uber s ydral Coat 2 Ultrafine Alumina Trihydrate (AT) A New Super-Functional Extender for Coil Coatings
Coil coatings are highly functional, designed to protect the substrate while providing superior aesthetic properties at very low film thickness. ydral Coat 2 Ultrafine Alumina Trihydrate (AT) from uber Engineered Materials is designed to lower the cost of thin film coil coatings without impacting gloss, durability or optical properties. Its unique particle size distribution and extremely high brightness characteristics combine to make it the perfect choice for extending coil coatings. 2 What property characteristics are important for coil coatings? Bright, deep, true colors Flexibility Adhesion Scratch resistance Gloss and gloss retention umidity resistance Exterior durability Chemical resistance What makes it difficult to choose an extender for coil coatings? Most extenders will reduce the gloss at low film thickness, due to their coarse particles. Most naturally occurring extenders impart yellowing and lower brightness. Some extenders have high oil absorption that increases viscosity and detracts from exterior durability. Barium sulfate extenders have a very high specific gravity (4.5). Leads to settling problems igh cost per gallon Why is AT a solid choice to use in coil coatings? Chemically inert Exterior durability Stain, scrub and water resistant UV transparent Non-abrasive, easy on equipment Relatively low oil absorption Extremely high brightness, extends without yellowing or discoloring Refractive index of 1.57, maintains intensity of color Alumina surface, disperses efficiently Non-toxic, easy to handle and process Low specific gravity (2.4), relatively low cost per gallon
Why is ydral Coat 2 Ultrafine AT uniquely suited for coil coatings? There are two value propositions, depending upon the color: 3 In Whites and Pastels: ydral Coat 2 effectively spaces titanium dioxide (TiO 2) and replaces a portion of the resin; thus, lowering cost without adversely impacting optical properties or durability. In Blacks and Deep-Tones: ydral Coat 2 increases solids, lowers cost and reduces volatile organic compounds (VOCs) without impacting jetness or durability. Physical properties of ydral Coat 2: Extremely small and narrow particle size distribution Outstanding brightness and purity Great TiO 2 dispersant interaction All the other benefits of AT Inert, exterior durability Low density means no settling in the coating reservoir, low cost per gallon Low abrasivity (Mohs 2.5) Same surface as alumina-treated TiO 2 (coatings grades) Particle Size Distribution Curves of Ultrafine Extenders Used in Coil Coatings Volume Frequency % 3 2.5 2 1.5 1 0.5 0 0.01 0.1 1 Particle Diameter ydral Coat 2 Ultrafine AT Precipitated Barium Sulfate Ground Barium Sulfate Arrows indicate large difference in the number of coarse particles. 10 100 Logarithmic scale indicating particle size distribution using a Saturn DigiSizer particle size analyzer. Maintaining high gloss is a function of oil absorption and the amount of coarse particles. Note that ydral Coat 2 has a much lower coarse fraction than the finest commonly used precipitated and ground barium sulfate products. In addition, the particle size distribution of ydral Coat 2 is very narrow. This is most important at low coat thickness, such as 0.5 dry mil (13 microns). The result: ydral Coat 2 has much less impact on gloss compared with competing products.
