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Thermosetting powder coatings are widely used in furniture, home appliances, and building materials due to their environmental friendliness and durability. However, many people still have questions about their composition, safety, and spraying operation—for example, is it toxic? What precautions should be taken during application? Today, we'll provide a comprehensive explanation in layman's terms regarding composition, safety, key points for spraying safety, and daily precautions, helping you use them with confidence and in accordance with regulations.
The ability of thermosetting powder coatings to form a strong film relies on two key components—acrylic powder and polyester powder. These two powders, mixed in a certain proportion, become the raw materials for common thermosetting powder coatings. In practical applications, the mixed powder is first charged by an electrostatic generator and then adsorbed onto the surface of workpieces such as iron plates—this is like "dressing" the workpiece; static electricity makes the powder firmly "stick" to the workpiece, preventing it from easily falling off. The workpiece is then placed in an oven and baked at a specific temperature, where the powder gradually melts, flows, and eventually solidifies into a film. Depending on the formulation, the cured coating may have a matte or semi-gloss finish to meet different aesthetic needs. For example, matte coatings are commonly used for appliance casings, while a matte texture may be preferred for furniture surfaces. The combination of these two core components is crucial: acrylic powder enhances the coating's weather resistance and gloss, preventing fading even outdoors; polyester powder strengthens the coating's hardness and adhesion, ensuring it's resistant to scratches and peeling. This combination makes thermosetting powder coatings both attractive and durable.
Many people worry about the toxicity of coatings, especially in home applications. In fact, thermosetting powder coatings are environmentally friendly materials and are inherently non-toxic, which is a major reason for their widespread use in indoor furniture and appliances. However, it's important to note that "non-toxic" refers to the finished coating and proper application. During spraying, as long as the operating procedures are strictly followed—such as proper protection and ventilation—its safety is guaranteed and it will not harm the human body. Furthermore, the cured coating is very stable and does not release toxic substances. It only releases a small amount of water vapor during the baking process, making it environmentally friendly and human-friendly.
While thermosetting powder coatings are inherently environmentally friendly, they are not entirely risk-free. It's crucial to distinguish between the different impacts of the "production stage" and the "application and use stage":
For workers producing powder coatings, the main risk comes from the hardener—some hardeners may contain irritating ingredients. Long-term direct contact may cause skin allergies or even mild respiratory irritation. However, this is an occupational health risk at the production stage, which ordinary users will not encounter when using finished coatings.
Ordinary users or construction workers mainly face three types of risks during use: Irritation Risk: If there is long-term direct contact with the powder during the spraying process, the powder particles may irritate the eyes, skin, and respiratory organs—for example, the eyes may feel dry and itchy, skin contact may cause rashes, and inhaling too much powder may cause throat discomfort. Ingestion Risk: Although rare, accidental ingestion of powder (such as during construction) can affect health and may cause gastrointestinal problems. Explosion Risk: When the powder concentration in the spraying environment reaches a certain level, it may explode upon contact with an open flame or electrical spark. This is the most critical safety hazard during spraying. However, there's no need to worry excessively; these risks can be effectively avoided with proper protective measures.
Three Key Details to Remember During spraying, three safety points must be kept in mind, directly affecting the safety of construction workers and the construction effect:
As mentioned earlier, long-term inhalation of powder can lead to pneumoconiosis and affect brain cell metabolism—this is no small matter. Therefore, a professional protective mask must be worn during construction to filter out airborne powder particles; at the same time, maintain ventilation in the construction environment, such as opening windows and turning on exhaust fans, to keep the powder concentration in the air within a safe range and reduce the risk of inhalation.
Many people don't know that the pigments in thermosetting powder coatings are mostly high-molecular-weight organic compounds, many of which are polar substances with low resistivity and a certain degree of conductivity—for example, common components such as benzene, xylene, and solvent gasoline all have conductive properties. This means that static electricity protection must be taken into account during construction to avoid sparks caused by static electricity, especially in environments with high dust concentrations, where static sparks can become the "trigger" for an explosion.
Spraying requires the use of equipment such as a powder spray gun: the paint particles are connected to the negative electrode, and the workpiece is connected to the positive electrode and grounded. When the voltage is high enough, an air ionization zone will form near the tip of the spray gun—at this time, the air will be intensely ionized and heated, and a dark red halo will appear. This is a normal electrostatic spraying phenomenon, but it is important to maintain a safe distance between the spray gun and the workpiece to avoid excessive local current, which could cause sparks or uneven coating.
