Harmony comes from the right interaction

Transcription

1 Harmony comes from the right interaction Kaolin innovations for interior and exterior coatings Peter Van Herzele, Dorfner XXVII ASEFAPI Technical Congress Madrid, October 26, 2017

2 Content (A) Calcined kaolins? (B) Coarse grade calcined kaolins? (C) Application properties (D) Filler package design (E) Exterior coatings (F) Wood coatings (G) Future developments 2

3 Who we are 3 Family-owned medium-sized company Own mineral deposits and refining expertise Products are tailored to the target industry Technical service expertise Dialog partner ánd development partner 300 employees

4 (A) Calcined kaolins?

5 So what exactly is calcined kaolin? Chemical name: aluminum silicate Highly refined kaolin Perfectly purified Well screened and graded Temperature treated (calcined) Specifically textured Silicium Aluminium Oxygen Hydroxyl group Our calcined kaolins are valuable functional filler materials, ideal for dispersion paints 5

6 How are they produced? Mining Preparation Refining Packaging Purification Screening and classifying etc. Temperature treatment Optimized engineering processes guarantee quality and high reproducibility 6

7 What happens during the refining of kaolin? 1. Controlled growth 2. Physical-chemical H 2 O refining Controlled movement through oven Temperature (hydrothermal) Time Phase transition native kaolin (purified, air classified) Products with - Defined structure and morphology - Homogeneous surface chemistry - Controlled particle size with narrow distribution - Outstanding specifications 7

8 (B) Coarse grade calcined kaolins

9 Coarse calcined kaolin? Most of the calcined kaolins in the world are fine (d50 = 0,5 1,5 µm) Dorfner deposits are coarse (d50 = 1,5 15 µm) It is all about the right filler package! Combination with fine calcium carbonate Combination with round particles The right combination of coarse/fine and platy/round particles brings the best performance 9

10 How to influence the performance of the fillers? PRO_VOID H 3 µm 1 µm Native kaolin 1 µm X_PAND 10 µm C1 Different physical and chemical refining processes result in products with a clear profile 10

11 How to influence the performance of the fillers? 11

12 (C) Coarse grade calcined kaolins and application properties

13 Surface properties Surface charge Adsorbed water, hydroxyl groups Low surface charge, low crystal water, less adsorbed water Refinement Temp., H2O Crystal water irreversible Natural kaolin: very hydrophilic and high surface activity Calcined kaolin: moderately hydrophilic, lower surface activity Ideal surface properties for integration in a polymer matrix 13

14 Structure viscosity and rheology Specially selected Kaolin platelets Force 3-dimensional gel (weak gel!) Sol-like state, liquid 14

15 ON/OFF mechanism Viscosity Fast transition Shearing ON Rest state Shearing OFF Shearing Time Makes the application process easier Prevents phase separation in storage 15

16 Importance of a well-designed particle size and shape distribution? Objective measurement of forces and surface coverage rate when applying dispersion paints Force sensors Data transfer Recording the forces Software analysis Application engineering tests new formulations with the aid of the wired-up painter* * Robert-Murjahn Institute, Ober Ramstadt, Germany 16

17 Importance of a well-designed particle size and shape distribution? Movement cycles of the roller Force during application Tack Stop Force sensor Time Dispersion paint with DORKAFILL Dispersion paint with conventional fillers 17

18 Bridging cracks Cracks in the surface Paint film with functional filler from Dorfner Cracks in the paint film Standard paint formulation Coarse kaolin is good for bridging cracks Reduces the tendency of recipes to crack 18

19 Splashing characteristics 100 % up to -15 % No use of coarse calcined kaolins 0 % Test recipe with DORKAFILL Test recipe without DORKAFILL With coarse calcined kaolins 19 Coarse calcined kaolins significantly reduce the tendency to splash

20 Matting and particle size Properties of the particles Glossy Size Large Small Medium gloss Matt Diffusion Matt Interface Reflection Glossy Flat matt 0 10 Particle diameter (d50) µm 20 Rough (textured) Matt Shape Smooth Glossy Platelet Tends towards matt Spheroid Tends towards glossy 20

