P OLY K OAT Polymer Coatings for Sheet Metal PolyKoat ALL INFORMATION CONTAINED IN THIS PRESENTATION IS THE SOLE PROPERTY OF DESIGN ANALYSIS INC AND CANNOT BE DISTRIBUTED WITHOUT AUTHORIZATION BY DAI.
What is PolyKoat? Design Analysis Inc., merged their innovative metal adhesion technology with unique polymer combinations to produce decorative and protective coatings for a wide variety of sheet metals.
A Superior Product PolyKoat is: highly resistant to abrasion, UV & weather  extremely resistant to typical chemicals formable into Zero-T bends & unique shapes produced using ½ the energy environmentally friendly, containing no VOCs or BPA  costs less to produce than painted coils PolyKoat’s patented process produces a superior alternative to paint and epoxy coatings
PolyKoat is more environmentally friendly than traditional paint & coating systems An Environmentally Friendly Process PolyKoat vs painted coatings:  No VOCs produced No BPA in the formulations Inert raw materials used No cleaning section required No caustic chemicals needed Simple, energy efficient process Energy Star ratings a potential
PolyKoat – JAX Lamination Line Max coil weight: 10,000 lbs Max coil width: 44” Dual side coating capable Coating thickness: 0.6-5 mils Capacity: 50k+ tons annual Standard lead-time: 2 weeks  Surface lubrication available Production is immediately available
Appearance: Surface No flow lines, streaks, blisters, or defects are visible Meets AAMA 2603
Appearance: Gloss Gloss range capable from 8 to 65  per ASTM D523
Toughness/Hardness   PolyKoat   Test Method   Scratch/Pencil Hardness    H    D3363  Gouge Pencil Hardness    2H    D3363  Five Finger    15N    1 mm Pin* Taber Abrasion    34 mg  D4060  Gravel Impact    No Cracking    No Flaking  SAE J400     No Peeling    (-40°F) * Ford test method: FLTM BN 108-13
Hardness/Toughness Excellent mar resistance per the “nickel rub” test. PolyKoat (right) and a typical garage door painted sample (left)  PolyKoat samples after gravel impact testing showed no cracking even at -40°F
Formability PolyKoat   Painted Zero T-Bend   Zero T-Bend No  Tape-Off  Microcracking PolyKoat’s excellent adhesion & flexibility enables the forming of Zero-T bends & Lock Seams with no cracking, flaking, or peeling  PolyKoat Lock Seam  No Tape-Off
Formability Cross Hatch: No Tape-Off (Magnified 10x & 60x) ASTM D3359  Impact & Impact/Cross Hatch (5/8” ball @ 40 in-lb): No Tape-Off ASTM 2794 Embossing: No Tape-Off and  No Pick Off
Accelerated Outdoor Exposure  PolyKoat lasted over 2500 hrs of Salt Spray testing with minimal property loss  Salt Spray – ASTM B117 Shown after ~500 hours
Regulatory Specific grades satisfy the listed regulatory approvals: FDA 21CFR 177.1660: Measured extractables after exposure in:  Distilled Water (2 hrs @ 250 ° F): <0.08 mg/in  n-Heptane (2 hrs @ 150°F): < 0.02 mg/in 3% aq Acetic Acid (2 hrs @ 212°F): < 0.04 mg/in 50% Ethanol (2 hrs @ 150°F): < 0.02 mg/in  NSF Standard 14 & Standard 61: Potable water contact
General Chemical Resistance Acetic Acid – G Acetone – G Ammonium Hydroxide – G Benzene - G Citric Acid – G Ethylene Glycol – G Formaldehyde – G Formic Acid – F Gasoline – G Hydrochloric Acid – F Hydrogen Peroxide - G Linseed Oil – G Methyl Ethyl Ketone – G Mineral Oils – G Nitric Acid (aq) – P Oleic Acid – G Phosphoric Acid – F Soap Solutions – G Sodium Carbonate – G Sulfuric Acid – F Toluene – G Water - G G = Good; F = Fair; P = Poor
Chemical Resistance Immersion Chemical   Days Tested     Affect Laundry Detergent 180   Negligible 1% Soap Solution 180    Negligible Buffer pH 4, 7, & 10 360   Negligible Gasoline – Unleaded 360   Negligible Motor Oil 360   Negligible Freon 360   Negligible Acetone 180    Minimal Ammonium Hydroxide   90    Minimal Benzene 360   Negligible Heptane 360   Negligible Hexane 360   Negligible Methyl Ethyl Ketone 360   Negligible Tri-Chloroethylene 180   Negligible 10% Sodium Chloride 360   Negligible Immersion testing performed on 1/8” x 2” diameter discs @ 73°F Affects include appearance, weight & tensile properties Values shown are general representation and are not intended for establishing actual performance specifications. Determination of the suitability for the intended use is the sole responsibility of the user/OEM, who must assure that all performance needs are met.