The powder concentration in the spraying environment is high, and open flames are the biggest safety hazard. Even a cigarette butt could cause an explosion. Therefore, smoking and other open flames (such as lighters, candles, etc.) must be strictly prohibited in the work area.
Only spray guns and necessary cables should be placed in the spraying room. Other electrical appliances (such as mobile phones, chargers, desk lamps, etc.) should be placed outdoors unless they are specially designed for dust and explosion protection, to avoid the risk of electrical sparks.
The ventilation system should promptly remove powder from the room, reducing dust concentration. Before construction, ensure it is working properly. If ventilation is poor, stop construction immediately, repair, and then continue.
Clamps and all electrical appliances must be properly grounded. This is crucial to prevent static electricity buildup. If grounding is poor, static electricity cannot be released in time, easily causing sparks and even equipment malfunction.
Operators themselves must also be properly grounded and should not wear insulated gloves or shoes—otherwise, static electricity will accumulate on the body, potentially generating sparks upon contact with equipment, posing a safety risk.
Operators should not enter the powder coating booth when working; personnel working in dusty environments must wear masks and protective clothing to avoid direct skin contact with powder.
Keep the ground within 5 meters of the spraying area clean. Avoid sweeping with a broom (as this will raise dust); use a damp mop or vacuum cleaner to reduce dust dispersion.
After spraying, be sure to wash your hands and face with hot water and soap to remove any powder that may be adhering to the skin, preventing powder from penetrating through the skin or being ingested.
The recovery device collects unabsorbed powder, reducing waste. It should be checked daily to ensure it is operating normally and to prevent powder accumulation due to poor recovery.
The high-voltage electrostatic generator is the core equipment for spraying. It must be confirmed that it is operating normally according to specifications, such as stable voltage and current, to avoid abnormal parameters affecting spraying results or causing safety issues.
The powder feeder is responsible for transporting powder. It should be checked for proper operation and blockages—poor powder supply will lead to uneven coating thickness and affect product quality.
The compressed air must be kept clean to prevent impurities from affecting powder quality. At the same time, the drain valve of the oil-water separator should be opened to release wastewater and oil, preventing moisture and oil from entering the powder supply system.
Clean equipment surfaces and work areas daily to prevent powder buildup, which can impair heat dissipation or cause static electricity hazards.
Keep safety doors and passageways for fire extinguishers clear and free of obstructions—ensuring quick access to fire extinguishers and timely evacuation in case of emergency.
Reconfirm that all electrical appliances are properly grounded and that high-voltage cables are intact—damaged cables can cause electrical leakage, posing a serious safety risk.
The temperature in each controlled zone of the drying tunnel or oven must be within normal limits. Abnormal temperatures can affect coating curing; for example, too low a temperature can lead to incomplete curing, while too high a temperature can cause the coating to yellow.
The conveyor chain is responsible for transporting workpieces, especially continuously variable transmission (CVT) devices, whose parameters are prone to fluctuation. It's crucial to confirm the speed is normal to avoid affecting spraying and baking time due to excessively fast or slow speeds.
Unexpected situations may occur during construction. Mastering the correct emergency measures can effectively reduce losses and ensure safety:
Immediately disconnect the power supply to prevent static electricity-related risks. Then, use a vacuum cleaner to remove the leaked powder. Do not sweep with a broom to avoid spreading the powder.
Immediately disconnect the gas supply and the power supply to the high-voltage electrostatic generator to prevent the fire from spreading. After the equipment cools down, check the cause of the ignition and repair it before using it again.
Immediately disconnect all power. Use appropriate fire extinguishing equipment—foam fire extinguisher, 1211 fire extinguisher, or water mist extinguisher are all acceptable. Do not use a high-pressure water gun to directly spray the equipment to avoid damaging electrical components.
Immediately rinse eyes with clean water or a specialized eyewash solution. Seek immediate medical attention. Do not rub eyes to prevent corneal abrasion.
Move the injured person to fresh air and loosen their collar to facilitate breathing. If breathing is difficult, seek immediate medical attention to prevent suffocation.
Thermosetting powder coatings are inherently environmentally friendly and non-toxic, but several safety details still require attention during production, application, and maintenance—from the characteristics of their components to protective measures during application, routine equipment checks, and emergency response. Every step must be taken seriously. For construction workers, remember "safety first": wear appropriate protective equipment, operate equipment correctly, conduct regular checks, and remain calm in emergencies. For companies, establish comprehensive safety management systems, provide regular employee training, and ensure everyone understands key safety points. Only in this way can we fully leverage the environmental and durability advantages of thermosetting powder coatings, producing high-quality coating products while ensuring the health of construction workers and the safety of the workshop.
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