Conference Program

Solvent based conversion varnishes have been the coatings of choice for industrial wood applications for many years. These coatings can provide an attractive durable finish that is cost effective. Kitchen cabinet and furniture manufacturers choose these coatings because they are fast drying, they are easily repaired, they tolerate climate differences well and they are extremely forgiving. Some of these coatings have good chemical and water resistance and good wear resistance. The disadvantage of these chemistries is the high volatile organic compound (VOC), the formaldehyde emissions and the pot life incurred when the conversion varnish is catalyzed with an acid catalyst. Due to increasing regulations, more environmentally friendly alternatives are now being considered. Waterborne acrylics and water-based UV coatings are becoming more common for use in industrial wood applications because they have excellent resistance and mechanical properties, excellent application properties and very low solvent emissions. Self-crosslinking acrylics have very good durability and moderately fast drying times. Waterborne (WB) UV chemistry is gaining market share over traditional solvent-based chemistry because it enables the end user to increase production efficiency and maintain a smaller manufacturing footprint. Both WB acrylics and WB UV can be formulated to pass Kitchen Cabinet Manufacturers Association (KCMA) and Architectural Woodworking Standards (AWS) specifications. A new platform of WB acrylics has been developed which lends itself to crosslinking with low toxicity carbodiimides. This paper will compare the performance of these new WB self-crosslinking acrylics in both 1K and 2K formulations with WB UV coatings and solvent-based conversion varnishes. Test methods and formulating techniques will be discussed.

Recently many innovate architects and green building engineers are using mass timber products mainly cross-laminated timber (CLT) to build multi-story wooden buildings. They are attractive and beautiful at first, but wood scientists are concerned how these buildings perform and look after a few years of natural weathering exposure. This study was designed to evaluate and test performance of a wide range of coatings available in North American market to screen and select best coatings for long-term weathering studies at two different sites. More than 35 different coatings (transparent and semi-transparent stains and paints) were purchased and analyzed in the lab by measuring their properties such as: solid content, pH, viscosity (Rheometer), glass transition temperature (Tg) using differential scanning calorimeter, surface tension (Tensiometer) and their dynamic contact angles on wood. In addition, moisture excluding efficacy and water vapor permeability of these coating on CLT samples were tested in the lab. Then, a chemometric model (PLSR) was developed to find correlations between coating properties and their performance in the lab to select the top best coatings for exterior application on mass timber.

Water-free systems of silane modified colloidal silica particles have been found to enhance mechanical properties of coatings. Aqueous colloidal silica has been used in co-polymerization of resins and co-polymerized colloidal silica resin hybrids are also used to enhance a variety of coatings properties like hardness, anti-blocking and reduced dirt-pickup. Non-surface modified colloidal silica has been tested as nano-filler in latex coatings with encouraging results concerning mechanical properties.

AkzoNobel has developed silane modified colloidal silica to use in waterborne coating. Concentrated epoxysilane modified colloidal silica in the form of aqueous sols is one of most readily available sources of nano-particles for the coating area. Such sols are characterized by high solids content, up to at least 50 % by weight of silica depending on particle size which ranges from about 5 nm to 100 nm. Compared with conventional silica sols, silane modified colloidal silica has greater stability towards aggregation and gelling, both as is and in latex-based coating formulations.

The effect of epoxysilane modified colloidal silica, added to water-based coating formulations, on the mechanical properties of resin films was studied. In general, the effect of the silica particles depended strongly on the resin and other components of the coating formulation but very significant improvements of block resistance (and hence sanding properties) were seen. In addition, extended open time, better penetration and substrate wetting for “anfeuerung” in acrylic resin based wood coatings and additionally of mechanical properties in 2-pack PUD system could be observed.

Vegetable oil modified urethane (OMU) has been widely used in wood flooring applications for many decades. Due to tightening Volatile Organic Compound (VOC) regulations in recent years, the market has been slowly shifting towards water-borne systems. However, most of the current water-borne OMUs either still contain N-Methyl-2-pyrrolidone (NMP), or the VOC is still relatively high at 135-250 g/L while the non-volatile (NV) content is relatively low at 32-38% and thus require multiple coats to achieve performance properties. In this paper we will demonstrate our most recent breakthrough in the development of a novel NMP free water-borne OMU with a VOC <100 g/L and a high 45% NV content that maintains the exceptional performance properties of traditional solvent-borne and water-borne OMUs in the market. Its potential applications include but are not limited to high performance clear wood floor coatings, conformal coatings, air dry and force cure coatings.

High solids and exempt solvent approaches are common techniques to reduce the VOC of solvent based alkyd coatings. Exempt solvents face limitations in odor, solubility, cost, flash point and geographic compliance. High solid approaches offer a more robust solution if performance can be maintained. Typically performance is not maintained as contemporary high solids alkyd technology often utilizes higher oil/fatty acid levels to reduce viscosity thereby compromising dry time and hardness development. Previously, Arkema/CCP introduced a branched long oil reactive diluent based on sucrose ester technology that offered low viscosity and fast dry. The sucrose ester approach offered a technical solution for achieving performance at reduced VOCs, however this solution was feedstock limited and commercially challenged. In response to this Arkema has developed a new polymer platform to overcome these issues. The new platform is derived from readily available feedstock materials and is useful for creating alkyd polymers with a low viscosity and fast dry profile. This paper will show how modifications of this new platform can be used to create low VOC alkyd paints for decorative, wood, and maintenance applications with a performance VOC balance not achievable with a conventional high solids approaches.