Particle Size Distribution of Common Extenders Used in Coil Coatings Compared with ydral Coat 2 Ultrafine AT (Two Measuring Techniques) 4 Extender Type Precipitated Barium Sulfate (Ultrafine) Ground Barium Sulfate (Ultrafine) ydral Coat 2 Ultrafine AT Extender Type Saturn DigiSizer 5200 Particle Size Analyzer (D90) 1.58 3.71 1.07 SediGraph 5100 Particle Size Analyzer (D90) Precipitated Barium Sulfate (Ultrafine) 1.55 Ground Barium Sulfate (Ultrafine) 3.89 ydral Coat 2 Ultrafine AT 1.16 Data Generated From One Representative Lot of Each Product Saturn DigiSizer 5200 (D50) 0.62 0.94 0.41 SediGraph 5100 (D50) 0.85 1.25 0.43 Saturn DigiSizer 5200 (D10) 0.20 0.25 0.15 SediGraph 5100 (D10) 0.42 0.41 0.20 Extending whites and pastels with ydral Coat 2 Ultrafine AT In whites and pastels: ydral Coat 2 effectively spaces TiO 2 and lowers cost without adversely impacting optical properties or durability. In the study below, Formulation A is the control, and formulations B, C and D are replacements for TiO 2. In formulation E, ydral Coat 2 is a partial replacement for TiO 2 and a partial replacement for resin. Formulation E is the lowest cost of the five formulations and it has comparable gloss and durability properties to the control at 25% PVC. White igh Gloss Polyester Melamine Coil Coating for uber Series U-101 Formulations Shown in Pounds Per 100 Gallons Ingredient Polymac 220-1935 Disperbyk 110 Titanium Dioxide, Enamel Grade Polymac 220-1935 Cymel 303 Nacure 2500 Xylene BYK 370 Polymac 220-1935 Cymel 303 TOTALS Use Dispersing Additive White Pigment Make above as a master batch. Mix well and weigh out 482.07 pounds (grams) for each trial. Xylene Titanium Dioxide, Enamel Grade White Pigment 117.95 29.39 53.73 ydral Coat 2 Ultrafine AT Extender 71.54 Precipitated Barium Sulfate Extender 126.92 Add above and disperse to 7 egman grind. Crosslinker Acid Catalyst Additive Make above as one large master batch. Weigh out 486.69 pounds (grams) for each trial. Crosslinker A 231.60 14.17 236.30 309.12 63.80 8.51 99.40 5.86 38.28 4.70 1129.69 B 231.60 14.17 236.30 309.12 63.80 8.51 99.40 5.86 38.28 4.70 1094.86 C 231.60 14.17 236.30 309.12 63.80 8.51 99.40 5.86 38.25 4.70 1083.25 D 231.60 14.17 236.30 309.12 63.80 8.51 99.40 5.86 38.25 4.70 1138.63 E 231.60 14.17 236.30 13.78 29.39 112.06 309.12 63.80 8.51 99.40 5.86 1123.99 Calculated Values Yield, Gallons Density, Pounds Per Gallon Non-Volatile, % by Weight Non-Volatile, % by Volume PVC, % P/B VOC (lbs/gal) VOC (gm/l) Raw Material Cost/Gal ($) 10 11.30 71.33 55.31 19.66 0.81 3.18 381.00 27.54 10 10.95 70.42 55.31 19.66 0.73 3.18 381.00 26.41 10 10.83 70.10 55.31 19.66 0.70 3.18 381.00 26.04 10 11.39 51.56 55.31 19.66 0.83 3.18 381.00 27.01 10 11.24 71.18 55.31 25.00 0.92 3.18 381.00 25.46
ydral Coat 2 Ultrafine AT and Precipitated Barium Sulfate vs. No Extender (TiO 2 Loading, Brightness, Opacity and Cost) 5 100 95 Values vs. Control Expressed as a % of the Control 90 85 80 75 70 TiO 2 Brightness Opacity Cost Formula E has 7% lower cost (blue) with nearly the same brightness (red) and opacity (green). 65 Control ydral Coat 2 with 25% TiO2 Replaced (by Volume) ydral Coat 2 with 33% TiO2 Replaced (by Volume) Precipitated Barium Sulfate with 33% TiO2 Replaced (by Volume) ydral Coat 2 with 25% TiO2 and Partial Replaced (by Volume) Paint Identification Durability QUV testing was conducted on formulations A, B, C, D and E from the preceding page. After 2,000 hours, there is no difference between the control panels and the panels extended with ydral Coat 2 Ultrafine AT. Opacity at low coat weights TiO 2 is used to impart opacity and whiteness in coil coatings due to its very high index of refraction (2.61). To impart opacity at the low dry film thickness in coil coatings, high levels of TiO 2 are required. owever, the Contrast Ratio with Increasing TiO 2 1 0.9 0.8 efficiency of adding TiO 2 is not linear. As more TiO 2 is added, the opacity (shown by contrast ratio) improves, but the efficiency deteriorates. Opacity takes place