Maincote TM AE-58/ProSperse TM 3001 Acrylic Epoxy

Transcription

1 Technical Data Sheet Maincote TM AE-58/ProSperse TM 3001 Acrylic Epoxy For Waterborne 2K Light Duty Maintenance and Institutional Coatings Regional Product Availability Description Features and Benefits Typical Physical Properties North America MAINCOTE TM AE-58 acrylic emulsion is a high Tg, hard acrylic binder containing functionality allowing it to react with the epoxy dispersion ProSperse TM 3001 providing coatings with low VOC, toxicity, and odor and a performance profile similar to conventional solvent borne 2- pack epoxy finishes. MAINCOTE TM AE-58/ ProSperse TM 3001 is designed for generalpurpose acrylic/epoxy paints which can be used on a variety of substrates such as exterior and interior metal and concrete where outstanding hardness, chemical resistance, and resistance to UV degradation are required. High hardness Excellent chemical, stain, and solvent resistance Rapid dry film property development Low VOC and odor Good exterior durability i.e. UV resistance and resistance to color change Easy water clean-up One-day pot life Maincote TM AE-58 Acrylic Binder* Solids Content, % 42.5 ph 7.5 Viscosity, cp 700 Density. Lbs/gal 8.6 Bulking Value, gal./lbs Dry Wet Equivalent Weight (solids basis) 1,700 MFFT ( C) 40 ProSperse TM 3001 Epoxy Dispersion Solids Content, % 64 Density, Lbs/gal 9.1 Viscosity, cp Epoxy Equivalent Weight (g/eq) on Solids Epoxy Equivalent Weight (g/eq) as Supplied ph 6.0 min. Appearance Milky White *Not to be considered specifications Page 1 of 17 December 2010

2 Konig Hardness (sec) Performance Comparisons Pot-Life/Property Retention Unique to MAINCOTE TM AE-58/ ProSperse TM 3001 two-part formulations is the excellent pot-life when compared to typical polyamide/ epoxy paints; see Table 1. After mixing the two components, the paint has a usable pot-life of one day, thereby reducing waste of paint which has exceeded its pot life. During the usable period, paints retain excellent application characteristics with little increase in viscosity or change in gloss in dried films toward the end of their usable pot-life. Also, no appreciable degradation of coating performance occurred when paints were applied 24 hours after mixing, even when samples were aged at 100 ºF. However, blends that were aged 24 hours at 120 ºF became too viscous for use. We recommend that blends not be held for more than 24 hours because of the potential for intraparticle cross linking and a corresponding attrition of properties. Table 1. Change in Viscosity after Mixing Acrylic Epoxy Coating Acrylic-Epoxy Formulation Epoxy Polyamide Stormer Viscosity After 24 hours Room Temperature 93 Gelled 100 F F Very viscous Hardness Development Chart 1 demonstrates the hardness development at 25 C and 50% humidity of Maincote TM AE-58/ ProSperse TM 3001 starting point formulations in comparison with a conventional high gloss acrylic and commercial WB epoxy amine coatings. The acrylic epoxy coating develops hardness over 3 weeks whereas the conventional acrylic shows no increase in hardness after 2 weeks. The acrylic epoxies are significantly harder than a conventional acrylic but not as hard as the WB epoxy amine coating. Chart 1. Hardness Development of Acrylic Epoxy, High Acrylic, and a Commercial Epoxy Amine Films as a Function of Cure Time (2-3 mils on untreated Aluminum) Cure Time (RT, Days) High Semi High Rapid Cure Semi Rapid Cure High Acrylic Commercial WB Epoxy/Amine Page 2 of 17 December 2010

