A SUSTAINABLE APPROACH TO MODERN COATING TECHNOLOGY WOOD COATINGS

A SUSTAINABLE APPROACH TO MODERN COATING TECHNOLOGY WOOD COATINGS

A Sustainable Approach to Modern Coating Technology Patcham FZC is a well-established manufacturer of specialty additives headquartered in the United Arab Emirates. Since its inception, Patcham has steadily grown into a leading supplier of specialty additives for the Paint & Coatings, Ink, PVC and Composite industries. The company s Pat-Add range of coating additives includes wetting & dispersing agents, defoamers, slip & leveling agents, rheology modifiers. Whilst keeping focus on environmental sustainability, the company produces products using green raw materials that are APEO free and have low or no VOC. These products are multi functional and multi compatible, which simplifies the production process, reduces the chance of errors and minimizes inventory thus improving cost effectiveness. Patcham has built a strong manufacturing and R&D infrastructure that enables the rapid transition from concept to products. The company has strategically located technical service laboratories, offices and representatives around the world to provide the most efficient customer service. In addition, a well-developed robust supply chain network enables it to deliver its products and services to customers around the globe with minimal lead-time.

Contents Introduction 1 Wood coat sealer and primer Waterborne sealer Solventborne sealer 3 5 Wood coat clear Waterborne clear Solventborne glossy and matt clear 8 9 Pigment concentrates / stain for wood coating Waterborne stain / pigment concentrate Solventborne stain / pigment concentrate 13 14

Introduction The main challenges involved in the development of wood coatings are poor substrate wetting, presence of air bubbles, insufficient leveling and pigment settling. The latter is attributed to primers and sealers with high pigmentations. To achieve flawless finishes, the coating should provide excellent substrate wetting and leveling, low foam, surface slip property, mar resistance, soft feel and surface smoothness. Patcham offers a line of additives that help customers to address the above challenges and provide best possible solutions. Patcham products allow coating formulators to develop aesthetic as well as durable wood finishes. Wood coating system Wood substrate Sanding with emery paper and cleaning of substrate Application of wood stain Application of 2 to 3 coats of wood sealer Sanding with emery paper Apply 2 coats of wood coat glossy/matt clear. Figure 1: Schematic representation of wood coating system 1

Woodcoat sealer and primer Due to the porous nature of wood it has to be properly sealed with sealer or primers. Primers pose challenges for sealing due to incorporation of air bubbles during the grinding stage. Patcham defoamers prevent the formation of micro/macro foam during manufacturing and application of wood coating sealers. Patcham has a line of defoamers for various types of wood sealer applications. Purpose of sealer To fill the grains in wood To get uniform coverage To get uniform color by reducing blotching Figure 2: Role of sealer in wood coatings Waterborne sealer Patcham offers a package of additives for waterborne wood coat sealers which includes wetting and dispersing agent, defoamer, coalescing agent and rheology/sag control agent. Table 1: Patcham additives for waterborne sealer Additive Pat-Add AF 34 Waterborne wood coat sealer Features Specially designed polysiloxane based defoamer to prevent micro and macro foams with excellent balance, foam control and compatibility Dosage on total formulation (%) 0.01-0.4 Grinding/Letdown Pat-Add DA 603 Wetting and dispersing agent for pigments and fillers; enables high filler loading, provides optimum viscosity and long term stability to the sealer. 0.5-2.0 Grinding stage Pat-Add Rheol 99/100 PU associative thickener provides best rate of viscosity regain with sufficient flow and finish. Avoids viscosity loss on tinting and exhibits good anti-settling properties 0.4-2.0 Grinding/Letdown 2