Chemical Resistance  Solvent Resistance  200 MEK Rubs  No Effect Mortar Resistance  ASTM C207  No Effect Nitric Acid Vapor  ASTM D2244  No Effect Detergent  ASTM D3359  No Effect Window Cleaner  Cross Hatch/Visual  No Effect Chemical   Test Method Result The engineered polymers utilized in PolyKoat enables it to withstand the harshest chemicals
Stain Testing
Stain Testing Results Values shown are based on testing of laboratory test specimens by Ticona LLC and represent data that falls within the normal range of properties for natural material. Colorants or other additives may cause significant variations in data values. These values are not intended for use in establishing maximum, minimum, or ranges of values for specification purposes. Any determination of the suitability of the material for any use contemplated by the user and the manner of such use is the sole responsibility of the user, who must assure himself that the material as subsequently processed meets the needs of his particular product or use. Sample 30 min @250 ° F 30 min @325 ° F 1. Mustard - Heinz  Bright yellow stain  Dull yellow stain 2. Catsup - Heinz  Pinkish-red stain  Brownish-orange stain 3. Egg - Raw/beaten  No stain   Slight stain 4. Milk - Whole  No stain  Tan-brown stain 5. Lemon - Fresh  Light yellow stain  Burnt-brown-yellow stain 6. Orange - Fresh  Slight yellow stain Medium brown stain 7. Tea - Lipton  No stain   No stain 8. Beef - Raw  No stain   Slight tan stain 9. Vinegar (apple)  Slight stain   Slight tan stain 10. Glass Cleaner No stain   No stain 11. Ammonium  No stain   No stain 12. Clorox  No stain   No stain 13. Isopropyl alcohol  No stain   No stain 14. Black shoe polish  Gray stain, matt finish  Gray stain, matt finish 15. Red Lipstick  Pink stain   Deeper-pink stain
Consumer Finishing  PolyKoat PolyKoat surfaces can be painted over with consumer available oil, enamel, solvent & water-based paints
Design Analysis Inc. Developer of the PolyKoat technology Holder of all PolyKoat patents Jim Velliky is the former General Mgr of WEIRTEC, Weirton Steel Tech  Center, responsible for developing new technology-based business  Through the 1980s & 1990s, Mr. Velliky held responsible positions at: Garrard Steel – West Coast Operations Director British Steel - North American Sales Manager Alliance Packaging N.W. - President United States Steel Corporation, Int’l & Domestic Commercial Dept Jim Velliky President 30 yrs Mark Loen Chief Engineer 30 yrs  John Richards Managing Director Operations 30 yrs  Ann Hicks GM Operations 30 yrs Jeff Sawka VP Commercial 25 yrs Bill Mula Consultant 30 yrs
An Innovative Process Extensive Testing, Proven Results One patent has been issued and other patents involving the polymer coating technology are pending (US 7,279,225 B2)  PolyKoat has been tested to rigorous protocols including:  Adhesion, hardness, abrasion resistance, color, gloss, forming/bending, accelerated corrosion testing, & weathering.  PolyKoat has demonstrated superior performance throughout a demanding series of tests and applications.  Results have been documented by independent testing laboratories.