3 Exterior /Color Change Resistance Coatings based on MAINCOTE TM AE-58/ ProSperse TM 3001 have been exposed to accelerated weathering in a QUV chamber and show improved gloss retention and yellowing resistance over a typical solvent borne or water borne polyamide/epoxy coatings See Table 2. After 1000 hours of QUVA exposure the change in yellowness is 0.56 for the High Rapid Cure whereas the Commercial WB Epoxy Amine shows an increase of yellowness of The largest change in 60 gloss (-9.9) is also for the High Rapid Cure Coating whereas the Commercial WB Epoxy dropped more than 55 in this period. By comparison a 100% acrylic dropped 3.7 units. Table 2. Change in Color and after 1000 hours QUVA Dry Exposure High Rapid Cure Semi Rapid Cure High Acrylic Commercial WB Epoxy Amine High Semi ΔL* Δa* Δb* Δ (20 ) Δ (60 ) Δ (85 ) Stain and Solvent Resistance Waterborne acrylic/epoxy coatings based on MAINCOTE TM AE-58/ ProSperse TM 3001 resist stains and solvents better than standard solvent borne polyamide/epoxy coatings or industrial alkyd coatings; see Table 3. After a 15 minute spot test with various solvents, the acrylic/epoxy coatings softened comparably to the solvent epoxy except where they were more resistant to Butyl Cellosolve. Both epoxy coatings outperformed the alkyd. A number of staining agents were tested by leaving the stain in contact with the coating for 24 hours prior to removal with household cleanser. The most severe stains tested were mustard, coffee, red ink, coke, and grape juice. The red ink stained the alkyd heavily and lightly stained the polyamide/epoxy coating whereas the acrylic/epoxy coating was untouched. Mustard also discolors the polyamide/epoxy and the alkyd coatings but has little staining effect on the aqueous system. CORROSION RESISTANCE Acrylic/epoxy coatings have good flash rust and early rust resistance which makes them good directto-metal coatings. Topcoats offer barrier corrosion resistance comparable to their solventborne counterpart while primers exhibit adequate X-scribe (damaged) protection. Photographs 1 through 3 are five year ocean front exposures showing the performance of MAINCOTE TM AE-58/ ProSperse TM 3001 by itself and in mixed systems. Photograph 1 shows the MAINCOTE TM AE-58 barrier resistance while Photograph 2 shows its X-scribe corrosion resistance. In both cases, the WB acrylic/epoxy compares favorably to a commercial solvent borne polyamide epoxy system. Photograph 3 shows waterborne as well as solvent borne topcoats over WB acrylic/epoxy as a universal primer. MAINCOTE TM AE-58/ ProSperse TM 3001 can also be used as a topcoat over solvent borne primers. Page 3 of 17 December 2010

4 Table 3. Resistance Properties of Acrylic Epoxy, SB Epoxy Polyamide, and Alkyd Paints to Solvents and Staining 3-Weeks Air Dry Solvent Resistance AE-58/3001 Epoxy Polyamide Alkyd MEK Rubs to Remove >300 > Lifted 15-Minute Spot Tests MEK Mod. Soft Mod. Soft Lifted Toluene Mod. Soft Mod. Soft Lt. Soft Gasoline Lt. Soft Lt. Soft Lt. Soft Butyl Cellosolve Lt. Soft Mod. Soft Mod. Soft Stain Resistance 24-Hour Spot Tests Mustard OK Lt. Stain Med. Stain Coffee OK Ok Ok Red Ink OK Lt. Stain Heavy Stain Soda Ok OK OK Grape Juice OK OK OK 24-hr immersion on concrete HCl No Effect No Effect No Effect NaOH No Effect No Effect Dissolved Page 4 of 17 December 2010

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7 Formulation Effects Coalescent and Co-solvent Effects The type and level of coalescents and co-solvents in a formulation can be critical to the balance of properties attained, particularly the early film properties. Water-soluble coalescents such as butyl Cellosolve or butyl Carbitol are generally not recommended as the sole coalescent for direct-tometal maintenance paints because they do not develop rapid corrosion resistance, particularly early rust resistance. The recommended coalescent package, Dowanol TM DPnB/Optifilm 400, gives good early water resistance and corrosion properties. The temperature at which a latex forms a continuous film is termed the minimum film formation temperature (MFFT) and is strongly dependent upon the coalescent used. Table 4 gives the MFFT for Maincote TM AE-58 for a variety of widely used coalescent solvents at 10% on resin solids. The most efficient coalescents are Dowanol DPnB, Optifilm 400, and Texanol. The epoxy cross linker is also an effective reactive coalescent at the recommended formulation levels. Table 4. Effect of Coalescent Solvent on Minimum Film Formation Temperature. Coalescent Solvent Level (%) On Resin Solids MFFT (visual, C) None Dowanol DPnB Methyl Carbitol Texanol Optifilm Dowanol DPM Dowanol dieph ProSperse Dowanol DPnB and ProSperse & Texanol and ProSperse & Optifilm 400 and ProSperse & Formulations with polymer-partitioning coalescents need water soluble co-solvents, such as DPM or propylene glycol to obtain freeze/thaw resistance. Excessive levels of propylene glycol or ethylene glycol detract from early rust resistance in direct-to-metal applications. The choice of coalescent and cosolvent can affect drying times, low-temperature film formation, gloss, heat stability, etc. of the paint. Drying/Cure Times/Hardness Development Drying times can be increased by the use of faster-evaporating coalescents or co-solvents or by lowering the epoxy content, but the effects of these on other properties, such as gloss and early rust, should be examined. Heat Stability All formulations pass accelerated heat age stability tests (i.e., 14 days aging at 40 ºC, See Table 5). Changes in coalescent and co-solvent can also change a paint's stability due to a change in the swellability of the polymer. Any change in solvent should be evaluated for its effect on paint stability. Dispersing agents and their level may be critical to the early rust performance and overall corrosion protection of a coating. The level of dispersing agent should be no higher than that necessary for adequate dispersion/paint stability. Tamol 165 dispersant is a good starting dispersant for finishes Page 7 of 17 December 2010