when substances of widely different 0.7 0.6 0.5 Pounds Per Gallon TiO 2 indices of refraction are adjacent. When TiO 2 loading levels are high, TiO 2 particles crowd together. When the particles are not spaced, there is diminishing opacity improvement. For the very low film thickness of coil coatings, high levels of TiO 2 are needed. This makes the coating expensive. For theoretically optimum opacity, every TiO 2 particle is spaced apart at half the wavelength of light (0.2 micron). ydral Coat 2 has nearly the same particle size, so it acts as a very efficient spacer of TiO 2. And, since it is less expensive and lower in specific gravity, it is also cost-effective. Contrast Ratio
Application data for black and deep-tone coil coatings 6 ydral Coat 2 Ultrafine AT increases solids, lowers cost and reduces VOCs without impacting jetness or durability. Black and deep-tone coil coatings have high resin to pigment content (low pigment volume content [PVC]) which makes them expensive. Thus, the addition of extenders to lower the cost is desirable, but most extenders will also reduce the gloss and/or adversely impact the jetness or depth of color. The extremely high brightness and small particle size of ydral Coat 2 Ultrafine AT allows the formulator to increase the PVC, lower the VOC of the formulation and reduce the total cost while maintaining gloss, jetness and durability. The formulation and application data tables on pages 7 and 8 shows how adding ydral Coat 2 can be used to increase PVC in a glossy black coil coating and maintain performance and lower VOCs, while lowering the cost of use. Compared with the control (Formulation A), the performance properties with ydral Coat 2 were unchanged at lower cost. And, compared with precipitated barium sulfate, ydral Coat 2 formulations had less settling and higher gloss. Metal Coaters
7 Black igh Gloss Polyester Melamine Coating Based on Polymac 220-1959 Material Use VS1-132-A Control VS1-132-B 10% AT VS1-132-C 15% AT VS1-132-D 15% Barium Sulfate VS1-132-E 20% AT Polymac 220-1959 30.36 30.36 30.36 30.36 30.36 Butyl Cellosolve 0.58 0.58 0.58 0.58 0.58 150 12.05 12.05 12.05 12.05 12.05 Disperbyk 170 Dispersant 18.82 18.82 18.82 18.82 18.82 Raven 14 Carbon Black 25.13 25.13 25.13 25.13 25.13 SANDMILL TO 7.5 EGMAN ydral Coat 2 Ultrafine Extender 54.25 80.40 107.15 Precipitated Barium Sulfate Ultrafine Extender 80.40 Polymac 220-1959 PCCR 41.73 61.84 61.84 82.40 Xylene 12.52 18.56 18.56 24.80 DISPERSE TO 7 EGMAN Polymac 220-1959 588.69 588.69 588.69 588.69 588.69 Cymel 303 Crosslinker 83.12 83.12 83.12 83.12 83.12 Xylene 19.10 19.10 19.10 19.10 19.10 Nacure 2500 Accelerator 8.55 8.55 8.55 8.55 8.55 BYK 370 Additive 0.90 0.90 0.90 0.90 0.90 Polymac 220-1959 82.40 41.20 20.60 20.60 Xylene 24.80 12.40 6.20 6.20 TOTALS 894.50 949.40 974.90 974.90 1001.65 Paint Properties Pigment Volume Concentration % PVC 1.46 5.88 7.87 5.09 9.82 Non-Volatile - Weight % NVW 63.63 65.71 66.63 66.63 67.52 Non-Volatile - Volume % NVV 56.78 57.90 58.42 57.70 58.94 Weight Per Gallon WPG 8.89 9.19 9.33 9.48 9.45 Volatile Organic Content 5% VOC Reduction! 3.22 3.13 3.10 3.15 3.06 Viscosity (Seconds, #4 EZ Zahn Cup) Directionally Positive 87 90 90 84 91 egman Grind 7 7 7 7 7 Settling Major Benefit NONE NONE NONE EAVY NONE Drying Schedule 30 @500 F 30 @500 F 30 @500 F 30 @500 F 30 @500 F Peak Metal Temperature 410 F 410 F 410 F 410 F 410 F
Black igh Gloss Polyester Melamine Coating Based on Polymac 220-1959 8 Material Use VS1-132-A Control VS1-132-B 10% AT VS1-132-C 15% AT VS1-132-D 15% Barium Sulfate VS1-132-E 20% AT Performance at 0.8 Mil Dry Film Thickness Target DFT 0.8 mil 0.8 mil 0.8 mil 0.8 mil 0.8 mil Dry Film Thickness 0.76 0.83 0.78 0.82 0.84 Gloss 60 DEG Gloss 20 DEG More Solids - Better Dispersion 89.80 51.00 92.90 58.00 94.00 63.40 92.30 55.60 94.10 62.30 Gloss 85 DEG 92.70 95.50 96.60 78.20 96.30 Flexibility Reverse Impact 80 /# Fabrication T-Bend Pencil ardness MEK, 100 DR, NES Color L 26.86 26.71 26.72 26.75 26.49 Color a Jetness