Although the decking industry is seeing changes in the types of materials used in new construction / rebuild, for example wood-plastic based composites, the use of stains and sealers remains dominant for the maintenance sector. Good aesthetics in combination with superior protection, penetration and wear are persistent themes in the decking market. It is therefore essential that these wood finishes provide both long lasting beauty and durability.

Aligned with the trend to more highly durable deck stain systems, we’ve seen a shift in technology from waterborne systems based on oil/alkyd to acrylic modified oil/alkyd and now to oil/alkyd modified acrylics. Allnex has developed an acrylic based core/shell technology where the composition of the core can be varied from homogeneous to gradient to multicore while the shell can be widely varied in terms of hydrophilicity and hydrophobicity. These variations enable the balancing of hardness-flexibility as well as penetration, flow & levelling, the properties needed to achieve high levels of both performance and appearance.

In this paper, this novel acrylic core/shell technology will be described. Fundamental considerations as well as performance properties of deck stains based on several prototype binders from this exciting new technology will be presented.

Polyurethane resins are durable materials effective at protecting a wide variety of substrates in both interior and exterior environments. While solventborne types have dominated the market for many years, increasing environmental regulations and new developments have led to waterborne products with robust performance, including good chemical resistance and mechanical properties. Such performance attributes have enabled the use of these materials as graffiti resistant coatings. The anti-graffiti market continues to grow annually in response to increasing vandalism. Billions of dollars are spent each year as companies attempt to protect their property. Anti-graffiti coatings are divided into two classes: temporary and permanent. Polyurethane dispersions (PUDs) classify as permanent systems that produce a protective surface that provides a barrier to paint and other staining while also resisting cleaning chemicals. Anti-graffiti coatings are also required to have excellent exterior durability, good adhesion to masonry substrates and high moisture vapor permeability. Experimental polyurethane dispersions have recently been developed to achieve the highest chemical resistance in a one component system. These products have been tested according to the ASTM standard for Graffiti resistance and produced exceptional results without the use of surface energy modifiers or external crosslinkers. Performance has also been benchmarked against several commercial standards which includes different resin technologies. Highly resistant and durable coatings have been produced showing promise for easy to clean surfaces. Such highly resistant materials can be useful in other markets as well. Further work has explored the application of these products in market areas such as interior automotive.

Two component waterborne polyurethane coatings have been recognized as coatings with excellent performance properties and used in a wide variety of applications. However, they require the introduction of a curing agent as a second component in order to provide the crosslinking needed to enhance coating performance. Several challenges for two component waterborne coatings are well known, including limited pot life, increased waste, potential risk for mixing failure and additional process steps before application. Therefore, in certain markets, paint formulators continue to look for one component waterborne coatings that perform comparable to two component waterborne coatings; for example, coatings for the residential vinyl windows market. Vinyl windows represent more than 70% of windows sold into the USA residential window market and nearly all of them are white in color. Consumers are demanding more color options besides just white and to meet that demand, window manufacturers are painting more and more windows today. Currently two component waterborne coatings are the market standard, but window manufacturers and applicators are seeking high performance one component waterborne coatings that are easy to apply and provide comparable performance to the two component waterborne coatings being used today. This paper discusses the performance properties, as defined in American Architectural Manufacturers Association 615-17 specification, of a newly developed one component polyurethane dispersion that demonstrates comparable performance properties to two component waterborne coatings used to paint residential vinyl windows in the market today.

Formulators are required to comply with increasingly stringent volatile organic compound (VOC) regulations and, at the same time, maintain the performance characteristics expected from the coating system. Traditionally, there have been three ways to reduce VOC’s in coatings: by moving toward waterborne formulations, making higher solid coatings, or using “exempt” solvents. Waterborne technology greatly reduces the VOC content, but commonly lags behind the performance of solvent borne coatings, while high solid systems are typically more expensive per gallon. Systems containing exempt solvents can only be used from a regulatory point of view in specific areas of the globe. In order to overcome these challenges, Stepan has developed a new set of polyester polyols with low room temperature viscosities that reduce VOC content in coating formulations and provide excellent coating characteristics. This paper demonstrates the use of these polyols in 2K polyurethane solvent borne low VOC systems and describes their performance characteristics in preventative maintenance and floor coatings.

Polyurethane Dispersions (PUD) are known to offer high performance, especially in terms of their combination of toughness, abrasion resistance, flexibility and chemical resistance. However, their use has not been expanded to some applications due to high cost in comparison with other water-borne systems such as acrylic latex, which offer good performance at a considerably less cost. The need to reduce the cost of polyurethane dispersions has led the use of blending of Acrylic Latex (AC) and PUD in a coating package, but often it leads to films of lower quality, which is frequently attributed low compatibility between the two resin systems. However, the development of hybrid systems containing chemically bonded polymer structures is expected to lead to better compatibility between components. This study contemplates the synthesis of Polyurethane/acrylic hybrid dispersions using two different grafting techniques.

An NCO terminated pre-polymer was reacted with 50% of the stoichiometric amount of hydroxyethyl acrylate (HEA) to obtain a pre-polymer containing both NCO and acrylate functionality. This polymer has been used for the synthesis of acrylic/PUD hybrids dispersions by two methods – (a) Emulsion polymerization: The pre-polymer is neutralized, dispersed in water and chain-extended with ethylenediamine (EDA), resulting dispersion is used as a seed for conventional emulsion polymerization, with acrylic monomers. (b) Monomer mixing process: pre-polymer is mixed with acrylic monomers and free radical initiator and then is neutralized, dispersed in water and chain extended using EDA. Temperature is then raised to the initiation temperature, and radical polymerization of monomers, within the stabilized droplets, is carried out. The acrylic to urethane ratio was kept at 50:50 by weight in both processes.The grafting efficiency is tested by acrylic monomer depletion using Fourier transform infrared (FTRI), and by comparison of mechanical and chemical properties of the films. Samples also have been evaluated for their emulsion stability (particle size analysis and visual observation). The properties of hybrid dispersion will be compared with the straight acrylic emulsion, straight polyurethane dispersion, and corresponding physical blends.