8 based on MAINCOTE TM AE-58. Other dispersant types could diminish corrosion resistance. Table 5. Properties of Acrylic Epoxy Starting Point Formulations. Property High Semi High Rapid Cure Semi Rapid Cure High Acrylic (20 ) (60 ) (85 ) Change in KU Viscosity 40 C) NA Konig Hardness (3-Week Cure) MEK Double Rubs (1-Week Cure) >300 >300 >400 > Reactive Pigments Many variables can affect the stability of a paint containing a reactive pigment. Following is a list of factors that can have a significant impact on the paint stability of a formulation. 1. Extender types and levels (soluble components) 2. Dispersant type 3. Coalescent type and level 4. PVC 5. Degree of stability required Our technical literature provides starting points that meet our criteria for metal protection and heatage stability. These starting points are intended to demonstrate the potential for a formulation approach. If factors such as the level of reactive pigment or the level of coalescent are changed, instability may occur and the consequences of any change must be checked by the formulator. Also, imparting excessive shear due to color shading or working in a hot plant can impact the viscosity stability of a paint and these conditions should be evaluated before the actual production of paint on a large scale. Thickeners Nonionic urethane thickeners, such as ACRYSOL TM RM-2020NPR, ACRYSOL TM RM-8W or ACRYSOL TM RM-845, and ACRYSOL TM RM-12W are a must to maintain good corrosion resistance. ACRYSOL RM-2020NPR is recommended for brushing/roller applications. ACRYSOL RM-845 and ACRYSOL RM-12W, which give a lower high shear viscosity, are more suitable for airless spray formulations. Acrylic/Epoxy Ratio The formulations presented in this brochure contain elevated levels of epoxy to improve corrosion resistance and film formation. Lower epoxy levels, near stoichiometric, give slightly faster drying times and slightly higher gloss but sacrifice corrosion resistance and film formation. Page 8 of 17 December 2010

9 Co-Curing Agents The amine hardener, D.E.H. TM 39 can be used to increase the rate of cross linking and the cross link density in the acrylic epoxy film. Results (See Chart 1) show that hardness and solvent resistance develop more rapidly and reach higher ultimate levels as well. In some cases, performance approaches standard conventional solvent borne epoxy polyamides. These gains, however, come at the slight expense of salt-spray corrosion resistance, acid resistance, yellowing, and decorative durability. The overall effect of an amine accelerator is the movement of the balance of properties towards that of a conventional solvent borne epoxy coating. An amine accelerator provides the coating manufacturer with more latitude to create formulations tailored to specific applications. Page 9 of 17 December 2010

10 Standard Maintenance Topcoat/DTM - Formulation Material Name Pounds Gallons Part A Grind Water Dowanol DPnB Ammonia (28%) Tamol 165A Triton CF Tego Foamex Ti-Pure R Water Grind at 2000 RPM for 10 minutes Grind Sub-total LetDown Maincote AE Tego Foamex Sodium Nitrite (15%) Acrysol RM-2020 NPR Acrysol RM-8W Part A Total Part B Premix Water ProSperse Part B Total Totals Property Value Total PVC (%) 18 Volume Solids (%) 37 Weight Solids (%) 49 VOC (g/l) 96 Mix Ratio 7:1 ph 8.7 KU Viscosity 94.7 ICI Viscosity 1.3 Page 10 of 17 December 2010