21 Matting and particle size reflection diffuse strong diffuse reflection reflection Standard filler with smooth surface DORKAFILL C1 DORKAFILL H DORKAFILL PRO_VOID Coarse, platy calcined kaolins are very efficient matting agents 21

22 Consumption of binders Unused binder Unused binder in cavities and gaps Coarse platelet form, compact and non-porous Diatomite Structured calcinated kaolins Coarse, platy calcined kaolins are extremely economical in terms of binder consumption 22

23 Binder consumption of matting agents Oil number (g/100g) DORKAFILL PRO_VOID Diatomite Diatomite substitute Calcined kaolin matting agents beat conventional matting agents by a mile in terms of binder consumption! 23

24 Strong platelets F Coarse calcined kaolin particles absorb forces without breaking Coarse calcined kaolins are hard Good for the mechanical durability and wet scrub resistance of coatings 24

25 Paints for construction purposes and wet scrub resistance Coating Substrate Abrasion tool with standardized nonwoven fabric Reduction of the coating thickness (AN) Soapy water Measurement Removal (AN) of the paint layer/µm (EN 13300) After n strokes of the abrasion tool 1 A N < A N < A N < A N < A N Measurement of the wet abrasion resistance acc. to EN The interaction between fillers material and binder is the key factor for wear resistance 25

26 Wet scrub resistance An ideal combination of visco-plastic properties and hardness for the respective formulation delivers the best abrasion values. Thanks to their excellent wettability, coarse platy calcined kaolins are optimally embedded in the polymer matrix. Optimal scrub resistance thanks to Low amounts of water absorption High level of hardness New standards in terms of wet scrub resistance classes 26

27 Opportunities In summary, coarse calcined kaolins offer unique characteristics like... Degree of whiteness Matting Wet scrub resistance Rheology Hiding power Durability Coarse calcined kaolins: The new convincing standard 27

28 (D) Filler package design

29 Principles Formulation = Binder + Pigments + Additives + Fillers Filler package most underestimated part of the formulation Focus: cost reduction using designed filler packages Without negative impact on paint characteristics (EN 13300) Without negative impact on application properties Dorfner hypothesis: Performance of fillers depends on the design of the package and the characteristics of its properties 29

30 Approach Design or Redesign of Filler package Use of hard, platy particles to optimize paint characteristics Median particle size 5 15 µm to gain the biggest impact on paint viscosity Ratio between coarse (PRO_VOID) and fine particles (H) depends on the development objectives Opportunities: Improved Quality at same cost, or Reduction of raw material cost, keeping properties Replace a high number of different fillers Reduce number of raw materials Target-oriented improvement of characteristics 30

31 Formulating strategy Replacement of functional fillers with multifunctional fillers with the right particle size/shape combination 31

32 Example 1: medium quality paint 32

33 Example 1: medium quality paint Initial formulation (was) Optimized formulation (is now) CLASSIFICATION BASED ON EN Wet scrub class 3 3 Class for hiding power 2 2 Gloss Flat matt Flat matt MEASUREMENT DATA PVC [%] Filler content [%] Solid particles [%] Shear stress at 1,200 s 1 [Pa] Wet scrub [µm] Yield [m 2 /l] 8 8 Standard color value Y Gloss 60 /85 2.4/ /2.6 Density [g/cm 3 ] Result: Save 20% of binder and 20% of TiO 2 33

34 Example 2: upper medium quality paint 34

35 Example 2: upper medium quality paint Initial formulation (was) Optimized formulation (is now) CLASSIFICATION BASED ON EN Wet scrub class Class for hiding power Gloss Flat matt Flat matt MEASUREMENT DATA PVC [%] Filler content [%] Solid particles [%] 56, Shear stress at 1,200 s 1 [Pa] Wet scrub [µm] Yield [m 2 /l] Standard color value Y Gloss 60 /85 2.4/3.6 2,3/2,3 Density [g/cm 3 ] 1, Result: Technical improvement + reduced consumption 21% less binder and 8% less TiO 2 35

