[China Aluminum Network] 1, Melt Extrusion
This method involves heating and extruding the metal pigment along with the other components of the powder coating, such as resin, through a screw extruder. Although this process ensures a thorough mixing of the metal pigment with the coating material, the high viscosity of the melt limits the proper orientation of the metal pigment. Furthermore, during the subsequent crushing process, the flake structure of the pigment is often damaged. As a result, the metal powder produced using this method tends to exhibit a dull, gray metallic effect when applied. Due to these drawbacks, this technique is typically only used for manufacturing hammer powder, where a less vibrant metallic finish is acceptable.
2, Dry Blending Method
In this approach, dry metal pigment powder is added to the crushed powder coating and mixed using a mechanical mixer. One of the main advantages of the dry blending method is that it minimizes the risk of deforming the flake-shaped metal pigment, preserving its metallic appearance. Additionally, the loose mixture allows for better orientation of the metallic particles, which enhances the overall shimmering effect. However, a significant disadvantage is that when recycled powder is processed using an automatic spray system, separation can occur due to differences in particle shape, density, and electrostatic charge between the metal pigment and resin particles.
3, Bonding Process
The bonding method involves dry-blending the metal pigment with the powder coating while simultaneously applying heat, just enough to bring the resin close to its softening point. At this temperature, the resin becomes slightly viscous, allowing the metal pigment to adhere to its surface. This prevents the metal pigment from separating from the resin particles after recovery and neutralization. This method has become widely adopted due to its effectiveness in maintaining a consistent metallic finish and improving the performance of the final product. It is now considered the standard practice in the industry.
Overall, each method has its own set of advantages and limitations, making them suitable for different applications depending on the desired outcome and production requirements. Understanding these processes helps manufacturers choose the most appropriate technique to achieve the best results in their powder coating formulations.
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