Ultra-Low VOC Waterborne Alkyd Coatings for Metal Protection
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1 Ultra-Low VOC Waterborne Alkyd Coatings for Metal Protection Erin Vogel, Ph.D. Research Scientist Industrial Coatings R&D, Dow Coating Materials Dow Chemical Company April 13,
2 Agenda Alkyd Overview Current Low VOC Alkyd Technology WB Alkyd Dispersion Technology Designing Alkyds for Metal Protection Ultra-Low VOC Alkyd Formulations with Exceptional Corrosion Resistance
3 What are Alkyds? Polyester modified by the addition of fatty acids and other components Low MW, flexible, low T g excellent wetting properties High gloss Good adhesion Good Corrosion Resistance Oxidative drying/cross-linking to form high MW network Improved Corrosion Resistance
4 What are Alkyds? Polyester modified by the addition of fatty acids and other components Low MW, flexible polymer, low T g excellent wetting properties High gloss Good adhesion Good Corrosion Resistance Oxidative drying/cross-linking to form high MW network Improved Corrosion Resistance Saturated Polyesters Short Oil Alkyds Medium Oil Alkyds Long Oil Alkyds % Oil and Fatty Acid % Phthalic Anhydride Cure Type Chemical Chemical Cure or Cure/Bake Oxidation; Bake or Air Dry Oxidative; Air Dry Oxidative; Slow Air Dry Gloss High High High High Semi-Gloss Hardness Very Hard Hard Mod. Hard Mod. Hard to Soft Utility OEM OEM Architectural, Trade Industrial Architectural, Trade Maintenance, OEM Industrial Maintenance Application Spray, Dip Spray, Dip Spray, Dip, Brush Spray, Brush, Dip, and Roll
5 What are Alkyds? Polyester modified by the addition of fatty acids and other components Low MW, flexible polymer, low T g excellent wetting properties High gloss Good adhesion Good Corrosion Resistance Oxidative drying/cross-linking to form high MW network Improved Corrosion Resistance Saturated Polyesters Short Oil Alkyds Medium Oil Alkyds Long Oil Alkyds % Oil and Fatty Acid % Phthalic Anhydride Cure Type Chemical Chemical Cure or Cure/Bake Oxidation; Bake or Air Dry Oxidative; Air Dry Oxidative; Slow Air Dry Gloss High High High High Semi-Gloss Hardness Very Hard Hard Mod. Hard Mod. Hard to Soft Utility OEM OEM Architectural, Trade Industrial Architectural, Trade Maintenance, OEM Industrial Maintenance Application Spray, Dip Spray, Dip Spray, Dip, Brush Spray, Brush, Dip, and Roll
6 In 2012, the Global Alkyd Market was >14 Billion lbs, worth ~ 25 Billion USD ROW, 4% Canada, 1% Mexico, 1% US, 6% Brazil, 4% Alkyd Breakdown by Application Other Asia, Oceania, 26% China, 36% West Europe, 12% East Europe, 9% Japan, 2% 22% Special Purpose 26% Ind. OEM 52% Architectural Breakdown by Country One of the most highly consumed types of coatings used in the world Low cost, versatility, and long familiarity Source: IHS Chemical Estimates, SRI Alkyd Surface Coatings 2013
7 Alkyds in Industrial Coatings Metal Furniture and Fixtures Appliances Sheet, Strip and Coil Machinery and Equipment Transportation Wood Furniture and Fixtures Electrical Insulation Containers Industrial Maintenance Aerosols Traffic Paints Automotive Refinish Source: US Paint & Coatings Market Analysis ( )
8 Solventborne Alkyds are Known for Their High Gloss, Good Adhesion, and Great Versatility Alkyd Breakdown by Technology 300 Hours Salt Spray Exposure 10% Waterborne 30% High Solids (SB) 60% Solventborne Commercial SB Alkyd Paint Commercial WB Alkyd Paint Commercial Premium Quality WB Acrylic Paint Solventborne (SB) Alkyds Continue to Dominate Alkyd Market Industrial Applications require excellent metal protection Current low VOC options, such as WB acrylics and WB alkyds have performance gaps: Gloss Corrosion resistance Hardness development Source: IHS Chemical Estimates, SRI Alkyd Surface Coatings Coatings 1 mil thick
9 Environmental Trends are Driving Growth in WB Alkyds A Great Majority Of Formulators Are Using or Considering WB Alkyds Using WB alkyds now Not using but considering WB alkyds Neither using nor considering WB alkyds 13% 57% 30% Trends Driving Growth in WB Alkyds Environmental regulations require lower VOC systems Alkyds can offer high gloss and adhesion Conclusions from Voice of Market Study Market needs better performing WB alkyds if it is to be technology of choice Closing the performance gap between SB and current WB alkyd technology could lead to widespread utility Source: SpecialChem Voice of the Market Study 2011