Stain Testing Stain testing performed by Ticona LLC per ASTM D 1308 (30 min @ 250°F & 325°F) Mustard (Heinz) Ketchup (Heinz) Egg – Raw beaten Milk (Whole) Lemon – Fresh Orange – Fresh Tea – Brewed (Lipton) Beef - Raw Apple Vinegar (Kingston Brand) Glass Cleaner (Windex) Ammonium (Top Crest brand) Clorox Bleach Isopropyl Alcohol (Walgreen's) Black Shoe Polish (Kiwi) Red Lipstick (Cover Girl Mocha)
Properties – Weather Resistance Surface    DL*   Da*   Db*   DE*   Unwashed  -2.17  0.33  1.16  2.48  Washed  -0.64  0.07  0.48  0.80  Surface     DL*   Da*   Db*   DE*   Unwashed  -3.15  0.06  -0.71  3.23  Washed  -1.81  0.29  0.25  1.85  Natural Exposure - 24 Months South Florida  Accelerated Exposure - Xenon Arc  *Values shown are based on testing of customer supplied specimens by Ticona LLC and represent data that are expected to fall within the normal range of properties for the material. To the best of our knowledge, the information contained herein is accurate. These values are not intended for use in establishing maximum, minimum, or ranges of values for specification purposes. Any determination of the suitability of the material for any use contemplated by the user and the manner of such use is the sole responsibility of the user, who must assure himself that the material as subsequently processed meets the needs of his particular product or use.
Irradiation, W/m²    0.55    -- Black Panel Temp, °C  70  38 Relative Humidity, %  50  95 Cycle Time:  40 min of Light/no spray  20 min of Light/front spray  60 min of Light/no spray  60 min of Dark/back spray  DL*  Lighter    Darker  Da*  Redder    Greener  Db*  Yellower    Bluer  DE*  Total Color Difference  Conditions: Illuminant D65; 10°Observer; Specular included; CIELab units   Xenon Test Condition SAE J1960  Color Difference Legend

Polykote Presentation Link

  • 1.
    P OLY KOAT Polymer Coatings for Sheet Metal PolyKoat ALL INFORMATION CONTAINED IN THIS PRESENTATION IS THE SOLE PROPERTY OF DESIGN ANALYSIS INC AND CANNOT BE DISTRIBUTED WITHOUT AUTHORIZATION BY DAI.
  • 2.
    What is PolyKoat?Design Analysis Inc., merged their innovative metal adhesion technology with unique polymer combinations to produce decorative and protective coatings for a wide variety of sheet metals.
  • 3.
    A Superior ProductPolyKoat is: highly resistant to abrasion, UV & weather extremely resistant to typical chemicals formable into Zero-T bends & unique shapes produced using ½ the energy environmentally friendly, containing no VOCs or BPA costs less to produce than painted coils PolyKoat’s patented process produces a superior alternative to paint and epoxy coatings
  • 4.
    PolyKoat is moreenvironmentally friendly than traditional paint & coating systems An Environmentally Friendly Process PolyKoat vs painted coatings: No VOCs produced No BPA in the formulations Inert raw materials used No cleaning section required No caustic chemicals needed Simple, energy efficient process Energy Star ratings a potential
  • 5.
    PolyKoat – JAXLamination Line Max coil weight: 10,000 lbs Max coil width: 44” Dual side coating capable Coating thickness: 0.6-5 mils Capacity: 50k+ tons annual Standard lead-time: 2 weeks Surface lubrication available Production is immediately available
  • 6.
    Appearance: Surface Noflow lines, streaks, blisters, or defects are visible Meets AAMA 2603
  • 7.
    Appearance: Gloss Glossrange capable from 8 to 65 per ASTM D523
  • 8.
    Toughness/Hardness PolyKoat Test Method Scratch/Pencil Hardness H D3363 Gouge Pencil Hardness 2H D3363 Five Finger 15N 1 mm Pin* Taber Abrasion 34 mg D4060 Gravel Impact No Cracking No Flaking SAE J400 No Peeling (-40°F) * Ford test method: FLTM BN 108-13
  • 9.
