High performance 1K waterborne acrylics for parquet and furniture

Transcription

1 High performance 1K waterborne acrylics for parquet and furniture Thomas Bernhofer Synthomer Deutschland GmbH,Technical Service Manager Coatings ECC Parquet and furniture coatings, , Düsseldorf

2 Agenda Short introduction Synthomer European market for industrial woodcoatings Product requirements for parquet and furniture Improvement of 1K acrylics Prestudy blended vs. multiphase acrylics Colloidal structure and polymer constitution Test-results Conclusion 2

3 Synthomer: Key facts Top 5 global supplier of emulsion and speciality polymers Total Sales 1,458 bn 1,900 Employees 6 Strategic Business Units Health & Protection Construction & Coatings Paper 90 Countries 33 Production Units Carpet, Compounds & Foam Functional Polymers Performance Polymers Headquarters Harlow, UK Americas 3 % Regional Centres Marl, Germany Kuala Lumpur, Malaysia Shanghai, China Asia 27 % Total Sales 1,458 Billion Western Europe 56 % Dubai, UAE Atlanta, USA Subsidiary of Yule Catto & Co plc a FTSE listed company Eastern Europe & ROW 6 % MEA 8 % 2011 results according to Yule Catto reporting 3

4 Our locations 4

5 European Market for Industrial Woodcoatings Application Market Size in kt Furniture 238 Joinery 117 Flooring 70 Total 425 Technology Market Size in kt Growth rate % Market Size in kt (Forecast) 2K-PU ( SB ) Waterborne Radcure UPE Acid catalyzed Nitrocellulose Others Total

6 Product requirements for parquet and furniture Aesthetic aspects Levelling Filling / coverage Low grain raising Wood Warmth ( Anfeuerung ) Functional needs chemical resistance EN 12720, DIN B, 1C, IOS MAT-0066 R2, R4 Black heel marking resistance (BHMR) Hand-cream resistance (Neutrogena, Atrix and Nivea) 6

7 Product requirements for parquet and furniture Functional needs mechanical properties Abrasion resistance Scratch / mar resistance Blocking resistance Operational constraints Fast physical drying Good stackability Low energy consumption for drying e.g. room temperature Robust application process Low process equipment investments necessary 7

8 Product requirements for parquet and furniture Legislative constraints VOC content max. 130 g/l for in-situ application (2004/42/EC) Factory applied follow 1999/13/EC More strict: GEV EMICODE max. 8 % (EC1 Plus: max. 5 %) Low toxicity (e.g. no SVHC) Cost-efficiency Industrial interior wood coatings performance levels: Level Chem. Resistance Cost Properties Economy DIN C ; IKEA R4 Low Good blocking, filling and sandability Medium DIN B ; IKEA R4 / R2 Medium Fast drying and stackability, better adhesion and resistance High DIN B ; IKEA R2 High High chemical and scratch resistance 8

9 Improvement of 1K acrylics Current position of 1K acrylics in interior wood coatings: Use as standalone and combination binder Economy and medium performance level Cost-effective, low VOC and robust Extend share in medium and high performance level: Industrial demand (e.g. IKEA) for cost-efficient 1K wb with improved visual appearance and surface resistance / stackability properties at the same time Improve competitiveness with PUDs, radiation curing (UV and EBC) and 2K systems Develop new grades or blending of 1K acrylics feasible? 9

10 Prestudy blended vs. multiphase acrylics Pendulum hardness 10

11 Prestudy blended vs. multiphase acrylics Elasticity 11

12 Prestudy blended vs. multiphase acrylics Result of prestudy: Significant better results with multiphase acrylics Better film integrity Higher gloss Higher transparency Reduced water sensitivity Improved flexibility 12

13 Colloidal structure and polymer constitution 13

14 Control of technical properties Correlations: Aesthetic aspects Functional needs Operational constraints Legislative constraints Cost-efficiency => Colloidal structure => Polymer constitution and Particle morphology => Colloidal structure => Polymer constitution and Colloidal structure => Polymer constitution and Colloidal structure 14

15 Polymer constitution HARD Monomer Tg (ºC) Monomer Tg (ºC) Methyl Methacrylate (MMA) 105 n-butyl Acrylate (BA) -55 Styrene (St) Ethyl Hexyl Acrylate (2-EHA) -85 Acrylonitrile (AcN) 100 SOFT Basic monomers BA and 2-EHA increase hydrophobicity Acrylonitrile for improved chemical resistance Chain structure Linear Branched 15

16 Polymer constitution cross-linking Internal cross-linking Use of difunctional (or higher) monomers External 1K cross-linking Self-condensation of N-Methylolmethacrylamide: Pro: Fast and efficient Contra: Formaldehyde release and requires T> 100 C 16

17 Polymer constitution cross-linking External 1K cross-linking Metal complex (chelates and salts), reaction of carboxylic groups with transition metals e.g. Zn Pro: Fast and efficient Contra: Careful formulation necessary, otherwise shelf-life critical Oxidative cross-linking of CC double-bond containing compounds e.g. fatty acids Pro: Enhances hydrophobicity and elasticity Contra: Slow reaction 17

18 Polymer constitution cross-linking External 1K cross-linking Ketone acid / dihydrazide e.g. diactone acrylamide (DAAM) with adipic dihydrazide (ADH) The dihydrazide stay in the water phase and reacts, once the water evaporates Pro: Fast and efficient Contra: Enhances hydrophilicity, if not reacted completely 18

19 Colloidal structure Particle morphology Core-shell Inner domains Raspberry Particle size Preferably nm to enable proper penetration, but keep reasonable physical drying 19

20 Colloidal structure Particle size distribution Monomodal Bimodal 20

21 Colloidal structure film formation 21

22 Test of improved 1K acrylics Test-samples: 1K Acrylic A: Self-crosslinking multiphase, not optimized, 42% SC 1K Acrylic B: Self-crosslinking multiphase, optimized, 42% SC PUD A: Aliphatic PUD, hard 35% SC PUD B: Aliphatic PUD, hard, 40% SC All samples were free of solvents Cost-Analysis: Price level 1K Acrylic set to 100% => PUD A and B 180 % (solid/solid) Possible cost-saving on binder: 100 % replacement: 44 % cost-saving 50 % replacement: 22 % cost-saving 22

23 Test-results Pendulum hardness with 1K Acrylic A, not optimized 1K Acrylic A is not able to keep hardness level neither of PUD A and nor PUD B 23

24 Test-results Pendulum hardness with 1K Acrylic B, optimized 1K Acrylic B is able to improve hardness level of PUD at a ratio 50:50 and 80:20 and with PUD B even from 80:20 till 20:80 24

25 Test-results Chemical resistance Tests according DIN B,1C No decrease in performance compared to PUD Good hand cream resistance and BHMR 25

26 Conclusion Introduced improvements at 1K acrylics: Multiphase binders / particle morphology Reduced blocking Improved stackability Improved hardness Functional monomers External self-crosslinking => improved chemical resistance Internal cross-linking => improved hardness 26

27 Conclusion Introduced improvements at 1K acrylics: Control of particle size and particle size distribution Higher gloss Improved levelling Improved penetration Improved wood warmth Cost-efficiency Significant cost-saving feasible ( % compared to aliphatic PUD ) 27

28 Thanks for your attention! Any questions? 28