10 Current Low VOC Alkyd Systems High Solids Alkyds: Increase solids levels by reducing viscosity of resin Decrease ratio of dibasic acid / polyol (-) Lower functionality for crosslinking reduced resistance properties (-) Increased dry times Water Reducible Alkyds: Incorporation of excess acid groups Neutralized with amine for water dispersibility Supplied as 70-80% solids in hydrophilic solvent (-) VOC levels of g/l (-) Short shelf life after reduction in water due to ester hydrolysis 10
11 Current Low VOC Alkyd Systems Alkyd Emulsions: Emulsion through use of anionic/nonionic surfactants Surfactant shell Uses solvent inversion process to disperse alkyd Low VOC (-) Requires 5-10 wt% surfactant (-) Cannot emulsify short oil alkyds (-) Reduced water resistance and corrosion protection Modified Alkyd Dispersions: Acrylic shell around an alkyd core protects ester linkages from hydrolysis Neutralized with amine for water dispersibility Lower VOC levels (<100 g/l) (-) Increased hydrophilicity of alkyd upon modification (-) Reduced corrosion protection compared to SB alkyd Alkyd Core High Acid Acrylic Shell Alkyd Core
12 Current WB Alkyd Solutions Fall Short Traditional Solventborne Short Oil Alkyds: High MW / Viscosity Good Corrosion protection High Gloss Require solvent to manage viscosity high VOC Low VOC Tradeoffs: Alkyd modified with acid groups or combined with external surfactants Increased water sensitivity Reduced corrosion protection Proprietary Alkyd Water Reducible Alkyds Not to scale Alkyd Emulsions Alkyd Dispersions Modified Alkyd Dispersions Performance of Solventborne Alkyds Dispersion Technology Bridge the Performance Gap
13 *manufactured without added solvent WB Short Oil Alkyd Dispersion Alkyd Initial Water Primary Mixer High Internal Phase Emulsion Dilution Mixer Waterborne Alkyd Dispersion Optimal surfactant Dilution Water Solvent-free* dispersing High solids capability (50-65%) Low surfactant compared to commercial WB alkyds No polymer modification necessary for dispersion Dispersions of uniform small particle sizes (< 200 nm) Broad alkyd composition flexibility
14 Increasing Performance Molecular Wt. / Viscosity Proprietary WB Alkyd Dispersions Ultra-Low VOC WB Alkyd Dispersions / SB Alkyds Unique Waterborne Alkyd Formulating Capability Alkyd and Modified Alkyd Dispersions Alkyd Emulsions Water Reducible Alkyds Acid Number or Ionizable Groups Decreasing Performance
15 % polyol 1 % polyol 1 Designing Alkyds for Performance Aim: Develop short and medium oil alkyds that help protect industrial metal Results: Identified top short oil and medium oil performers and scaled sample for paint formulation development DOE Design Space Oil Length Output 1 Oil Length Degree of Branching Medium Oil Probe Augmented Design Expand Design to Shorter Oil Lengths Decouple MW and Acid Value Oil Type, Acid Type and Polyol Type Medium Short Oil Medium Oil Short Oil 1 st Generation Medium Oil 1 st Generation Probe is still best performer 2 nd Generation Medium Oil Probe Short Oil Probe Identified % aromatic acid 1
16 WB Alkyd Dispersion Alkyd Initial Water Primary Mixer High Internal Phase Emulsion Dilution Mixer Waterborne Alkyd Dispersion Optimal surfactant Dilution Water Property Short Oil WB Alkyd Dispersion Medium Oil WB Alkyd Dispersion Appearance Milky White Liquid Milky White Liquid Solids (%) Particle Size (nm) Viscosity* (cp) 2,800 1,800 ph Typical Properties, not to be construed as specifications *Viscosity measured with Brookfield Viscometer: Spindle #4, 10 rpm
17 Short Oil WB Alkyd Dispersion Retains SB Performance 200 Hours Salt Spray Exposure Same alkyd resin used in both coatings SB Alkyd Coating VOC = 560 g/l WB Alkyd Coating VOC = <5 g/l Description Formulation VOC (g/l) Gloss Gloss Adhesion Pencil MEK double Hardness rubs SO Alkyd SB B B 45 SO Alkyd WB < B B 47 All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