Same -0.10-0.10-0.09-0.13-0.04 Color b -0.77-0.76-0.71-0.62-0.69 umidity 1,000 ours 1/64" - 5 1/64" - 2 2/32" - 3 3/32" - 5 3/32" - 3 umidity 1,000 ours - % Gloss Retention 98.40 93.50 92.20 97.70 96.40 Performance at 0.5 Mil Dry Film Thickness Target DFT 0.5 mil 0.5 mil 0.5 mil 0.5 mil 0.5 mil Dry Film Thickness 0.50 0.49 0.53 0.51 0.54 Gloss 60 DEG Gloss 20 DEG More Solids - Better Dispersion 89.50 53.30 89.20 54.30 90.50 51.10 87.30 54.10 91.00 60.20 Gloss 85 DEG 94.00 93.40 95.30 93.60 94.60 Flexibility Reverse Impact - 80 /# Fabrication T-Bend Pencil ardness MEK, 100 DR, NES Color L 26.62 26.37 26.53 26.58 26.30 Color a Jetness Same -0.15-0.02-0.03-0.08-0.13 Color b -0.68-0.67-0.66-0.67-0.46 umidity 1,000 ours 1/64-7 1/64-6 3/32-9 3/32-0 4/32-2 umidity 1,000 ours - % Gloss Retention Major Benefit vs. Precipitated Barium Sulfate 97.50 99.00 96.20 68.70 96.50
ow products differing in specific gravity have significant impact on 9 cost per gallon The specific gravity of ydral Coat 2 Ultrafine AT is 2.42. At the same cost per pound as precipitated barium sulfate, the cost of a gallon of ydral Coat 2 is 46% LESS than the cost of a gallon of precipitated barium sulfate. Since paints are sold on a cost per gallon basis, AT is a much more cost-effective extender than barium sulfate. Specific Gravity Index Cost/Lb Cost/Gal % of Barium Sulfate AT 2.42 1 $ 2.42 54% Barium Sulfate 4.5 1 $ 4.50 100% Coil coating conditions Formulations containing ydral Coat 2 can be used in typical operating conditions where the coating is exposed to high temperatures for approximately 30 seconds. owever, if the exposure is longer, there is a risk of gloss reduction.
10 In Summary uber s ydral Coat 2 Ultrafine AT is designed to extend high gloss coil coatings like the aluminum siding pictured above. The application data shown throughout this piece shows that formulations extended with ydral Coat 2 maintain color and gloss in both white and dark colors and do not deteriorate under extended QUV exposure. This result is not surprising, given the fact that ydral Coat 2 has an ultrafine particle size, a narrow particle size distribution, low oil absorption, is inert and does not decompose under exterior conditions. In black and deep-tone formulations, ydral Coat 2 can be also increase the PVC, increase the mileage (spreading rate per gallon), lower cost and reduce VOCs. uber Engineered Materials is your flame retardant additive expert with over 30 years of experience offering product use guidance and a dedicated technical team for strong customer focus and support. Contact us today and let us consult with you about how ydral Coat 2 can work for you in your coil coatings application. Call: 866-JMUBER (866-564-8237) Click: hubermaterials.com Email: hubermaterials@huber.com uber Engineered Materials expresses its appreciation to PCCR USA, Inc. for their valuable guidance in generating white coil coating data and to Metal Coaters for photographic assistance. TERE ARE NO IMPLIED WARRANTIES OF MERCANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Refer to uber s Standard Conditions of Sale for the only express warranties applicable to the uber products. Products incorporating uber products are not warranted by uber. In no event is uber liable for consequential damages. ydral is used, applied for, or registered as a trademark of uber Specialty ydrates, LLC for alumina trihydrate in various countries around the world. Saturn DigiSizer and SediGraph are registered trademarks of Micromeritics Instrument Corporation. Polymac is a registered trademark of PCCR USA, Inc. Disperbyk and BYK are registered trademarks of BYK-Chemie Gmb. Cymel is a registered trademark of Allnex USA Inc. Nacure is a registered trademark of King Industries, Inc. Butyl Cellosolve is a registered trademark of The Dow Chemical Company. Raven is a registered trademark of the Columbian Chemicals Company. EZ TM is a registered trademark of the Paul N. Gardner Company, Inc. 2014 J.M. uber Corporation FRA/ydralCoat2/April2014