36 Example 3: premium quality paint 36

37 Example 3: premium quality paint Initial formulation (was) Optimized formulation (is now) CLASSIFICATION BASED ON EN Wet scrub class Class for hiding power Gloss Flat matt Flat matt MEASUREMENT DATA PVC [%] Filler content [%] Solid particles [%] Shear stress at 1,200 s 1 [Pa] 1,580 1,660 Wet scrub [µm] Yield [m 2 /l] Standard color value Y Gloss 60 /85 2.4/ /1.4 Density [g/cm 3 ] Result: Technical improvement and higher classification at the same system costs. 37

38 Summary Calcined kaolins are widely used fillers for decorative paints Coarse calcined kaolins are very efficient multifunctional fillers The performance of the fillers can be influenced by Particle size Particle shape By re-designing the filler package of the formulation Price / Quality ratio can be improved Many raw materials can be substituted: simplification Number of raw materials can be reduced Rationalization programs 38

39 (E) Exterior coatings

40 "Growing" Problem More complex situation: humidity 40

41 Status Quo Working principle: reduction of water absorption Acrylate dispersions 1. High binder content 2. Additives Silicone resin paint Minimize water absorption by using 1. Silicone resin (approx. 2-6%), Less acrylate dispersion needed (approx. 15%) 2. Silicone additives as well (approx. 1%) Silicone resin increases susceptibility to soiling High system costs due to high binder content and silicones! 41

42 Goals Improve performance of coarse calcined kaolins in exterior coatings Reduce system costs Reduce consumption of silicone resin and additives Reduce binder consumption Prevent fouling on exterior wall Keep water out of the coating Exterior walls dry out faster 42

43 Platelets with hydrophobic function Solution: coarse calcined kaolin with hydrophobic function hydrophobic groups chemically bound readily dispersible Protects against moisture penetration 43

44 Platelets with hydrophobic function Substrate Coating Hydrophobic Core DORVALIT SHO Easy-dry effect 44

45 List of constituents Formulation Optimization Step 1 Step 2 Step 3 Water 280,0 280,0 280,0 Rheotech ,0 4,0 4,0 Tylose MH 6000 YG8 4,0 4,0 4,0 Lopon LF 4,0 4,0 4,0 Agitan 381 2,5 2,5 2,5 Acticide MBS 7,5 7,5 7,5 Dowanol DPnB 10,0 10,0 10,0 Kronos ,0 60,0 60,0 Omyacarb 2 GU 180,0 180,0 180,0 Omyacarb 5 GU 200,0 200,0 200,0 DORVALIT SHO 100,0 Finntalc M15 100,0 100,0 Tego Phobe ,0 Acronal S ,0 158,0 158,0 Total 1070,0 1010,0 1010,0 45

46 w-wert kg/(m² h0,5) Results - Water Absorption Coefficient Comparison of water absorption coefficients* 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0 Step 1: Silicone resin paint Step 2:No silicone resin Step 3: With DORVALIT SHO Coarse kaolin with a hydrophobic function brings the formulation back on track 46 * Evaluation based on DIN EN ; determination of water absorption coefficient after 10-day cyclic water absorption; cycle: 6 hr. water exposure, 18 hr. drying

47 Anti-Fouling Results External test - mold fouling* Step 1: Silicone resin Step 2: No silicone resin Step 3: DORVALIT SHO Coarse kaolin with a hydrophobic function inhibits fouling * Based on ASTMD 3273, constant relative humidity > 95 %, 28 C duration: 48 days, test chamber inoculated with spores 47

48 Results Functional fillers are replaced by coarse calcined kaolin with hydrophobic function Silicone resin was removed from the formulation No change of water vapour diffusion (sd = <0,1m for all formulations) Reduction in water absorption Fouling inhibition Introduction of a hydrophobic function enables coarse calcined kaolin to give exterior wall paints the same level of performance as silicone paint 48