18 WB Alkyd Formulation Property Appearance Developmental WB Alkyd Dispersion Milky White Liquid Solids (%) 57 Particle Size (nm) 160 Viscosity* (cp) 2,800 ph 8.6 Typical Properties, not to be construed as specifications *Viscosity measured with Brookfield Viscometer: Spindle #4, 10 rpm Proper additive selection is crucial! Material Name PoundsGallons Grind Water Defoamer Dispersant Base Rheology Modifier Pigment Auxiliary Drier Grind Sub-total LetDown WB Alkyd Dispersion Primary Drier Flash rust inhibitor Property Totals Value Total PVC 14.1% Volume Solids 50.1% Weight Solids 60.5% VOC Generic Water Excl. <5 g/l
19 Formulation is Key *150 hrs 300 Hours Salt Spray Exposure Dispersant 1 Dispersant 2 Dispersant 3 Dispersant 4 Dispersant 5 Dispersant choice plays a critical role in coating performance All coatings were cured for 14 days at 23 C, 50% rh; 14% PVC ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
20 Formulation is Key Dispersant 3 Top Down SEM Images Dispersant 1 Dispersant 4 Dispersant 2 Dispersant 5 Effective pigment dispersion is seen only with dispersant 5 All coatings were cured for 14 days at 23 C, 50% rh; 14% PVC ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
21 All coatings were cured for 14 days; 14% PVC ~1 mil DFT on CRS panels; ASTM B117 corrosion testing WB Short Oil Alkyd - Drier Study Sample Co/Zr Fe Set to Touch (hr) Tack Free (hr) DFT (mil) Gloss Gloss König Hardness b Adhesion 5B 5B Direct Impact Hours Salt Spray Exposure Co/Zr Drier System Fe Drier System Good performance with both Co/Zr and Fe drier systems
22 Alkyd Benchmark Study Paints: 6 Commercial SB alkyd paints 1 Commercial water reducible alkyd paint 3 Commercial WB alkyd paints 2 Developmental WB alkyd paint Target Film Thickness: ~1 mil DFT Drawdowns Substrate: Cold rolled steel Panel Age: 14 day cure before testing Controlled temperature and humidity (23 C, 50% rh) VOC of Paints Evaluated: <10 g/l - >600 g/l
23 Performance Against Commercial WB Alkyd Paints Sample WB SO Alkyd Dispersion Developmental WB Alkyd Paints have a good balance of properties High gloss Comparable hardness Good adhesion WB MO Alkyd Dispersion Commercial water reducible alkyd 1 Commercial WB alkyd 2 Commercial WB alkyd 3 Commercial WB alkyd primer 4 VOC (g/l) <5 <5 >330 <10 >50 <5 DFT (mil) Tack Free (hr) Gloss Gloss König Hardness Pencil Hardness B B B B B B Adhesion 5B 5B 2B 3B 4B 4B Direct Impact All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; probe formulation is 14% PVC
24 60 Gloss Dow s WB Alkyd Offers Improved Corrosion Protection Compared to Commercial WB Alkyds SO WB alkyd dispersion (<5 g/l VOC) MO WB alkyd dispersion (<5 g/l VOC) Hours Salt Spray Exposure WB 1 WB 2 WB 3 WB 4 Devl. Alkyd Commercial water reducible alkyd 1 (336 g/l VOC) Commercial WB alkyd 2 (10 g/l VOC) Commercial WB alkyd 3 (60 g/l VOC) Commercial WB alkyd 4 (5 g/l VOC) All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
25 Performance Against Commercial SB Alkyd Paints Sample WB SO Alkyd Dispersion Developmental WB Alkyd Paints have a good balance of properties at <10 g/l VOC Low VOC High gloss Good adhesion WB MO Alkyd Dispersion Comm. SB MO alkyd 1 Comm. SB alkyd 2 Comm. SB alkyd 3 Comm. SB SO alkyd 4 Comm. SB alkyd primer 5 Comm. SB alkyd primer 6 VOC (g/l) <5 < DFT (mil) Tack Free (hr) Gloss Gloss König Hardness Pencil Hardness B B 5B 3B 3B H 3B B Adhesion 5B 5B 3B 4B 3B 5B 4B 3B Direct Impact All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; probe formulation is 14% PVC
26 Dow s WB Alkyd Offers Excellent Corrosion Protection at <10 g/l VOC! SO WB alkyd dispersion (<5 g/l VOC) MO WB alkyd dispersion (<5 g/l VOC) Commercial SB MO alkyd 1 (410 g/l VOC) Commercial SB alkyd 2 (330 g/l VOC) 300 Hours Salt Spray Exposure Commercial SB alkyd 3 (430 g/l VOC) Commercial SB SO alkyd 4 (600 g/l VOC) Commercial SB alkyd primer 5 (450 g/l VOC) Commercial SB alkyd primer 6 (500 g/l VOC) All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
27 Short Oil Medium Oil Alkyd Comparison Name WB SO Alkyd WB MO Alkyd Dispersion Dispersion VOC (g/l) <5 <5 DFT (mil) Tack Free (hr) Dry Hard (hr) > Gloss Gloss König Hardness (s) Pencil Hardness B B Adhesion 5B 5B MEK double rubs Direct Impact Indirect Impact Hours Salt Spray Exposure WB SO Alkyd WB MO Alkyd 300 Hours Salt Spray Exposure WB SO Alkyd WB MO Alkyd Medium Oil Alkyd Dispersion Improved Flexibility / Impact Resistance Improved Solvent / Scrub Resistance Short Oil Alkyd Dispersion Improved Corrosion Resistance (>500 hrs) All coatings were cured for 14 days at 23 C, 50% rh; ~1 mil DFT on CRS panels; ASTM B117 corrosion testing