Woodcoat sealer and primer - Waterborne sealer Patcham additives have wide compatibility with waterborne 2K PU, PUD, acrylics and other waterborne resin systems. Pat-Add AF 34 is an oil and VOC free defoamer used in waterborne wood, plastic and industrial coatings Pat-Add DA 603 is a specially designed wetting and dispersing agent for all kinds of pigments, extenders, fillers and sanding aids. It also contributes to less foam generation during wetting and provides stability to the dispersion Pat-Add Rheol 99/100 is a PU associative rheology modifier with balanced rheology profile maintaining mid and high shear viscosity Table 2: Formulation of waterborne acrylic sealer Formulation of WB acrylic sanding sealer Raw materials Weight (%) Water HEC ph Regulator Pat-Add DA 603 Pat-Add AF 34 Propylene glycol Biocide Talc Zinc stearate dispersion (50% solution) Letdown Acrylic resin Pat-Add Rheol 99 Coalescing agent Total 9.10 0.40 0.30 0.50 0.10 6.50 0.30 5.00 16.00 60.00 0.30 1.50 3

Woodcoat sealer and primer - Waterborne sealer Pat-Add AF 34 is an efficient defoamer for sealer application as shown in Figure 3 by roller application test. This is further supported by the density cup test which also shows that sealer with Pat-Add AF 34 has more density than reference, indicating less foam inclusion in the sealer. Reference Pat-Add AF 34 Figure 3: Foam test by roller application Density test of WB acrylic sealer 1.05 1.03 Density g/i 1 0.95 0.9 0.88 0.85 0.8 Blank Pat-Add AF 34 Figure 4: Density test to study the defoaming efficiency of Pat-Add AF 34 Pat-Add DA 603 provides excellent wetting and dispersion of extenders and sanding aids that gives optimum viscosity and long term stability to the sealer. Pat-Add Rheol 99 further optimises viscosity, anti sagging property and therefore prevents settling of heavy pigments in the system. The flow behavior of the sealer is shown in Figure 5. Before incubation After incubation @ 50 0 C Figure 5: Stability of waterborne acrylic sealer with Pat-Add additives 4

Woodcoat sealer and primer - Solventborne sealer The package of Patcham additives for solventborne wood coating provides effective wetting and dispersion of fillers, extenders and sanding aids; efficient defoaming properties during manufacturing and application; excellent leveling, substrate wetting of wood and excellent stability for the sealer. Table 3: Patcham additives for solventborne sealer Solventborne wood coat sealer Additive Pat-Add AF 62 Features Silicone free, polymeric defoamer for both clear and pigmented systems. Suitable for all kinds of SB resin systems Dosage on total formulation (%) 0.05-0.4 Grinding/Letdown Pat-Add DA 1801 Effective wetting and dispersing agent for sanding aids, matting agents, extenders and pigments. 0.2-1.5 Grinding stage Pat-Add LE 1020 Polyether modified polysiloxane surface modifier improves substrate wetting and matting agent orientations 0.05-1.0 Grinding/Letdown Pat-Add AF 62 is an efficient deairing and defoaming agent for solventborne coatings and suitable for various types of applications like brushing, spraying, airless spraying, roller and curtain coating Pat-Add DA 1801 is an effective wetting and dispersing agent for zinc stearate, extenders and fillers which effectively reduces the viscosity and enhances the stability of dispersion. It also provides wetting of wood substrates and releases the air trapped in the pores Pat-Add LE 1020 aids flow, leveling, slip and mar resistance for wood coatings. It also supports the wetting of wood substrate and enhances the orientation of fillers and matting agents The package has good compatibility with PU, Acrylic, Polyester melamine, acid catalyst and other solventborne resin systems. 5

Woodcoat sealer and primer - Solventborne sealer Table 4: Formulation of solventborne 2K PU sealer 2K PU sealer for wood coating Raw materials Weight (%) Part A Acrylic polyol (50%) Pat-Add DA 1801 Zinc stearate Butyl acetate Pat-Add LE 1020 Pat-Add AF 62 Xylene Butyl acetate Part B Aliphatic polyisocyanate Mixing ratio (w/w) Total 70.00 0.30 6.00 10.00 0.10 0.30 7.40 5.80 6.00 100:6 Reference Pat-Add additives Figure 6: Effectiveness of Pat-Add additive package in 2K PU sealer 6

