questions

3. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
2002 Decorative Veneer built the 1st UV cured powder coating system
for MDF in North America
2005 The Decorative Veneer system is moved to Cleveland, OH and the
company rebrands as DVUV
2006 Keyland Polymer UV Powder is founded, by 2007 it begins
formulating and manufacturing coatings for DVUV
2013 Keyland UV resins begin making solid resins in Spain specifically for
Keyland Polymer UV powder
2019 Keyland Polymer UV Materials, Spain is formed to produce and sell
UV resins for the global market
History of Keyland Polymer and
UV Cured Powder Coatings

4. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
R&D
Light & Energy
Cured
Solid Resins
Manufacturing
Light & Energy
Cured
Solid Resins
Manufacturing
UVCured
Powder Coatings
Manufacturing
UVCured
Powder Coating for
MDF Furniture
R&D
UVCured
Powder Coatings
R&D
UV LED Light Cured
3D PrintingMaterials

5. Aerospace Material Advancements Opportunities
The 787 Dreamliner began flying in 2011 and
its material composition is 20% aluminum,
50% composite and 30% other.
Approximately, 60,000kg of composite
materials are used in one plane.
The Boeing 777 began flying in 1990, and its
material composition is 50% aluminum, 12%
composite materials, and 38% other.

6. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Materials that provide a performance improvement
• Lighter weight
• Stronger
Materials that are more cost effective to produce
• Injection molded
• Additive manufacturing
Aerospace Materials
Plastics, Composites, and Carbon Fiber

7. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Difficulties Powder Coating Plastics, Composites,
& Carbon Fiber
Problem 1: Heat Sensitive
• Melt
• Deform
• Degrade
• Outgas
Problem 2: Not Conductive
• Very poor powder adherence
Problem 3: Low Surface Energy & Surface Contaminates
• Poor to mediocre adhesion

8. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Solution: UV Curable Powder Coatings
Problem 1: Substrates are Heat Sensitive
Why: Requires significantly less heat than traditional thermoset powder
coatings because it is only used to melt the powder

9. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Goal: Melt the powder not heating part
• Total time entry to exit 120 seconds
• Total dwell time in front of IR panel 96 seconds
• Surface temperature end of cure – 85°C/185°F
1 second
65°C/150 °F
47 seconds
78°C/172 °F
96 seconds
104°C/221 °F
UV Cured Powder Coating Thermal Profile

10. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Benefits
• Faster - 3.5 to 10 times
• Uses less energy – 25% to 90%
• Smaller plant footprint – 40%
• More productive – 6% - 30%
• Higher profits per hour – 5% - >20%
The UV Curing Advantage
0 10 20 30 40 50
Liquid Coatings
Thermoset Powder
Low Bake Powder
UV Powder
Finishing Cycle Time Analysis
Coating Application Melt & Flow UV Cure
Solvent Flash Thermal Cure

11. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Solution: Conductive Primers
Problem 2: Substrate is Not Conductive
PLASTICS AND COMPOSITES ARE GENERALLY NON-CONDUCTIVE
• Resulting in low to no transfer efficiency
• Percent of powder transferred out of the gun onto the part
HOW DO WE OVERCOME THIS?
• Apply a thin coat of conductive primer to the substrate
• Conductive primers consist of electrolyte solutions thus producing a
conductive surface where applied
With Conductive
Primer
Raw Panel
Without
Conductive
Primer

12. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Solution: Surface Modification Using Plasma Treating
Problem 3: Low Surface Energy and Surface
Contaminates
WHAT IS PLASMA?
• Partially ionized and neutralized gas mixture containing physically active and
chemically reactive species, like ions, electrons and free radicals.
• Sometimes referred to as the 4th state/phase of matter
• Similar to gas phase, but capable of conducting electricity
HOW DOES PLASMA WORK?
• Surface activation, cleaning, and etching by chemical reaction and physical
bombardment of ionized gas

13. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
High Contact Angle Low Contact Angle
Contact Angle & Surface Modification
Untreated Low Contact Angle
Before After

14. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Vacuum Plasma Technology
How It Is Done:
• Evacuate air, input desired process gas
• Apply electromagnetic (RF) energy across electrodes
for surface treatment
• 3D surface treatment
• Low temperature

15. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
ADHESION OF UV POWDER AFTER PLASMA TREATING
ADHESION OF UV POWDER WITHOUT PLASMA TREATING
Material #1 Material #4Material #2 Material #3
Material #4 Gas #1Material #1 Gas #2 Material #3 Gas #2Material #2 Gas #2

16. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Adhesion Test Results Following Plasma
0 4 5
0 4 5 4 0 4 5
2
5
3 4
Adhesion
ASTM D3359
0b - 5b

17. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
UV Cured Powder Coating Performance
Test Result
60° Gloss ASTM D 523 5 – 90
Film Build ASTM D 4138, Method A Destructive, Tooke Gauge 1.5 – 2.5 mils
Adhesion ASTM D 3359, Method A 5B – No loss of adhesion
Pencil Hardness ASTM D 3363-05 Scratch Resistance H – 4H
MEK Resistance PCI Test Method # 8 No softening after 50 double rubs
Abrasion Resistance ASTM D 4060, CS-17 Wheel 500g, 500 Cycles 25-35 MG Material Loss

18. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Vertical Burn Test Results (12-s) and (60-s)
Sample Ignition Time Flame Time (sec) Drip Flame Time (sec) Burn Length
1 60.0 0.0 0.0 No Drips 0.0
2 60.0 0.0 0.0 No Drips 0.0
3 60.0 0.0 0.0 No Drips 0.0
Average: 0.0 0.0 0.0
Result: Pass Pass Pass

19. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Gas Limit (ppm) at 4 Min
Sample 1
Sample 2
Value Method Results Value Method Results
HCN 150 <1 DT Pass <1 DT Pass
CO 3500 14 GF Pass 14 GF Pass
NO/NO² 100 3 GF Pass 3 GF Pass
SO² 100 0 GF Pass 0 GF Pass
HF 200 <1 DT Pass <1 DT Pass
HCL 500 <1 DT Pass <1 DT Pass
Toxicity (Flaming Mode) BSS 7239

20. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Benefits of UV Cured Powder on Plastic & Composites

21. Featuring
March 16-19, 2020 | Exhibits: March 17-18
Fort Worth (TX) Convention Center
Plastics, composites, and carbon fiber are a viable alternative to traditional materials for the
aerospace industry
• Materials provide processing, lightweight, and performance advantages
Plastics, composites, and carbon fiber are difficult materials to finish
• Low surface energy and presence of containments from mold release and processing impedes the adhesion
of coatings
• Low melt or heat deflection temperatures
UV cured powder coating used in combination with a conductive primer and plasma treating is an
effective and efficient finishing system for coating novel materials
• High productivity
• Low temperature and fast melting eliminates distortion of substrate
• Same durable finish
Conclusion

22. Evan Knoblauch
Keyland Polymer UV Powder, LLC
4621 Hinckley Industrial Parkway Unit 8
Cleveland, OH 44109 USA
216-741-7915 ext 205
eknoblauch@keylandpolymer.com
www.kpuvpowder.com