Polyurethane dispersion (PUD), has received more and more attention in coatings due to its water-borne nature and excellent overall properties. PUD’s are also the top selection for exterior coatings applications in consideration of weathering stability. PUD's weathering stability can be further enhanced by adding UV absorbers to the PUD to increase UV stability and provide long term durability.

Among UVA absorbers, benzotriazole (BZT) based UVA’s as shown below, provide the best protection on TPU against UV light. BZT UVA is manufactured in either a solid or liquid state. Solid BZT’s are not suitable for PUD resins as there is no melting step in the PUD coating process.

Liquid BZT UVA is easily formulated into the PUD coating if there is a pre-emulsifying process prior to addition. However, pre-emulsion can sometimes be difficult with a sophisticated challenging formulation. Liquid BZT UVA has another significant drawback: lowering of the Tg point of PU coating and subsequently reducing the hardness. Chitec is proud to report a new way to add a high performance BZT UVA into PUD system by using a novel Reactable BTZ UVA.

Figure (1) demonstrates a glycol functionality as shown below. This reactive UVA can be easily co-polymerized into the PUD back-bone by using a standard PUD preparation process, therefore eliminating the emulsion process.

Please note Figure #1 Chemical Backbone Diagram was not able to transfer to this form. It can be supplied via Word File if needed.

(Figure 1) Chiguard® 5530 Hydrophilic BZT

Testing in a PUD system containing 1% of Figure 3 - (fully reactable BZT UVA) was compared with a PUD system containing 1% of Figure 1 - (a hydrophilic BZT) and additional testing with Figure 2 - (a hydrophobic BZT). All products were tested with and without hindered amine light stabilizers. Figure 3 showed significant improvement of photopermance, haze, hardness, and adhesion under ASTM G-154.

Please note Figure #2 Chemical Backbone Diagram was not able to transfer to this form. It can be supplied via Word File if needed.

(Figure 2) Chiguard® 5582 Hydrophobic BZT

Please note Figure #3 Chemical Backbone Diagram was not able to transfer to this form. It can be supplied via Word File if needed.

(Figure 3) Chiguard® R-455 Fully Reactable BZT

In this paper, the process to prepare Figure 3 will be outlined along with the performance comparison against other BZT type chemistries. Global registration status will be also be presented.

The use of water borne (WB) UV polyurethane dispersions (UV PUDs) has been steadily increasing as low viscosity, sprayable coatings based on these materials can be made without using solvent or large amounts of diluents. UV PUDs combine the ease of use of conventional WB resins with the chemical, stain and high scratch resistance of crosslinked UV systems. Initially used in coatings for wood or resilient flooring, UV PUDs are being modified for use in other applications. This talk will briefly review the structure and properties of the UV-PUDs used for wood coatings and then highlight the development of several new UV PUDs that have been tailored for use in newer markets such as digital inks for the packaging market (including satisfying the regulatory requirements) as well as hardcoats for plastics, including cosmetic packaging.

Coating industry across all markets from construction to marine to electronics is constantly facing the challenges from regulatory agencies and consumers. These challenges include meeting more stringent emission requirement and fulfilling the need to reduce process time in order to improve productivity and costs while maintaining high coating performance. Technology advancements equipped the industry with new waterborne epoxy systems that deliver fast cure speed, improved coating robustness and better aesthetics over the service life. Thanks to the low volatile organic content (VOC) and excellent coating properties, waterborne epoxy coatings have become a commercially important technology and gained wide acceptance as environmentally friendly alternatives for solvent borne and solvent free epoxy systems.

This paper will highlight the development of a new waterborne epoxy curing agent based on a novel amine technology. The paper will also discuss the key advantages of the new waterborne epoxy system for civil engineering application. This new system provides an extremely fast cure speed even under adverse condition such as low temperature and high humidity, and superior adhesion to substrates when used as a primer, in particularly on damp concrete. It also provides excellent surface aesthetics when used as a topcoat. This fast cure system enables coating formulators to design new coating concepts, such as a 1-day floor system, consisting of a primer and topcoat that could be applied on the same day and deliver walk-on readiness the next morning.

In January 2015, China’s government implemented new regulations that limit the emission of volatile organic compounds (VOC) from the coating processes. Many industries are impacted including those that require heavy duty performance such as freight container, construction steel, and heavy machinery amongst others. Solutions being considered to address the low VOC challenge include the use of Waterborne coatings systems. Formulators face a number of challenges in converting solvent-borne formulations to waterborne formulations while retaining the performance characteristics of traditional systems. Many heavy duty Epoxy systems rely on three-layer systems; a Zinc (Zn) rich or an anticorrosive Epoxy primer, followed by an Epoxy mid-coat, followed by a top coat. Both primer options pose challenges for low VOC formulations. The inherent challenge of dispersing Zn in waterborne dispersions have made three-component (3K) systems a common solution. However, this has drawbacks such as ease of use in the field and consistent quality of the final product. Traditional anticorrosive waterborne primer systems use VOC in the form of co-solvents to enable required leveling for film formation, limiting the reduction in total VOC.

In this paper Olin Epoxy will present two low VOC waterborne Epoxy primer systems designed to enable solvent-borne performance for metal protection in both Zn rich 2K waterborne formulations and zero VOC anticorrosive Epoxy waterborne formulations, thus addressing the inherent challenges of traditional waterborne solutions. Comparative physical properties and performance benchmark data will be shared.

