Ultraviolet (UV) light has been used to cure coatings for more than 30 years, and companies have been successfully using UV-cured powder coatings for more than 20 years. UV-cured powder coatings can replace solvent liquid coating (in some cases thermoset powder coating) and are a finishing material of interest for many new materials and products.

1. Keyland Polymer UV Powder, LLC
Cleveland, Ohio
RadTech uv.eb WEST 2017
UV LED Curing of UV-Cured
Powder Coatings

2. Develop, formulate, manufacture
and sell UV- cured powder
coatings.
Sold under UVMax brand used on
wood, metal, plastic & composite
substrates
Develop , produce and sell solid
polyester, epoxy & other resins
used in UV-cured solid materials
Produces & sells MDF wood
components
to commercial and industrial
furniture companies using
UVMax powder coatings made by
Keyland Polymer UV Powder
Development of Ultra Violet (UV)
microwave or UV LED curing
solutions of solid materials used as
coatings, additive materials and
other product applications
Focus on solid UV & EB cured materials
Resins – Powders – Materials - Applications

3. UV-Cured Solid Material

4. UV-Cured Solid Material

5.  Polyester – broad range of performance attributes – can achieve
ASTM 1000 hour corrosion resistance – BPA Free
 MDF
 Metal
 Composite
 Epoxy – Hard functional coatings – primarily for interior applications
 Metal
 Composite
 Hybrid – Polyester/Epoxy – for specialized applications
 MDF
 Metal
 Plastics
 Composites
Resin Platform

6.  The differentiating characteristic of UV-curable powder coating is the
separation of melt & flow from cure
UV-Cured Powder Coating
Melt & Flow
1-2 minutes
UV Cure
(seconds)
Minimal
cooling
Electrostatic
Powder
Deposition
Finished
Product
Substrate
Pretreatment
Melt, Flow & Cure
5 to >60 mins
+ cooling
Thermal Powder Coating
UV Powder Coating

7. UV-Cured Powder Coating Thermal
Profile
1 second 47 seconds 96 seconds
65°C 78°C 104°C
Total time in front of IR panel 120 seconds
Total dwell time in front of IR panel 96 seconds
Surface temperature end of cure – 85o C
Melting powder not heating part

8.  Reduction in energy consumption
 Shorter & faster thermal cycles
 No oxygen inhibition
 Less time in oven(s)
 Smaller ovens
 Finish heat sensitive substrates
 MDF/Wood
 Plastics
 Composites
 Assembled products
 Less risk to substrates
 Reduced moisture loss in MDF & wood
 Reduced potential thermal cracking in MDF & wood
 Reduced potential of outgassing cast metals
 Eliminate damage to heat sensitive gaskets and seals
Advantages of UV-Cured Powder
Coating

9.  UV LED technology is increasing market interest and demand for UV
cured materials
 Higher energy output efficiency
 Longer useful life
 Lower total cost of energy
 Targeted curing
 Cure complex shapes/geometries
 No heavy metals
 No IR
UV LED Curing Technology

10.  Substrates
 MDF – Low heat – less moisture volatilization more stable substrate
 Wood – Low heat – less resin volatilization
 Plastics – Low heat – less warp of certain plastics
 Composites – No degradation of substrate
 Metals – ASTM B-117 – 1000 hour corrosion resistance
 Assembled parts – Low heat – no damage to heat sensitive gaskets and seals
Substrates for UV LED Powder
Coatings

11. UV LED Market Growth

12. UV VISIBLE IR
l
100n
m
400n
m
760n
m
1,000,000n
m
100n
m
280n
m
320
nm
445
nm
400
nm
UV A UV VUV BUV C
0
500
1000
1500
UV C UV B UV A UV V
Dosis(mJ/cm2)
H-Lamp (Hg)
V-Lamp (Ga)
UV Spectra & Lamps

13. UV Light Spectrum

14. % Power 50 60 70 80 90 100
5 ft/min 5622 7100 8655 9822 10000 10000
10 ft/min 2683 3500 4274 4819 5216 5857
15 ft/min 1796 2291 2844 3196 3515 3966
20 ft/min 1218 1632 2033 2293 2569 2821
600W Microwave Lamp - Exposure
mJ/cm2
(Exposure)UVV
4” Focal Distance

15. 0
500
1000
1500
2000
2500
3000
50 60 70 80 90 100
IrradiancemW/cm2
% Power
Irradiance at 4" Focal Distance
5 ft/min
10 ft/min
15 ft/min
20 ft/min
600W Microwave Lamp - Irradiance
% Power 50 60 70 80 90 100
5 ft/min 1244 1528 1896 2117 2167 2232
10 ft/min 1239 1585 1854 2110 2046 2170
15 ft/min 1135 1465 1813 2027 2081 2136
20 ft/min 1056 1393 1693 1900 1960 2075
mW/cm2
(Irradiance)
UVV

16. Lamp Type
Power
Spectrum
Exposure
mJ/cm2
Irradiance
mW/cm2
300W Medium
Pressure@ 100%
UVV
2811 1088
600W Medium
Pressure@100%
UVV
10000 2232
600W Medium
Pressure@50%
UVV
5622 1244
395nm
LED@100%
8W UVA2
12312 2711
5'/minute @ 4" distance
Comparison 300W, 600W & 395nm
UV LED
Irradiance (intensity)–
lamp power or output
called peak. Irradiance
is measured by power
and at a distance -
mW/cm2
Exposure (energy
density) – amount of
energy on the surface
measured in mJ/cm2,
determined by
irradiance and time