    Hardness/Toughness Excellent marresistance per the “nickel rub” test. PolyKoat (right) and a typical garage door painted sample (left) PolyKoat samples after gravel impact testing showed no cracking even at -40°F
  • 10.
    Formability PolyKoat Painted Zero T-Bend Zero T-Bend No Tape-Off Microcracking PolyKoat’s excellent adhesion & flexibility enables the forming of Zero-T bends & Lock Seams with no cracking, flaking, or peeling PolyKoat Lock Seam No Tape-Off
  • 11.
    Formability Cross Hatch:No Tape-Off (Magnified 10x & 60x) ASTM D3359 Impact & Impact/Cross Hatch (5/8” ball @ 40 in-lb): No Tape-Off ASTM 2794 Embossing: No Tape-Off and No Pick Off
  • 12.
    Accelerated Outdoor Exposure PolyKoat lasted over 2500 hrs of Salt Spray testing with minimal property loss Salt Spray – ASTM B117 Shown after ~500 hours
  • 13.
    Regulatory Specific gradessatisfy the listed regulatory approvals: FDA 21CFR 177.1660: Measured extractables after exposure in: Distilled Water (2 hrs @ 250 ° F): <0.08 mg/in n-Heptane (2 hrs @ 150°F): < 0.02 mg/in 3% aq Acetic Acid (2 hrs @ 212°F): < 0.04 mg/in 50% Ethanol (2 hrs @ 150°F): < 0.02 mg/in NSF Standard 14 & Standard 61: Potable water contact
  • 14.
    General Chemical ResistanceAcetic Acid – G Acetone – G Ammonium Hydroxide – G Benzene - G Citric Acid – G Ethylene Glycol – G Formaldehyde – G Formic Acid – F Gasoline – G Hydrochloric Acid – F Hydrogen Peroxide - G Linseed Oil – G Methyl Ethyl Ketone – G Mineral Oils – G Nitric Acid (aq) – P Oleic Acid – G Phosphoric Acid – F Soap Solutions – G Sodium Carbonate – G Sulfuric Acid – F Toluene – G Water - G G = Good; F = Fair; P = Poor
  • 15.
    Chemical Resistance ImmersionChemical Days Tested Affect Laundry Detergent 180 Negligible 1% Soap Solution 180 Negligible Buffer pH 4, 7, & 10 360 Negligible Gasoline – Unleaded 360 Negligible Motor Oil 360 Negligible Freon 360 Negligible Acetone 180 Minimal Ammonium Hydroxide 90 Minimal Benzene 360 Negligible Heptane 360 Negligible Hexane 360 Negligible Methyl Ethyl Ketone 360 Negligible Tri-Chloroethylene 180 Negligible 10% Sodium Chloride 360 Negligible Immersion testing performed on 1/8” x 2” diameter discs @ 73°F Affects include appearance, weight & tensile properties Values shown are general representation and are not intended for establishing actual performance specifications. Determination of the suitability for the intended use is the sole responsibility of the user/OEM, who must assure that all performance needs are met.
  • 16.
    Chemical Resistance Solvent Resistance 200 MEK Rubs No Effect Mortar Resistance ASTM C207 No Effect Nitric Acid Vapor ASTM D2244 No Effect Detergent ASTM D3359 No Effect Window Cleaner Cross Hatch/Visual No Effect Chemical Test Method Result The engineered polymers utilized in PolyKoat enables it to withstand the harshest chemicals
  • 17.
  • 18.