Epoxy coatings are often used in applications over metal substrates due to their excellent performance properties, including corrosion resistance and chemical/solvent resistance. Inadequate properties of epoxy chemistry often include poor UV light durability and brittleness, and epoxy coatings often have poor gloss/color retention and resistance to chalking on exterior exposure as well as poor flexibility and impact resistance. Many epoxy coatings also contain solvents which contribute to high volatile organic content (VOC) levels. Relative to solventborne versions, waterborne epoxy coatings can often be formulated to lower VOC, but exterior durability and flexibility still remain a challenge. Combining excellent corrosion protection and chemical/solvent resistance with exterior durability, flexibility and low VOC in a coating based on epoxy chemistry is not an easy target. This paper will describe a new waterborne acrylic-epoxy hybrid polymer that facilitates formulation of two-component metal primers and direct-to-metal (DTM) finishes with this important balance of properties. The system has versatility in that the acrylic-epoxy hybrid polymer can be cured with either traditional waterborne amine hardeners or with acid-functional acrylic hardeners. Performance of the waterborne acrylic-epoxy hybrid technology in gloss DTM finishes and anticorrosive primers will be described, along with comparisons to traditional waterborne and solventborne epoxy coatings.

A new class of metal free catalysts has been developed that promotes the crosslinking reaction of epoxy functional polymers with carboxyl functional compounds and polymers. These catalysts are particularly effective at much lower cure temperatures, provide stable single package formulations and improved resistance properties. In addition, unlike amine based compounds, these catalysts do not yellow during cure or on over bake.

In the challenging world of industrial, protective and marine coatings, two component epoxy systems are established as the benchmark technologies due to the combined offerings of excellent corrosion protection while being compliant with regional VOC standards. Today, productivity has emerged as a major driver and innovation is focused on developing epoxy coatings which have greater application versatility while providing enhanced performance properties, such as dry speed, rapid recoat and through cure. For Marine and Protective, the need is for faster cure and blush resistant coatings when applied under adverse, low temperatures conditions. In the OEM sector, the wet-on wet application process means there is a requirement for epoxy systems to provide rapid overcoatability with polyureathane and/or polyaspartic top coats within minutes after initial application of the primer. In the OEM sector the drivers are to increase productivity with faster application of multiple layers coupled with lower bake temperatures which can provide energy savings.

This paper will focus on the performance attributes of a novel polycyclic- aliphatic amine and its use in the development of new epoxy curing agents designed for to provide added value in the above markets. The supporting data includes the functional properties; thermal analysis, Glass transition (Tg), IR cure profile, confirming the rapid through cure and cross-linking capabilities in epoxy systems. In addition a review of model coating formulations and their key performance attributes, including the rapid recoat times, improved intercoat adhesion, excellent corrosion protection properties will be discussed.

The weathering of epoxy based coating is known to be a challenge for several applications such as flooring, protective coatings and windmills. In this study, Azelis and Clariant cooperated to develop the next generation of light stabilizers additives that would enhance the weathering of epoxy coatings. The results of the study to be presented will include effect of light stabilizers additives on epoxy coating gel time, hardness, visual appearance as well as weathering performance.

Thermal resistance to staining is tested by use of ISO 2812-5. The standard originating from 2007 is based in 1970’s equipment and early 21st century automotive coatings. Much has changed. Modern applications as super yacht coating systems, mobile phones, dashboard coatings and thermal chromatic applications all require new additional tests. The chemical composition and type of pollutants have changed together with visual rating effect. Modern coating systems require a new approach to thermal testing and chemical resistance. This paper discusses the additional requirements for new coatings and test procedures. Illustrating broad application of a standard that originated just in the car industry.

To take Nondestructive Testing (DNT) measurements at height, currently one needs to utilize a lift, scaffolding, ladders or other solutions to reach areas on ships, bridges, aboveground storage tanks, flare stacks and other Infrastructure and Industrial sites. This is both dangerous, due to the possibility of falls, and time consuming.

Utilizing an aerial robotics platform for NDT measurements such as Dry Film Thickness (DFT) allows workers to remain safely on the ground to take measurements. Further, since there is no need to move a lift, scaffolding or ladders or for the person taking the DFT readings to move from their current position, the DFT measurement process is faster in addition to being safer.

This is a new and novel application utilizing existing technologies (DFT readers, drones, etc.) with a system of complex integrations that allows for a better application of science. The system has the potential to improve the inspection, testing and data collection aspects of coated assets, in part, by making the DFT measurement “process” easier and safer thus allowing for more frequent measurements and/or a larger quantity of measurement samples.

With an easier, faster, and safer method to collect DFT measurements from locations of height we can expand the science of coating thickness measurements by collecting data from locations where data was either inaccessible or difficult to obtain (access issues, safety considerations, etc.). The technology is patented and video will be shown of the system wherein the drone flies up to a structure with a metal sub-straight, then under full autonomous software control, touches a DFT measurement probe to the target and records the measurement data compliant with SSPC-PA2 standards. The session will make participants aware of this new technology as well as provide information as to its efficacy, limitations and operational requirements.

Microscopy and vibrational spectroscopy are complementary techniques and the combination of the two can provide the most complete information regarding the distributions of different coatings ingredients, as well as the fate and the impact of liquids or particulates that come in contact with the dried coating films. Confocal Raman microscopes, for example, combine the sensitivity and specificity of spectroscopy and are thus powerful, non-destructive analytical tools for mapping relative spatial locations of various chemical species in heterogeneous systems like coating films.