49 At a Glance Coarse calcined kaolins can also be used to optimize exterior wall paint A hydrophobic function is introduced Reduction of water absorption Fouling inhibition Improvement of the performance of exterior wall paint Option 1: Elimination of silicone resin or hydrophobic agents Option 2: Reduction acrylate dispersion consumption 49

50 (F) Wood coatings

51 51 Market Expectations > Perfect wood finishes > Durable furniture and interior decoration > Homes and furnishings retain their value Innovative products from Dorfner can do just that

52 Challenges with Wood Coatings 1st coat Discoloration is a common problem with coatings 2nd coat Discoloration shows through 3rd coat Applying another coat over the discoloration is futile Discoloration is caused by wood extractives 52

53 The strong Coloring of Wood Extractives in Nature Wood extractives protect trees and their wood against: 53

54 Wood Extractives Content % (w/v) e.g. merbau 20 % e.g. balsa wood 1 % Lightweight wood e.g. scots pine (pinus sylvestris) 5 % Wood from temperate zones Tropical wood 54

55 Undesired Side Effects of Wood Extractives They are responsible for discolorations and bleeding in coatings 55

56 Common water-based Wood Primer O 2 + Sunlight Water-based topcoat Common water-based primer Wood substrate Wood extractives The wood extractives migrate into the primer and the topcoat 56

57 DORVALIT WSP Prevents discoloration Water-based topcoat Undesired side effect of wood extractives Water-based primer with DORVALIT WSP Woodsubstrate Wood extractives The Wood Stain Protection Technology of DORVALIT WSP effectively binds the extractives and avoids their migration. 57

58 DORVALIT WSP in action the `Lock-and-key mechanism Extractives Primer with DORVALIT WSP: Patent pending `lock-and-key mechanism Wood Substrate 58

59 Dorfner Core Expertise Surface Modification of Minerals substrate + Wood Stain Protection Functionality: "capture" function "anchoring" function DORVALIT WSP 59

60 Dorfner Wood Stain Protection Technology "forceps" kaolin firmly bonded R Extractive (tannin) lock & key mechanism R DORVALIT WSP captures wood extractives Extractives are firmly bound and prevented from migrating DORVALIT WSP has an outstanding barrier effect 60

61 Competing Systems Organometallic Compounds Sunlight O 2 Halox XTain or Stainban Topcoat Primer Me n+ forms complexes with constituents Wood substrate Me n+ : Zn 2+, Zr(IV), Al(III) Extractives Organometallic compounds are less effective than DORVALIT WSP and in most cases require special labeling 61

62 Green Barrier Coat Primers DORVALIT WSP is non-hazardous Primers containing DORVALIT WSP do not require warning labels 62

63 Guideline Formulation Containing DORVALIT WSP Water 24,9 24,9 Coapur ,3 0,3 Disperbyk 190 0,4 0,4 Agitan 381 0,1 0,1 TR 92 12,5 12,5 Kaolin 15 0 DORVALIT WSP 0 15 Acticide MBS 0,2 0,2 Agitan 381 0,2 0,2 AMP 90 0,2 0,2 Viscoatex 46 1,2 1,2 Mowilith LDM ,0 45,0 Total 100 % 100 % 63

64 Practical Trial (Guideline Formulation, 1/2) without with DORVALIT WSP Merbau Without DORVALIT WSP heavy discoloration With DORVALIT WSP minimal discoloration 64

65 Practical Trial (Guideline Formulation, 2/2) without with DORVALIT WSP Larch Without DORVALIT WSP extensive yellowing With DORVALIT WSP very little discoloration 65

66 DORVALIT WSP in Comparative Practical Trials A B C D with DORVALIT WSP no discoloration A: Basis: anti-stain primer X (branded product // as made // on merbau) B: plus 15 % kaolin C: plus 15 % DORVALIT WSP D: plus 15 % chalk DORVALIT WSP significantly improvesthe effectiveness of a standard anti-stain primer 66

