How Smartvacuum improves several aspects of the basecoat application process

Verniciatura fondo pannelli piani

Applying a basecoat to a flat panel is usually performed using one of the following techniques: roller coating, spray coating or curtain coating. Each system has specific advantages depending on a number of factors. Introducing an innovative application technique using vacuum technology adds a new set of opportunities and benefits for manufacturers of cabinet doors, panels and bathroom furniture.

Any wood or wood-based flat panel can be coated using vacuum application technology, especially those with rounded edges.

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A closer look at vacuum application technology

Easily used to process flat rounded doors, J-pull versions and panels with ABS edges, Smartvacuum applies 100% UV acrylic paint in a single pass without the application head coming into physical contact with the substrate. Between 100 and 140 g/sqm are deposited in an extremely clean, homogeneous manner avoiding any product build-up on any parts of the panel. The process is simple, clean, eco-friendly and cost-efficient.

Flash-off is performed after basecoat application and prior to the panel completing its drying in a UV-R oven.

Which benefits does Smartvacuum add to the coating process?

Using a 100% solid UV product, this makes it a relatively sustainable process and the coating is more stable over time compared to polyurethane or polyester-based products, also requiring a shorter drying time. One benefit which distinguishes the use of vacuum application techniques regards the matching between panel surface and edge.

Smartvacuum is the perfect partner for Smartedge

They use the same technique and the same lacquer. That makes it simple to achieve the best junction seam between the flat surface and the edge of the panel. Softer to the touch than what can be achieved using other techniques, the quality of the finish on panels with rounded edges is improved and fewer operations are required to obtain the perfect finish.

A complementary solution to other application techniques

Vacuum application boasts several advantages over other coating technologies, but there is no need to consider it an alternative. To appreciate the benefits, we need to consider the current techniques.

Roller coating lines

Roller coating lines include:

  • substrate sanding
  • application of basecoat for adhesion
  • three base coat applications with single and double coaters and intermediate gelling
  • final drying
  • base coat sanding followed by finishing

Curtain coating lines

Curtain coating lines include:

  • substrate sanding
  • basecoat application
  • UV gelling 
  • UV base coat application with curtain coater and special flash-off tunnel
  • drying
  • base coat sanding followed by finishing

Spray coating lines

Spray coating lines are a closed-circuit solution applying polyurethane or polyester-based basecoats in multiple steps on flat surfaces and edges. This is followed by lengthy drying times since the panels must be stabilised at suitable intervals in the warehouse before the sanding and finishing processes.

Smartvacuum and Smartedge for vacuum painting of flat panels

Comparing the benefits of vacuum application technology

Starting from the eco-friendliness of 100% UV acrylic paints, there are a host of benefits which will reduce consumables, costs, lead times, handling requirements and the need for space.

  • no need to round off corners after drying and before sanding
  • fewer machines required, so less cleaning and lower consumption
  • lower sanding costs and less waste
  • shorter lead times, production flexibility
  • smaller footprint, more space in the factory
  • fewer process stages resulting in fewer panel handling requirements
  • clean edge at machine inlet vs. curtain coating
Linea verniciatura con Smartvacuum

Implementing Smartvacuum, the coating line would look like this:

  • panel sanding
  • basecoat application and gelling
  • application of 100-140 g/sqm of 100% UV product in a single pass
  • flash-off for 5/6 minutes
  • UV oven drying
  • sanding or matt/glossy finish, if required, performed using another coating technique

 

The Smartvacuum technology, associated with the Smartedge range for edge finishing, makes the process simpler, faster, ecological and cost-efficient, eliminating many manual operations.

Frequently Asked Questions

哪些基材适合真空涂装?

真空涂装适用于木材及其衍生物、金属、石膏板、复合材料和PVC型材。

这种技术非常适合于…?

当进行大批量型材涂装时,此技术是理想选择,可实现高水平的生产效率。

真空涂装的优点是什么?

这项技术有很多优势。 首先,传输效率达到惊人的99%。 真空涂装机体积小,因此占用的工厂空间很小。,使用真空涂装机,可一站完成360°砂光,型材涂装和漆膜固化,使生产效率得以优化。 没有空喷漆雾,不对环境造成任何污染。 漆膜厚度高,以玻璃棉面板为例,漆膜厚度可达700 µm。

如何评估漆膜质量?

对漆膜质量的评判带有很强的主观性。 但是,如果产品对漆膜硬度要求较高,那么该技术通过使用固体含量为80%的涂料,可以实现较高的漆膜厚度(例如,天花板可达到700 g / m2),并同时减少干燥段费用。即使是较复杂的型材,稳定的漆膜厚度也是真空涂装技术在质量方面的关键优势。。

在真空涂装过程中,我需要考虑哪些消耗因素?

这将取决于你是使用紫外线固化涂料还是水性涂料。使用UV涂料,真空涂装机每道油漆涂布量为25至75µm(1至3 mills),而使用水性涂料,真空涂装机每道油漆涂布量为25至150µm(1至6 mills)。您还需要考虑电能消耗和压缩空气消耗。

真空涂装可加工工件的尺寸范围是多少?

最小长度为915 mm(36“),最大宽度为305 mm(12”)。这个范围之内的任何尺寸都可以。

清洁真空涂装机需要多长时间?

清洗时间根据机器大小和所用油漆的类型而不同。水性涂料所需的时间比粘性紫外线涂料短。平均来说,更改配置文件时,需要10到15分钟。如果您还需要改变颜色,需要30分钟。

涂料消耗量是否可控?

可以。通过调整模板开合度、真空压力和涂布速度,可以控制涂层厚度和涂料消耗。在使用UV涂料时,涂料粘度可以通过温度进行控制,并进一步影响涂料消耗量。

除了真空涂装机,还需要哪些设备来完成整个流程?

为了使生产流程更流畅,可以配备进料和出料输送机。任何情况下,我们都可提供包括材料制备、涂装和干燥在内的全套解决方案。边部涂装机通常安装在现有的双端开榫机上,以实现更精确的工件导向,避免过度喷涂。

设备灵活度如何?

由于真空涂装适用于大批量相同或相似类型的型材,因此柔性不是该设备或工艺的关键特征。当切换型材类型时,用户只需变更模型或喷头。

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