This paper reports new applications of two confocal microscopy techniques in coatings research: 1) to detect low levels of surfactants leached out of dry paint films; 2) to determine the location of paint additives to confirm either uniform spatial distribution or surface segregation; 3) to semi-quantitatively characterize adsorption, penetration and removal of liquid stains that contain an inherently fluorescent compound. Confocal Raman microscopy (CRM) and confocal fluorescence microscopy (CFM) are employed to analyze and solve some coatings common problems such as surfactant leaching, stain resistance, and washability. The usefulness and advantages of these confocal techniques are demonstrated by the examples given in this paper.

A common goal of clearcoat manufacturers is to increase the resistance to scratch and mar events; however, characterizing this type of damage can be challenging. Sophisticated nano and micro scratch techniques have been developed that have the ability to accurately characterize the mechanical performance of coating surface. Ultimately, one needs to relate differences in scratch performance to basic mechanical and thermo-mechanical properties of the film. In this work, various clearcoat formulations and processing conditions were characterized using advanced nano scratch techniques to measure scratch and mar performance. Additionally, the mechanical and thermo-mechanical properties of the films were characterized including tensile properties, indentation hardness, dynamic moduli, and glass transition temperature. This study explores how a coating’s resistance to scratch and mar damage is influenced by the mechanical properties of the film via coating chemistry or application process as well as how the inherent parameters of the scratch test may influence the measured results.

Achieving a balance of desired paint performance characteristics can be challenging, resource-intensive, and time-consuming to paint manufacturers. The Dow Chemical Company has developed high throughput methodologies to facilitate the quick screening of large libraries of coatings samples, shortening the innovation timeline for new technologies and increasing the compositional breadth for formulating products to address market needs. Here we address the development and advantages of recent high throughput methods and their use toward achieving designated performance targets and understanding market landscapes. Specific examples include methods that address MPI specifications and case studies that highlight benefits of high throughput over traditional laboratory approaches.

Natural language processing tools are data workflows created using software and machine learning models. These tools are used to extract structured, semantic information from English text, and have been used to create online chatbots and to quickly assess sentiment about a product or brand on social media platforms. Natural language processing and text mining tools have not been fully leveraged in the chemical sciences, and certainly not in the domain of coatings science and engineering. Here, we propose a rules-based and template-assisted framework for the semantic recording and delivery of coatings formulation information. This framework may be combined with text mining and natural language processing tools in order to extract chemical entity information, as well as formulation relationships between those entities. The resulting information is automatically ‘tidy’ and ready for data mining and modeling activities, without the need for arduous spreadsheet data entry and manipulation. The proposed framework allows for easy dissemination of formulation information, be it in trade journals, technical data sheets, peer-reviewed publications, or within or between industrial organizations and laboratories. The objective is to transform the ubiquitous formulation sheet—the format of which varies from organization to organization—into a simple, prose-based format which is simultaneously information dense as well as reader friendly, to both human and robot readers. The proposed framework has the capability to turn ‘information archeology’ into an automated process, eventually leading to automated and machine-led analysis and interpretation of scientific results related to coating formulation and performance. Adopting a standard and widespread approach to formulation information fosters scientific reproducibility, open innovation, and standardization of reporting, as well as easy, reliable, and long-lasting access to data.

This paper will discuss a commercially viable, sustainable, industrial mineral derived from recycled paint waste. Using pyrolysis under specific processing conditions, recovered paint scrap is first converted into gas and used as energy. This process then creates an ash cake from the inorganic materials present in the original paint. The ash is mostly a combination of titanium dioxide and silicate minerals that once milled create a useful industrial mineral. The process currently generates approximately 20% ash byproduct by weight of initial paint scrap. With approximately 12 million pounds of post-industrial paint waste and approximately another 29 million pounds of post-consumer paint waste being landfilled in the US annually, this produces a new stream of about 4000 tons of sustainable industrial minerals. Initially, the ash is being developed as reinforcing filler for thermoplastics. One application being evaluated for these filled plastics is the production of new paint cans. However, after further refining and removing the carbon from the ash has shown that it can also be used back into industrial paints. Streams of scrap that have been evaluated for recycling so far include paint booth overspray collection during the manufacture of automobiles, and consolidated, post-consumer architectural coatings.

Dicyclopentadiene (DCPD) is a low cost raw material in polymer industry. To develop DCPD new application we have invented a new synthesis methods to produce DCPD based acrylic resins. The DCPD based acrylic resins contain bridged bicyclic skeleton, which is different with traditional linear or cyclic aliphatic and aromatic structure and show a different application properties such as higher glass transition temperature; lower UV absorption; lower viscosity. These new DCPD based acrylic resins will be an alternative raw material for coating production and will increase DCPD application for low cost coating resins. In this report the synthesis process, properties and application of DCPD based acrylic resins will be presented.

With the recent advances in the formulation of powder coatings, it's quite possible to formulate powder coatings that apply to temperature sensitive surfaces and cure at low temperatures using IR or UV cure. However, the challenge still remains with the electrostatic application of powder and liquid coatings that enable acceptable adhesion to non-traditional substrates (MDF, plastics and composites, glass, ceramic etc.) and achieve good transfer efficiency. Insufficient and/or nonuniform surface treatment of these substrates prior to application results in a non-uniform finish, multiple film defects and poor transfer efficiency.

