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Influence of Finishing Process Parameters of HDF Boards on Selected Properties of Coatings in Modern UV Lines and Their Relation to Energy Consumption
This study analyzes the influence of energy generated by emitters on the adhesive properties of varnish coatings in multilayer UV systems. The experimental material, in the form of a cell board finished with UV varnish products, was prepared on a prototype line under the conditions of Borne Furniture in Gorzów Wielkopolski. The roughness and wettability were measured using a OneAttension tensiometer integrated with a topographic module, taking into account the Wenzel coefficient. The adhesion of the examined systems was verified using the PositiTest AT-A automatic pull-off device. Energy consumption by the prototype production line was compared to the standard line, utilizing mercury emitters and mercury emitters with added gallium. Energy consumption was calculated for selected variants. The influence of the Wenzel coefficient on the wettability angle was observed. Significant differences between contact angles (CA and CAc) were noted for coatings formed with sealers (stages I and II). The largest discrepancies, reaching up to 30 degrees, were recorded at the lowest UVA and UVV doses of 26 mJ/cm2. In adhesion tests, values below 1 MPa were obtained. Insufficient energy doses in the curing process of UV systems led to delamination between the coatings. Five variants were selected where delamination within the substrate predominated (˃90% A) and were characterized by the lowest energy consumption in the processes. Topographic images helped identify the presence of various surface microstructures at different stages of the production cycle. The greatest energy savings, up to 50%, were achieved in stages III and IV of the technological process.
Interlayer Adhesion of Coating System in Analogue and Digital Printing Technologies Formed on Lightweight Honeycomb Furniture Panels
This article concerns research into the influence of the energy dose distributed by UV lamps on selected parameters of varnish coatings formed during the varnishing process of lightweight cellular panels. The lightweight cellular board used in the study was made according to an innovative solution. The surface finishing of the boards was carried out using the roller method in combination with digital and analogue printing under industrial conditions. Contact angle measurements of the obtained varnish coatings were carried out, from which the surface free energy was calculated. In addition, interlayer adhesion was assessed by pull-off tests. Irrespective of the radiation dose, higher contact angle values (54.3–89.9°) were recorded for the last two applied layers (base coat 2 and base coat 3) than for the other coatings (39.6–64.1°). For all systems tested, the γsp component showed lower values (2.25–28.99 mJ/m2) than γsd (28.66–32.80 mJ/m2). The adhesion test results ranged from 0.5 to 0.9 MPa, although with varying types of delamination. Based on the test results, the most favourable variants from the furniture manufacturer’s point of view were selected that provided the desired level of adhesion, in which cohesive damage located within the substrate (A) predominated.
Adhesion of varnish coatings as a background for analogue and digital printing technologies
In analogue and digital printing technologies, from 3 up to 12 layers of lacquer products are applied. Technological parameters significantly influence the adhesion in the coating system. This article refers to the analysis of the influence of selected technological parameters, such as the number of layers, energy doses distributed by the radiators, and line speed, on the topography and adhesion of varnish coatings formed in the process of varnishing with rollers and UV-curing systems. The appropriately prepared surface can be used as a background layer for the analogue and digital printing technology. Manufacturers must adapt the production process to the particular varnish to obtain finished products with the best possible performance properties. The state of surface free energy and finally adhesion can be assessed by theoretically determining the possibility of an adhesive bonding between the product and the substrate, taking into account the assumptions of the adsorption theory of adhesion and measurement of the contact angle (Θ). An experimental confirmation of adhesion measurements included removing the coatings from the substrate via stamps glued to the coating.