The Powder Coating Process
In 1967, a man by the name of Allan Davies first used a revolutionary surface finishing technique called powder coating. This technique involves electrostatically applying dry paint pigment to a material, which is then cured under extreme heat. The result is a hard finish that is more durable than conventional paint. This is usually the preferred finishing method of coating metals, aluminium extrusions, plastic and, recently, medium density fibreboard.
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Powder coating involves more specialised methods and equipment than ordinary painting. First, the material to be coated must be free from oil, dirt, grease, metal oxides, and other impurities. This step is essential for the powder to successfully bond with the material. Pre-treatment chemicals such as phosphates or chromates, or mechanical means such as sandblasting are typically used for this process.
Applying the powder is commonly done by using an electrostatic gun, a kind of spray gun powered by compressed air. This apparatus gives the paint powder a powerful electrostatic positive charge. The charge allows the powder to adhere to the material. Another technique is to use an electrostatic fluidised bed wherein the material is dipped into the charged particles, rather than having it sprayed. The powder can also be applied using an electromagnetic brush, a kind of roller similar to that used in photocopier machines. The roller applies an accurate layer of charged powders, usually around 5 to 100 micrometres, to the material.
Finally, the material is then heated to around 200 degrees Celsius for 10 minutes, melting the powder into a uniform film. The melted powder flows out and chemically reacts to the material, forming a hard high-molecular weight polymer with a microscopic network-like structure when it cools.