Our research has led to the development of rapid drying conductive adhesion promoters (CAP’s) with improved adhesion of powder and liquid coatings to nonconductive substrates such as ABS, Polycarbonate, Noryl GTX, SMC and Polyolefinics etc.; while at the same time improving transfer efficiency by dissipating static charge. The ability of our CAP technology to dry quickly permits application in a continuous/conveyorized production line followed by the application and curing of powder and liquid coatings. The use of CAP’s in this process eliminates the need for preheating, plasma treatment and chemical etching of plastic substrates while improving both film appearance and application efficiency. UV curable as well as LTC (low temperature cure) powder and liquid coatings can now be applied uniformly even in recess areas/faraday cage areas. This patent pending technology utilizes novel conductive materials in conjunction with a polymeric adhesion promoter and at the same time improves flexibility and interfacial adhesion along with anti-static properties.

Other treatments used to enhance surface conductivity utilize quaternary ammonium salts dispersions (QAS) which render the coated substrate conductive, but moisture sensitive as the QAS conductive treatment are water sensitive and migratory. Lastly QAS technology does not enhance adhesion and flexibility.

The rheological properties of an industrial coating, adhesive or sealant are vital to its success. A well formulated industrial coating, adhesive or sealant has balanced rheological properties, easy but controlled application, good sag or slump resistance and storage stability. The thickeners incorporated in the coating, adhesive or sealant formulations provide the manufacturers the ability to design the rheological characteristics they need for a specific end use.

Organic thixotropes are castor oil or polyamide based materials that are especially useful in systems such as industrial coatings, construction sealants, caulks, adhesives, and mastics. These additives provide outstanding efficiency for shear thinning, viscosity build, sag control, and pigment suspension. However, the high activation temperature is sometimes a deterrent for a broader use. In this paper, we present a new generation of highly efficient organic thixotrope based thickeners that can be activated at significantly lower temperatures. These new materials can be successfully incorporated in industrial coatings or sealant formulas for better viscosity build, sag resistance and higher extrusion rates. They display a wider process window and may require less energy in production.

Key Words: Next generation thickeners, rheology control, industrial coatings, construction, sealants, organic thixotropes.

European regulations are driving cobalt and certain cobalt compounds to be reclassified, and some of these compounds will no longer be available for use in certain applications. Accordingly allnex has recently developed an “easy to incorporate” cobalt free drier system for solvent or water borne oxidative drying paints that fully complies with the new regulation, and are low VOC and free from hazardous labeling. These ‘next-generation’ Driers are highly efficient for set and through drying of alkyd paints used in segments such as decorative and industrial coatings. Thick coat skinning often seen with cobalt metal driers, is alleviated with this newly developed driers. The drier package of primary and secondary driers can be added individually or as a synergistic package tailored to the applications demand.

In conclusion, these innovative new co-free driers meet the latest European regulations of cobalt elimination while improving the performance over the previous generations of cobalt containing driers.

Adhesion is one of the most important properties of both decorative and protective coatings. Coatings have to provide excellent adhesion to many different or even mixed substrates and even overcome the hurdles created by poorly prepared or cleaned surfaces. The adhesion between different paint layers is also critical to the long-term performance of industrial coatings. As the demand for better adhesion increases, and regulations continue to limit formulation freedom, additives that can help to improve adhesion become more critical. This can be particularly challenging for water-based and high solids formulations.

There are many different approaches to improving the adhesion of paint, both chemical and mechanical. Polyester resins are a class of additives that can improve the adhesion of high solids and water-based coatings to different surfaces. These additives combine flexible polymer chain segments with different functional groups that can provide adhesion and interaction with different surfaces and binders to enhance adhesion and other physical properties of a coating formulation. Originally developed for solvent based coatings, newer generation polyester adhesion promoters have been developed for water-based and high solids applications.

This paper will highlight a new, select class of polyester adhesion promoters and outline their improvement to adhesion in mainstream formulations. It will also give guidelines on how these can be formulated to support existing formulations and avoid extensive and costly reformulating efforts to improve adhesion.

Design and development of organic-inorganic hybrid materials has been the attention of paint researchers to balance aesthetics and performance requirement. In recent years, nano based coating systems is getting importance to develop hygienic coating.

In the present study, a special type of acrylic resin was synthesised via conventional solution polymerization technique. The resin was neutralized with a base to develop the resin in water based system for wider application and VOC control. This acrylic resin was further modified with nanostructured silica in presence of chitosan by a novel technique to form organic-inorganic hybrid polymer matrix. Chitosan based biopolymers are well known for several outstanding features like antimicrobial activity and deodorizing property. However, incorporation of chitosan into any polymer matrix is quite challenging due to its low reactivity. In the current work, chitosan was incorporated in the polymer matrix through the formation of an ion complex by suitable organic acid. The presence of chitosan in the polymer backbone was confirmed by spectroscopic analysis.

This hybrid polymer based coating exhibited hydrophobicity, water repellency, antimicrobial activity as well as formaldehyde adsorption ability. The degree of hydrophobicity and water repellency was controlled by the concentration of nanoparticles which was revealed through the surface morphology analysis of the film. The coating performance clearly showed significant influence of nano silica as well as chitosan in the hybrid polymer matrix.

Applications of such a facile and environmentally benign route would play a key role for the development of self-cleaning, anti-icing, anti-microbial and fouling release water-borne coating to fulfil general hygiene, safety and sustainability requirements of coating.

The development of sustainable, low emissions, high performance wood coating technologies continues to be of urgent interest to the coatings industry. Sustainable content in these coatings contributes to an improved environmental footprint, while low emitting technologies improve the indoor air quality and thereby, the health and well-being of building and home occupants desiring to re-occupy these structures as soon as possible after installation. Resinate Materials Group has developed biorenewable polyols that utilize low VOC (<150 g/liter) technology to yield 2K polyurethane wood coatings that have excellent stain and chemical resistance, excellent adhesion to both bare and prefinished wood, good abrasion resistance, low odor and excellent gloss. The new coating properties may be readily tailored to meet the individual needs of different wood coatings by simply adjusting the isocyanate index and/or isocyanate type. Progress on converting these new coating polyols into waterborne systems will also be reviewed.