Wood coat clear - Waterborne clear The clear coats for wood should provide proper leveling, smooth surface, slip property, scratch, chemical and UV resistance. Patcham offers a package of additives to achieve exceptional properties for clear coats that includes wetting and dispersing agent (if dispersion of pigments are required), defoamers and leveling agents. These additives are compatible with PU, Epoxy, Polyester-melamine, TPA and acid catalyzed systems to provide superior performance. Waterborne additive package for wood coat clear The package of Pat-Add additives for waterborne wood coating include leveling agents, defoamer and rheology modifier. Table 5: Patcham additives for waterborne wood coating Waterborne wood coat clear Additive Pat-Add LE 1030 Pat-Add LE 1040 Pat-Add Rheol 99/100 Pat-Add AF 31 Pat-Add AF 32 Features Polyether modified polysiloxane enhances flow and leveling, substrate wetting and supports air release from the system Provides flow, leveling, slip and mar resistance. Contributes to orientation of matting agents and metallic pigments PU associative thickener. Provides balanced flow and sag properties. Avoids viscosity loss on tinting and exhibits good anti-settling properties Oil free, easily dispersible defoamer for clear and low pigmented WB resin systems with no adverse effects Specially designed polysiloxane, oil and VOC free defoamer for versatile applications compatibile with all WB resin systems Dosage on total formulation (%) 0.05-0.4 Letdown stage 0.05-1.0 Letdown stage 0.4-2.0 Letdown stage 0.01-0.4 Letdown stage 0.01-0.4 Letdown stage Pat-Add LE s additives provide excellent flow, leveling, perfect DOI, gloss and substrate wetting Pat-Add AF 32 eliminates foams during processing and application Pat-Add Rheol 99/100 improves flow and anti sag properties of the paint systems 7

Wood coat clear - Waterborne clear Table 6: Formulation of waterborne 1K PU clear Waterborne 1K PU clear Raw materials Polyurethane dispersion Polyacrylate dispersion Dipropylene glycol methyl ether (DPM) Butyl diglycol (BDG) Pat-Add Rheol 99 Pat-Add LE 1030 Pat-Add AF 31 Water Total Weight (%) 26.00 66.00 2.50 2.50 0.50 0.30 0.10 2.10 Table 7: Formulation of waterborne 2K PU clearcoat Figure 7: Wetting of substrate with Pat-Add LE 1030 Waterborne 2K PU clear Raw materials Weight (%) Part A Hydroxy polyacrylic dispersion Pat-Add AF 32 Pat-Add LE 1030 Pat-Add Rheol 99 Water Part B Aliphatic polyisocyanate MPA Total 60.00 0.06 0.10 0.25 21.54 12.50 5.55 Figure 8: Illustrating the DOI and gloss of 2K WB PU clear 8

Wood coat clear - Solventborne glossy and matt clear Table 8: Patcham additive for solventborne wood clear Solventborne wood coat glossy and matt clear Additive Pat-Add DA 1801 Pat-Add AF 62 Features Wetting and dispersing agent for matting agents and other pigments. Provides stabilization to the pigments Silicone free defoamer for both glossy and matt systems. Suitable for all kinds of SB resin systems Dosage on total formulation (%) 0.2-1.5 Grinding stage 0.5-0.4 Grinding/Letdown Pat-Add LE 1020 Pat-Add LE 1477 Pat-Add FL 7 Pat-Add SL 1120 Polyether modified polysiloxane surface modifier improves substrate wetting and matting agent orientations Fluoro based leveling agent for efficient surface tension reduction with no adverse effects. Suitable for water repellent coatings Polyacrylate surface modifier for excellent flow and leveling and no influence on recoatability and intercoat adhesion. Suitable for all SB systems. Provides slip, mar resistance and contributes to perfect leveling 0.05-1.0 Letdown stage 0.05-1.0 Letdown stage 0.4-2.0 Letdown stage 0.05-1.0 Letdown stage Pat-Add DA 1801 is used for the dispersion of pigments and matting agents to have a uniform film. It promotes the orientation of matting agents and stabilizes the pigments Pat-Add AF 62 defoamer provides optimal balance between defoaming efficiency and compatibility with the coating Pat-Add Leveling agents are multifuctional additives and they contribute as follows: Excellent leveling and substrate wetting Slip and mar resistance properties Offer better orientation of matting agents Provides soft feel effect Contributes to air releasing properties Lower the coefficient of friction Gives exceptional DOI No adverse effect on dry film 9