28 Short Oil Medium Oil Alkyd Blends wt% medium oil in blend 100% 80% 60% 40% 20% 0% DFT gloss gloss Tack Free (hr) Dry Hard (hr) >24 >24 >24 König (sec) Pencil Gouge HB B HB B B HB Adhesion 5B 5B 5B 5B 5B 5B Direct Impact Reverse Impact <10 <10 <10 <10 High Gloss Good Hardness Development Excellent Adhesion Impact Resistance and Dry Time Related to % MOA in Blend All coatings were cured for 14 days at 23 C, 50% rh; ~1.5 mil DFT on CRS panels
29 Short Oil Medium Oil Alkyd Blends 200 Hours Salt Spray Exposure 100% MOA 80% MOA 60% MOA 40% MOA 20% MOA 0% MOA Excellent corrosion protection out to 200 hours salt spray exposure Extended corrosion protection with more short oil alkyd in blend All coatings were cured for 14 days at 23 C, 50% rh; ~1.5 mil DFT on CRS panels; ASTM B117 corrosion testing
30 Improving Dry Time of Short Oil Alkyd Dispersion Variables Drier type: Co, Zr, Fe, Mn Drier level: low very high recommended levels Dry Time (hr) 3 or 4 driers combination Outcome Ability to adjust dry time / hardness based on drier package
31 Improving Dry Time of Short Oil Alkyd Dispersion Volume Solids Dispersant Solvent VOC (g/l) Set-to-Touch Time (hr) Tack-Free Time (hr) Dry Hard Time (hr) 50% 1 n < >24 40% 1 n < % 1 y < % 2 y < % 1 y < % 2 y < Variables 2 Dispersants Solvent addition Volume Solids of Formulation Outcome Inclusion of Ca as auxiliary drier improved dry times Proper additive / solvent selection improves dry times
32 Summary Proprietary mechanical dispersion technology facilitates WB dispersions of short and medium oil alkyds. These WB alkyd dispersions can be formulated into coatings with performance comparable to solventborne systems at <10 g/l VOC. Blends of the short and medium oil WB alkyd dispersions allows formulators to enhance properties for specific applications Samples are available.
33 Acknowledgements Marty Beebe Daryoosh Beigzadeh Bob Bills Christina Ellison Sue Machelski Guy Maslowski Rebecca Ortiz Alan Piwowar Jay Romick Jamie Sullivan Vennesa Williams Contact Information Erin Vogel Dow Chemical Company 1707 Building Midland, MI
34 HANDLING PRECAUTIONS PRODUCT STEWARDSHIP CUSTOMER NOTICE Before using any product mentioned herein, consult the product s Material Safety Data Sheet (MSDS)/Safety Data Sheet (SDS) for details on product hazards, recommended handling precautions and product storage. Dow has a fundamental concern for all who make, distribute, and use its products, and for the environment in which we live. This concern is the basis for our product stewardship philosophy by which we assess the safety, health, and environmental information on our products and then take appropriate steps to protect employee and public health and our environment. The success of our product stewardship program rests with each and every individual involved with Dow products - from the initial concept and research, to manufacture, use, sale, disposal, and recycle of each product. Dow strongly encourages its customers to review both their manufacturing processes and their applications of Dow products from the standpoint of human health and environmental quality to ensure that Dow products are not used in ways for which they are not intended or tested. Dow personnel are available to answer your questions and to provide reasonable technical support. Dow product literature, including safety data sheets, should be consulted prior to use of Dow products. Current safety data sheets are available from Dow. Notice: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document. References to Dow or the Company mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. EXPERIMENTAL/ DEVELOPMENTAL PRODUCT NOTICE: If products are described as experimental or developmental : (1) product specifications may not be fully determined; (2) analysis of hazards and caution in handling and use are required; (3) there is greater potential for Dow to change specifications and/or discontinue production; and (4) although Dow may from time to time provide samples of such products, Dow is not obligated to supply or otherwise commercialize such products for any use or application whatsoever. Trademark of The Dow Chemical Company ( Dow ) or an affiliated company of Dow Form No NAR-EN-CDP
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