Powder coating is an inherently green technology combining solvent-free and high transfer efficiency processes. Incorporating biobased resins such as those derived from soybean oil introduces another layer of green attributes by utilizing sustainable and renewable feedstocks. Battelle is developing novel soy-based resins with advantageous melt flow properties with the goal of creating a low-temperature cure thermoset resin system suitable for temperature sensitive substrates such as medium density fiberboard (MDF), plastics and composites. Thus far a high biobased content resin (84%) has been prepared, formulated with conventional curatives and cured coatings produced with acceptable properties with temperatures down to 125°C on steel panels. In this effort Battelle is working closely with formulators and evaluators during development to address industry needs and speed commercial introduction.

Low VOC waterborne (WB) Zn-rich primers and high performance WB epoxy primers have been developed based on novel Cashew NutShell Liquid (CNSL)- derived curing agents for industrial and protective coating applications. Those unique WB curing agents were synthesized from a natural, non-food chain and renewable biomaterial and could help to formulate WB primer systems that meet strict VOC regulations as well as high performance requirements.

This paper will present the latest performance studies of new CNSL-based WB Zn-rich primers and epoxy primers, and discuss some of the challenges faced in formulating such systems.

The new 2K WB Zn-rich primers were formulated with a water-free CNSL-based curing agent. Study results showed the WB Zn-rich primers had good compatibility with various commercial solid epoxy dispersions and delivered good cure and mechanical properties; importantly, those WB Zn-rich primers provided superb adhesion to both metal substrates and commercial polyurethane (PU) topcoats without the use of adhesion promoters. Excellent corrosion protection and good resistance to undercutting at the scribe were observed after 3000 hours Q-Fog exposure.

Additionally, newly developed WB high performance primers based on zero-VOC WB phenalkamines were evaluated either in combination with WB Zn-rich primers or by direct application to metal substrates. It has been found that those WB epoxy primers could enhance corrosion protection as mid-coats to WB Zn-rich primers; and when used as direct-to-metal coatings, WB epoxy primers also exhibited good mechanical and adhesion properties that benefited the overall anti-corrosion performances.

Polysaccharides are important biopolymers with a wide range of industrial and consumer applications. Historically, structural polysaccharides such as cellulose have been the backbone of early material science for applications in fibers, coatings and early thermoplastics.

DuPont Industrial Biosciences has developed a family of engineered polysaccharides ranging in molecular weight, solubility, and polymer architecture. The enzymatic polymerization process offers the opportunity to allow for the rational design of polysaccharide polymer structure, architecture and material morphology. The presentation will discuss this new bioprocess and the use of the derived class of biomaterials as component in coating applications.

Over the course of a human lifespan, it is estimated that 90% of that time is spent indoors. As people desire to live in healthier indoor surroundings, they increasingly demand water-based paints that are free from air pollutants, hazardous substances and allergens. For consumers, it can be difficult to keep track of the different critical substances, therefore they rely on ecolabels in their buying decisions.

With currently available raw materials and additives, it is no easy task for a paint formulator to develop a high-quality paint that offers performance advantages, is easy-to-use and at the same time fulfills the stringent ecolabel criteria. Formulators select paint ingredients based not only on function but also its environmental profile. Additives should be multifunctional and universally applicable in order to reduce formulation complexity, raw material handling and logistic costs. In addition, they need to comply with regulatory requirements, safety and environmental-relevant aspects.

As key supplier to the paint industry, Clariant understands the formulators’ challenges and unmet needs. Clariant’s latest innovation for the paint industry is a renewable-based and VOC/SVOC-free specialty amine without any hazard labeling; thus the ideal ingredient for ecolabel certified paints. The additive is used as a neutralizing agent, compatibilizer and stabilizer for water-based systems and offers superior performance in comparison to standard neutralizing agents such as ammonia or multifunctional additives such as aminomethyl propanol.

A novel strategy to combine polymerizable surfactant properties and N-halamine chlorine modulated antimicrobial performance in a single monomer is explored. Thanks to their amphiphilic structure and in a manner similar to the non-polymerizable analogues, polymerizable surfactants play a crucial role in providing colloidal stability when used in emulsion polymerization. In this report, a family of novel cationic polymerizable surfactants, with unique structural attributes will be presented. Once co-polymerized, these positively charged surfactants impart N-halamine functionality to the polymer backbone, which can subsequently provide antimicrobial properties to the binder after film formation, and upon treatment with a dilute bleach solution. The polymerizable surfactants are introduced into a typical Styrene-Acrylic formulation, and the prepared binder is characterized and compared against a control.

Low or zero VOC products have an increasing market share in the paint industry. The demand for lower VOC products has forced paint manufacturers to increase the amount of water and water-based raw materials while decreasing VOC contenting solvent levels. This has a severe impact on microbial susceptibility of the end-products since it provides an optimal environment for microorganisms. The microbial growth leads to the degradation of the paint. Some typical characteristics of a spoiled paint are: loss of viscosity, discoloration, odor and change in physical properties. This shift to more water based formulations makes it critical to incorporate the appropriate biocide system into the formulation to control the microbial growth.

Historically, isothiazolines, bronopol, and formaldehyde releasers have been the biocides of choice for preventing microbial growth in the container. Besides these commonly used active ingredients, Dibromodicyanobutane (DBDCB) has been used successfully in detergents and adhesives, these excellent results could be easily transfered to emulsion systems like paints and coatings. This paper will address the challenges for formulators when selecting the correct biocide system in water based paint as well as the benefits of different types of biocides.