Wood coat clear - Solventborne glossy and matt clear The formulation based on Patcham additives in 2K PU clear are shown below in Tables 9 and 10. Table 9: Formulation of 2K PU glossy clear Table 10: Formulation of 2K PU matt clear 2K PU wood coat glossy clear 2K PU wood coat matt clear Raw materials Weight (%) Raw materials Weight (%) Part A Part A Acrylic polyol (60%) 75.00 Acrylic polyol (60%) 75.00 CAB solution (20%) 1.00 CAB solution (20%) 1.00 Pat-Add LE 1477 / LE 1020 0.20 Pat-Add DA 1801 0.20 Pat-Add AF 62 0.50 Pat-Add LE 1477 / LE 1020 0.20 PU solvent 16.35 Pat-Add AF 62 0.50 Ethyl 3-ethoxypropionate solvent 6.95 PU solvent 7.00 Total Matting agent 4.00 Part B PU solvent 5.35 Aliphatic polyisocyanate 18.00 Ethyl 3-ethoxypropionate solvent 6.95 Total Part B Aliphatic polyisocyanate 18.00 Water beading test for 2K PU clear clearly shows that Pat-Add LE 1477 surface modifier based clear coat repels water droplet better than the reference. This is evident by looking at the shape of the droplet on the surface. Lower coefficient of friction value shows that Pat-Add LE 1477 has better slip properties than the reference. Figure 9: Water beading test on wood coat 2K PU clear 10

Wood coat clear - Solventborne glossy and matt clear 0.39 0.38 Coefficient of friction 0.38 0.37 COF 0.36 0.35 0.34 0.33 0.33 0.32 0.31 0.3 Pat-Add LE Reference Figure 10: Coefficient of friction for 2K PU clear Guideline formulation of acid catalyzed wood clear with Pat-Add additives are shown in Tables 11 and 12. Table 11: Formulation of acid catalyzed wood coat glossy clear Table 12: Formulation of acid catalyzed wood coat matt clear Acid catalyzed wood coat glossy clear Acid catalyzed wood coat matt clear Raw materials Weight (%) Raw materials Weight (%) Part A Short oil alkyd Urea formaldehyde Melamine formaldehyde Xylene Pat-Add LE 1477 / LE 1020 Pat-Add AF 62 Toluene n-butyl alcohol Solvesso 100 Total Part B PTSA (40% solution in butanol) 33.00 26.00 2.20 14.70 0.20 0.20 8.00 5.50 10.20 4.00 Part A Short oil alkyd Urea formaldehyde Melamine formaldehyde Xylene Pat-Add DA 1801 Pat-Add LE 1477 / LE 1020 Pat-Add AF 62 Matting agent Solvesso 100 n-butyl alcohol Toluene Xylene 33.00 26.00 2.20 8.70 0.20 0.20 0.20 4.00 10.20 5.00 8.00 2.30 Total Part B PTSA (40% solution in butanol) 4.00 11

Wood coat clear - Solventborne glossy and matt clear 8 7 Defoaming time 7 Time (min) 6 5 4 5 3 3 2 1 0 Pat-Add LE 1020 Pat-Add LE 1477 Reference Figure 11: Defoaming property of leveling agents in acid catalyzed glossy clear The air releasing property of Pat-Add LE 1020 and LE 1477 are illustrated in Figure 11. Pat-Add LE 1477 shows stronger efficiency in air releasing properties than the reference. Pat-Add LE 1020 also supports the orientation of matting agents in the wood coating systems and the panels are shown below. Figure 12: Representing orientation of matting agents in acid catalyzed system 12