11 Fast-Curing Maintenance Topcoat - Formulation C Material Name Pounds Gallons Part A Grind Water Dowanol DPnB Ammonia (28%) Tamol 165A Triton CF Tego Foamex D.E.H Ti-Pure R Water Grind at 2000 RPM for 10 minutes Grind Sub-total LetDown Maincote AE Tego Foamex Sodium Nitrite (15%) Acrysol RM-2020 NPR Acrysol RM-8W Part A Total Part B Premix Water ProSperse Part B Total Totals Property Value Total PVC (%) 17 Volume Solids (%) 38 Weight Solids (%) 50 VOC (g/l) 92 Mix Ratio 7:1 ph 10.0 KU Viscosity 97.2 ICI Viscosity 1.5 Page 11 of 17 December 2010

12 Standard Semi Topcoat/DTM - Formulation Material Name Pounds Gallons Part A Grind Water Dowanol DPnB Ammonia (28%) Tamol 165A Triton CF Tego Foamex Microtalc MP Ti-Pure R Grind at 2500 RPM for 15 minutes Grind Sub-total LetDown Maincote AE Water Tego Foamex Sodium Nitrite (15%) Acrysol RM-2020 NPR Acrysol RM-8W Part A Total Part B Premix Water ProSperse Part B Total Totals Property Value Total PVC (%) 30 Volume Solids (%) 37 Weight Solids (%) 52 VOC (g/l) 87 Mix Ratio 7:1 ph 8.8 KU Viscosity 101 ICI Viscosity 1.6 Page 12 of 17 December 2010

13 Fast-Curing Semi Topcoat - Formulation A Material Name Pounds Gallons Part A Grind Water Dowanol DPnB Ammonia (28%) D.E.H Tamol 165A Triton CF Tego Foamex Microtalc MP Ti-Pure R Grind at 2500 RPM for 15 minutes Grind Sub-total LetDown Maincote AE Water Tego Foamex Sodium Nitrite (15%) Acrysol RM-2020 NPR Acrysol RM-8W Part A Total Part B Premix Water ProSperse Part B Total Totals Property Value Total PVC (%) 29 Volume Solids (%) 38 Weight Solids (%) 53 VOC (g/l) 83 Mix Ratio 7:1 ph 10.0 KU Viscosity 89.9 ICI Viscosity 1.4 Page 13 of 17 December 2010

14 Anticorrosive Maintenance Primer - Formulation Material Name Pounds Gallons Part A Grind Dowanol DPnB Water Tamol 165A Ammonia (28%) Tego Foamex Surfynol 104PG Microtalc MP Halox SZP Shieldex AC Ti-Pure R Water Grind at 2500 RPM for 10 Minutes Grind Sub-total LetDown Maincote AE Sodium Nitrite (15%) Tego Foamex Acrysol RM-2020 NPR Acrysol RM-8W Part A Total Part B Premix ProSperse Water Part B Total Totals Property Value Total PVC (%) 31 Volume Solids (%) 35 Weight Solids (%) 47 VOC (g/l) 99 Mix Ratio 7:1 ph 8.5 KU Viscosity 84 ICI Viscosity 0.4 Page 14 of 17 December 2010

15 Raw Material Suppliers and Web Addresses Raw Material Supplier Name Web Address Acrysol RM-2020 NPR Dow Chemical Acrysol RM-8W Dow Chemical D.E.H. 39 Dow Chemical Dowanol DPnB Dow Chemical Halox SZP-391 Halox Maincote AE-58 Dow Chemical Microtalc MP Minerals Technology Shieldex AC5 W. R. Grace and Company Sodium Nitrite GFS Chemicals Surfynol 104PG50 Air Products Tamol 165A Dow Chemical Tego Foamex 1488 Tego Ti-Pure R-706 DuPont Titanium Technologies logies Triton CF-10 Dow Chemical XZ Dow Chemical Handling Precautions Storage Disposal Considerations Before using this product, consult the Material Safety Data Sheet (MSDS)/Safety Data Sheet (SDS) for details on product hazards, recommended handling precautions and product storage. Store products in tightly closed original containers at temperatures recommended on the product label. Dispose in accordance with all local, state (provincial) and federal regulations. Empty containers may contain hazardous residues. This material and its container must be disposed in a safe and legal manner. It is the user's responsibility to verify that treatment and disposal procedures comply with local, state (provincial) and federal regulations. Contact your Dow Coating Materials Technical Representative for more information. Product Stewardship Customer Notice 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 Page 15 of 17 December 2010

16 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. Page 16 of 17 December 2010

17 Contact: North America: Latin America: (+55) Europe: (+800) Asia-Pacific: (+800) Notice: No freedom from 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. Page 17 of 17 UNRESTRICTED Form No NAR-EN-CDP, Rev 0 Product Name / Dow Coating Materials