The possibility that bacteria and or other micro-organisms such as fungi, moulds and algae accumulate on surfaces is a threat to the durability of materials as well as to human and animal health. This problem is evident on many materials and in many situations, such as medical devices, ship hulls and any moist environments in house- holds, e.g., showers, bathrooms, and kitchens. Over the years many ways of tackling this problem have been developed and have become well known in the art. Most available antimicrobial coatings are active by a slow release of toxic biocides like silver-ions to its environment. The slow release and accumulation of these biocides is of growing concern. The Regulation of Antimicrobials in paint and coatings are getting stricter and are driving the industry towards the development of more environmentally safe antimicrobials. The environmental impact of the leachable antimicrobials from façade coatings is one of the examples which have attracted increased attention in recent years, while the microbial resistance to these antimicrobials is another major challenge.

In order to achieve long-active antimicrobial solutions Croda develops non-toxic, surface- active antimicrobial resins for paint applications. By using a special polymerization process, an antimicrobial resin is fabricated. This resin develops a cationic/ hydrophobic surface during the curing (hardening) process. A polymer with different charges and polarity ranges on its surface can induce electrostatic attraction to the different parts of bacterial cell mem- branes, making it a hostile environment and thus reducing their proliferation. Like using a mouse trap instead of a poison, the novel technology works like a kind of microbe trap on a nano scale. Apart from being completely safe for man and environment, this physical action has another big advantage: microbes will not become resistant to this kind of control. The antimicrobial technology, its working mechanism and test results will be discussed.

Copper oxide based anti-fouling coatings are increasingly under regulatory scrutiny. Typically, very high loadings of copper oxide biocide are needed to achieve required high performance, sometimes higher than 50 weight-%. The amount of copper oxide can be reduced dramatically by incorporating a novel structure modified, nanostructured synthetic silica, while the coating still offers full anti-fouling performance.

Formulating with structure-modified silica in marine coatings improves the stability of the surface. Thus, the coating is more durable and robust against abrasion that may occur for example during underwater cleaning.

This paper addresses the effect of structure-modified, nanostructured silica in marine anti-fouling coatings. It will elaborate on the synergistic effect between silica and cuprous oxide and give results on the anti-fouling performance from field tests. Special focus will highlight the improved abrasion resistance and mechanical stability of marine coatings supported by applications data.

Antifouling coatings prevent the attachment and growth of marine organisms on surfaces in seawater. Fouling increases surface resistance movement, thereby increasing fuel consumption of the vessels to maintain speed.

After the ban on tin-based antifouling (more than two decades ago), most suppliers start to use copper-based coatings. However, dissolved copper from these coatings systems has increased in certain poorly flushed basins and in crowded marinas exceeding the Clean Water Act standard for copper. Scientific studies have shown high concentrations of dissolved copper in ocean water can affect the growth, development, and reproduction of mussels, oysters, scallops, sea urchins, and crustaceans.

Since 2012, significant R&D resources have been allocated for the development of copper-free antifouling coatings in anticipation of increasing restrictions.

Biomimetx SA a Portuguese biotechnology company developed a mixture of compounds – BMX-11 - produced by a proprietary bacterium, that are biodegradable, cost effective and broad spectrum. We are presenting for the first time this biological biocide, capable of being incorporated in marine paints to replace current toxic biocides, namely copper and that is enviromently friendly.

BMX-11 proved in the laboratory to be active against a wide range of organisms and in raft tests after incorporated in paint showed that is still active against soft and hard fouling (namely algae and tube worms). Raft test took place in several locations, in the presence of different fouling organisms and water temperature.

BMX-11 production is done by bacterial fermentation with very simple downstream processing and it reached industrial scale, showing that can be deliver to industrial customers cost effectively. Toxicological studies showed that BMX-11 is not harmful to mammals. These data allowed BMX-11 to be considered a Biochemical pesticide by US EPA, shortening the registration process that is underway and should be concluded next year.

In today’s globalized architectural coatings market there is free movement of raw materials and technology across international borders. This globalization has provided benefits, however as global supply chains become interconnected and interdependent there is greater potential for disruption from regional regulatory changes. While any raw material can potentially be impacted, the antimicrobials (biocides) used in coatings pose a unique challenge to formulators, as they are often subject to obscure regulatory provisions.

Regulatory trends for preservatives have severely limited the options for in-can protection of paints and coatings. More recently there have been proposed changes in the hazard communication requirements for a commonly used preservative active agent. These changes will cause the presence of many commonly used preservative systems to trigger consumer unfriendly hazard labeling on the associated paint containers. These hazard phrases can alarm consumers, and alter their buying behaviors.

Past approaches to developing preservative blends which avoid triggering hazard phrases have focused on using a combination of active agents selected such that each active is present below its trigger concentration. This approach assumes a future regulatory environment where the active agents will always be considered independently, and the individual preservative concentrations will never be summed together and considered as an aggregate total preservative load. Under this label driven approach, switching preservative systems to avoid hazard phrases can have the odd result that the total amount of preservative active agent present in the coating formulation actually increases. Therefore any subsequent regulatory change in the trigger concentration of any of the actives in the blend, or any movement towards consideration of preservative loading as an aggregate, requires a time consuming re-qualification of a readjusted preservative system.

This paper describes how a novel formulation approach was used to create a more efficient preservative system. This innovative approach makes it possible to lower the total amount of preservative active agent present in the preserved coating formulation, and therefore it provides a protection system that is more robust against future regulatory changes. Supporting data and examples are provided from regions where this new technology has already been commercialized.