Pigment concentrates/stain for wood coating Stain creates a rich, deep color that highlights the natural wood grain and enhances the aesthetics of a wood coating. Highly loaded pigment concentrates and stains can be used to provide desired color for wood coating. Waterborne stain and pigment concentrates for wood coating Pat-Add DA 603 is a robust dispersing and wetting additive for various types of pigments. The additive enables high pigment loading and stabilizes the pigment dispersion whilst being compatible with all types of WB resins. Table 13: Patcham additive for waterborne colorants System Additive Features Dosage (%) WB Pigment concentrates/stain for wood coating Pat-Add DA 603 Pat-Add AF 34 Versatile wetting and dispersing agent suitable for pigment concentrates of organic, inorganic, black pigments and compatible with all WB resins. Specially designed polysiloxane based defoamer prevents micro and macro foams with the excellent balance foam control and compatibility with WB resins White pigment : 1-5 Carbon black : 30-200 Inorganic pigments : 10-20 Organic pigments : 30-70 On SOP (Grinding stage) 0.05-0.4 Grinding/Letdown On total formulation Table 14: Formulation of waterborne wood stain Rubine red PR 254 DPP orange PO 73 Yellow PY 110 Waterborne wood stain Raw materials Weight (%) Styrene acrylic emulsion Water ph regulator Pat-Add DA 603 Transparent red iron oxide Fumed silica Pat-Add AF 34 Total 60.00 33.25 1.00 0.40 5.00 0.30 0.05 Figure 13: Flow behavior of waterborne colorant for wood coating Figure 14: DOI and gloss of wood panel coated with 2K PU clear with Pat-Add DA 603 based colorant 13

Pigment concentrates/stain for wood coating Solventborne wood stain and pigment concentrates Table 15: Patcham additive for solventborne colorants SB pigment concentrates/stain for wood coating Additive Features Dosage on SOP (%) Pat-Add DA 932 High Molar Volume technology polymeric dispersing agent for all kind of carbon blacks, organic and inorganic pigments. Enables high loading of pigment concentrates and supports stabilization of pigments White pigment : 1-5 Carbon black : 30-120 Inorganic pigments : 10-20 Organic pigments : 30-70 Grinding stage Table 16: Formulation of solventborne resin free pigment concentrate Raw materials Pat-Add DA 932 Pigment Xylene : MPA (1:1) Xylene : MPA (1:1) Solventborne resin free pigment concentrates TiO PY 74 PR 170 PR 101 PB 15:3 2 22.00 60.00 16.00 2.00 9.00 26.00 50.00 15.00 Mill base 21.27 20.00 20.00 Letdown 38.73 15.00 40.00 25.00 20.00 36.50 20.00 20.00 23.50 Carbon black 38.20 18.00 41.00 2.80 Total SB resin free pigment concentrates for wood coating Figure 15: Flow behavior of resin free pigment concentrates Figure 16: Wood panel coated with stain and 2K PU clear shows excellent gloss and DOI 14

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PATCHAM (FZC) P.O. Box: 7753, Saif Zone, Sharjah, UAE Tel: +971-6-5570035 Fax: +971-6-5570038 Email: patcham@emirates.net.ae PATCHAM INDIA B-52, Pravasi Industrial Estate Vishweshwar Nagar, Off Aarey Road Goregoan (E), Mumbai - 400 063 (India) Tel: +91-22-29272471 Email: india@patchamltd.com PATCHAM EUROPE BV Klavermaten 65-1 7472 DD Goor Netherlands Email: eu@patchamltd.com PATCHAM USA LLC 10 Commerce Road Fairfield, New Jersey 07004 Tel: (201) 293-4282 Fax: (201) 820-0818 Email: info@patchamusa.com The information given in this booklet is intended for technical guidance without obligation. Ver. 1.0