    Stain Testing ResultsValues shown are based on testing of laboratory test specimens by Ticona LLC and represent data that falls within the normal range of properties for natural material. Colorants or other additives may cause significant variations in data values. These values are not intended for use in establishing maximum, minimum, or ranges of values for specification purposes. Any determination of the suitability of the material for any use contemplated by the user and the manner of such use is the sole responsibility of the user, who must assure himself that the material as subsequently processed meets the needs of his particular product or use. Sample 30 min @250 ° F 30 min @325 ° F 1. Mustard - Heinz Bright yellow stain Dull yellow stain 2. Catsup - Heinz Pinkish-red stain Brownish-orange stain 3. Egg - Raw/beaten No stain Slight stain 4. Milk - Whole No stain Tan-brown stain 5. Lemon - Fresh Light yellow stain Burnt-brown-yellow stain 6. Orange - Fresh Slight yellow stain Medium brown stain 7. Tea - Lipton No stain No stain 8. Beef - Raw No stain Slight tan stain 9. Vinegar (apple) Slight stain Slight tan stain 10. Glass Cleaner No stain No stain 11. Ammonium No stain No stain 12. Clorox No stain No stain 13. Isopropyl alcohol No stain No stain 14. Black shoe polish Gray stain, matt finish Gray stain, matt finish 15. Red Lipstick Pink stain Deeper-pink stain
  • 19.
    Consumer Finishing PolyKoat PolyKoat surfaces can be painted over with consumer available oil, enamel, solvent & water-based paints
  • 20.
    Design Analysis Inc.Developer of the PolyKoat technology Holder of all PolyKoat patents Jim Velliky is the former General Mgr of WEIRTEC, Weirton Steel Tech Center, responsible for developing new technology-based business Through the 1980s & 1990s, Mr. Velliky held responsible positions at: Garrard Steel – West Coast Operations Director British Steel - North American Sales Manager Alliance Packaging N.W. - President United States Steel Corporation, Int’l & Domestic Commercial Dept Jim Velliky President 30 yrs Mark Loen Chief Engineer 30 yrs John Richards Managing Director Operations 30 yrs Ann Hicks GM Operations 30 yrs Jeff Sawka VP Commercial 25 yrs Bill Mula Consultant 30 yrs
  • 21.
    An Innovative ProcessExtensive Testing, Proven Results One patent has been issued and other patents involving the polymer coating technology are pending (US 7,279,225 B2) PolyKoat has been tested to rigorous protocols including: Adhesion, hardness, abrasion resistance, color, gloss, forming/bending, accelerated corrosion testing, & weathering. PolyKoat has demonstrated superior performance throughout a demanding series of tests and applications. Results have been documented by independent testing laboratories.
  • 22.
    Stain Testing Staintesting performed by Ticona LLC per ASTM D 1308 (30 min @ 250°F & 325°F) Mustard (Heinz) Ketchup (Heinz) Egg – Raw beaten Milk (Whole) Lemon – Fresh Orange – Fresh Tea – Brewed (Lipton) Beef - Raw Apple Vinegar (Kingston Brand) Glass Cleaner (Windex) Ammonium (Top Crest brand) Clorox Bleach Isopropyl Alcohol (Walgreen's) Black Shoe Polish (Kiwi) Red Lipstick (Cover Girl Mocha)
  • 23.
    Properties – WeatherResistance Surface DL* Da* Db* DE* Unwashed -2.17 0.33 1.16 2.48 Washed -0.64 0.07 0.48 0.80 Surface DL* Da* Db* DE* Unwashed -3.15 0.06 -0.71 3.23 Washed -1.81 0.29 0.25 1.85 Natural Exposure - 24 Months South Florida Accelerated Exposure - Xenon Arc *Values shown are based on testing of customer supplied specimens by Ticona LLC and represent data that are expected to fall within the normal range of properties for the material. To the best of our knowledge, the information contained herein is accurate. These values are not intended for use in establishing maximum, minimum, or ranges of values for specification purposes. Any determination of the suitability of the material for any use contemplated by the user and the manner of such use is the sole responsibility of the user, who must assure himself that the material as subsequently processed meets the needs of his particular product or use.
  • 24.
    Irradiation, W/m² 0.55 -- Black Panel Temp, °C 70 38 Relative Humidity, % 50 95 Cycle Time: 40 min of Light/no spray 20 min of Light/front spray 60 min of Light/no spray 60 min of Dark/back spray DL* Lighter Darker Da* Redder Greener Db* Yellower Bluer DE* Total Color Difference Conditions: Illuminant D65; 10°Observer; Specular included; CIELab units Xenon Test Condition SAE J1960 Color Difference Legend