17. Distance
inches
Exposure
mJ/cm2
Irradiance
mW/cm2
0.5 20616 12485
2 18112 6283
5'/ minute 395nm 8W UVICure Plus II UVA2
UV LED 395nm

18. Material & Set Cure Method
Lamp
Distance cm
Film Build
Mils
Final Tg oC Cure Evaluation
Clear 1 300W V bulb 6 2 82 Cured
White 1 300W V bulb 6 2 69 Just Cured
Clear 2 300W V bulb 18.5 2 79 Cured
White 2 300W V bulb 18.5 2 60 Uncured
Clear 3 395 UV LED 1.3 2 84 Cured
Clear 3 395 UV LED 5 2 88 Cured
Clear 3 395 UV LED 10.2 2 82 Cured
White 4 395 UV LED 1.3 2 73 Cured
White 4 395 UV LED 5 2 73 Cured
White 4 395 UV LED 10.2 2 61 Uncured
Clear 5 395 UV LED 10.2 3 84 Cured
White 6 395 UV LED 5 3 74 Cured
White 6 395UV LED 10.2 3 70 Cured
Black 7 395 UV LED 1.3 2 96 Cured
Black 7 395 UV LED 5 2 92 Cured
Black 7 395 UV LED 10.2 2 83 Cured
Black 9 395 UV LED 1.3 2 96 Cured
Black 9 395 UV LED 5 3 88 Cured
Black 9 395 UV LED 10.2 3 84 Cured
Black 10 395 UV LED 1.3 3 90 Cured
Black 10 395 UV LED 5 3 87 Cured
Black 10 395UV LED 10.2 3 87 Cured
UV LED Cure Clear, Black, White

19. Material & Set Photoinitiator
Cure
Method
Lamp
Distance
CM
Final Tg oC
MEK
rating
50
Double
Rubs
Cure Evaluation
White HR1 std Standard
300W V
bulb
6 76 NA Cured
White JR1 Standard
300W V
bulb
6 78 NA Cured
White FR1 Standard
300W V
bulb
6 72 NA Cured
White JR1 Standard 395 UV LED 1.3 77 10 Cured
White JR1 Standard 395 UV LED 5 75 9 Cured
White JR1 Standard 395 UV LED 10.2 76 10 Cured
White JR2 Non standard 1 395 UV LED 1.3 66 10 Uncured
White JR2 Non standard 1 395 UV LED 5 71 10 Cured
White JR2 Non standard 1 395 UV LED 10.2 74 10 Cured
White JR5 Non standard 2 395 UV LED 1.3 No data 10 NA
White JR5 Non standard 2 395 UV LED 5 77 10 Cured
White JR5 Non standard 2 395 UV LED 10.2 75 9 Cured
White JR7 Non standard 3 395 UV LED 1.3 68 10 Just cured
White JR7 Non standard 3 395 UV LED 5 No data 10 NA
White JR7 Non standard 4 395 UV LED 10.2 71 10 Cured
White JR9 Non standard 5 395 UV LED 1.3 45 0 Uncured
UV LED Cure Photoinitiator Study

20. UV LED Cure Study

21.  Cure is the measure of the crosslinked oligomer chains or fully reacted double
bonds residing in the coating matrix following exposure to the curing system,
which can be thermal energy or Ultra Violet light exposure. Differential Scanning
Calorimetry (DSC) is a scientifically recognized, reliable and repeatable
methodology to measure the cure of a coating system.
 Ultra-Violet (UV) powder coatings are photopolymerized coatings containing a
chemical photoinitiator that instantly responds to UV light energy initiating a
chain reaction and curing the coating. The melt stage is separate from the curing
of the coating. Melting is typically 1-2 minutes and is followed by UV-curing. As
long as the proper amount of UV energy is present, the UV-cured powder
coating will cure in a matter of seconds.
Definition of Cure & UV-Cure

22. Relationship of Lamp Distance and Tg

23.  A 395nm UV LED will cure a clear, black, white and other non-
conflicting UV absorbing pigmented UV-cured powder coating
 Increasing power output of UV LED expand application possibilities
 Additional R&D is needed to overcome UV absorption conflicts
 New photoinitiators
 Pigments analysis
 UV LED cured powder coatings are suitable for use on various
substrates, simple and complex geometries
 UV LED enables targeted and robotic lamp movement to cure
complex geometries
 UV LED curing of UV-cured powder coating is an enabling technology,
expanding the product and market opportunities for powder coating
Conclusions

24.  Equipment:
 NobleCure NC-B1-8W395/L3, 100% Power, Various heights, 5 ft/min
 LED Power Supply: LED-PSCC2-8-10-48
 UVICURE PLUS II with UVA2 Sensor
 Extech Digital Contact Tachometer Model 461891
 RayTek ST ProPlus Infrared Thermometer
 Convection Oven Set At 400 °F (for 4 min flash)
 Mettler DSC822e cooled with liquid nitrogen
 EIT Power puck
 Testing locations:
 Keyland Polymer, LLC. Cleveland, Ohio
 Heraeus Noblelight America, LLC. Gaithersburg, Maryland
 Thermodynamics Laboratory Department of the ETSEIB, Universitat
Politecnica de Catalunya (UPC, Barcelona, Spain).
Equipment &Technical Assistance

25. Questions
Michael Knoblauch
Keyland Polymer, Ltd.
4621 Hinckley Ind Pky
Cleveland, OH 44109
216-741-7915
mfk@keylandpolymer.com
www.keylandpolymer.com
Thank you