67 DORVALIT WSP in Comparative Practical Trials A B C D A: Basis: anti-stain primer Y (branded product // as made // on merbau) B: plus 15 % kaolin C: plus 15 % DORVALIT WSP D: plus 15 % chalk with DORVALIT WSP no discoloration DORVALIT WSP greatly enhances the barrier effect of standard anti-stain primers 67

68 DORVALIT WSP in Comparative Practical Trials A B C D with DORVALIT WSP no discoloration A: Basis: anti-stain primer Z (branded product // as made // on merbau) B: plus 15 % kaolin C: plus 15 % DORVALIT WSP D: plus 15 % chalk DORVALIT WSP has high anti-stain power any anti-stain primer can benefit 68

69 DORVALIT WSP Competitive Test 15% calcium carbonate 15% calcium carbonate 2% inhibitor Primed wood sample Merbau with standard formulation (primer and commercial surface layer with a constant layer thickness of 200 m) 15% DORVALIT WSP DORVALIT WSP significantly improves the effectiveness of a standard anti-stain primer 69

70 DORVALIT WSP Competitive Test Isolating solids Beside expensive liquid additves, isolating solids are used Performance and price of these are lower Not neccessarily label-free Higher amounts are required for the same performance Adjustment of filler content required DORVALIT WSP gives high performance, filler properties and is easily to formulate. 70

71 DORVALIT WSP Competitive Test Isolating solids Product Labeling Quantity 1 2 Handling as hazardous substance contains 2 water polluting materials contains a toxic material contains up to 2.5% zinc phosphate None 5-15% 2-5% (for thin-coating systems) 3 contains zinc phosphate and zinc oxide labeling of the coating 2-5% (for thin-coating systems) WSP None 5-15% DORVALIT WSP is a green product without labelling requirements, it replaces organometallic systems currently in use 71

72 DORVALIT WSP Competitive Test Formula Recipe1 Recipe 2 Recipe 3 Water 10,97 10,97 10,97 Coapur ,30 0,30 0,30 Disperbyk 190 0,40 0,40 0,40 Byk-346 0,30 0,30 0,30 Agitan 381 0,10 0,10 0,10 Fego Foamex K8 0,30 0,30 0,30 TR 92 12,50 12,50 12,50 Isolating Additive 15,00 10,00 5,00 Finntalc M15 0 5,00 10,00 Water 13,83 13,83 13,83 Acticide MBS 0,20 0,20 0,20 AMP 90 0,20 0,20 0,20 AP10 0,20 0,20 0,20 AP20 0,20 0,20 0,20 Texanol 0,50 0,50 0,50 Plextol ,00 45,00 45,00 Summe 100,00 100,00 100,00 5 %, 10 % and 15 % isolating additive were used Finntalc compensates the filler content 72

73 DORVALIT WSP Competitive Test 1 2 DORVALIT WSP 3 Quantity 15 % 1. layer 2. layer Quantity 10% 1. layer 2. layer Quantity 5% 1. layer 2. layer DORVALIT WSP increases the performance in first and second coating Wood has a varying extend of emitting wood extractives! 73

74 Summary Innovative technology Patent-pending Wood Stain Protection Technology. Surface modified mineral-based filler. Improved efficiency due irreversibly bound wood extractives. Easy application Suitable for almost every wood primer. Easy to disperse within water-based formulations. Improves filler properties and other coating parameters. Environmental performance and cost efficiency Minimization of complaints due to reliable mechanism of action. Eco-friendly and therefore label-free solution. Potential for overall users cost reduction up to 25 %. 74

75 (G) Future developments

76 THANK YOU FOR YOUR ATTENTION Questions? Peter Van Herzele Head of Sales Paint Gebrüder Dorfner GmbH & Co KG Scharhof Hirschau Germany peter.vanherzele@dorfner.com 76