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High Performance Low VOC Coatings for 2006
Final Report Seminar May 9, 2006
John L. Massingill, Jr., Ph.D.
Institute for Environmental and Industrial ScienceTexas State University
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Texas State University
Room 340, Centennial HallTexas State UniversitySan Marcos, TX 78666
512-245-9618 ♦ 512-245-1892 (fax)www.txstate.edu/ieis
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ACKNOWLEDGEMENTS
The author wishes to thank the following for their direct financial support
• California Air Resources Board ICAT • United Soybean Board• Iowa Soybean Promotion Board
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ACKNOWLEDGEMENTSThe author wishes to thank the following for
their in-kind financial support for POLYOL evaluations:
ArkemaPrecision Coatings
Cook Composites and PaintsNiemann & Associates
Rohm & HaasSherwin-Williams
Valspar
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ACKNOWLEDGEMENTSThe author wishes to thank the following for their
technical contributions to the project:
Post-docs:• Yinzhong Guo • John Hardesty• Ananth Iyer• Vijay Mannari• Pulin Patel• Maruf Rahim • Greg Sarnecki
Graduate Students:• Zhigang Chen • Pranav Mathuria• Chirag Shaw• Bin Zhong
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Objectives
• High Performance Alkyd Coatings–Container–General Metal–Wood
• VOC Compliant- target ~100 g/L• Economical• Easy to Produce
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ApproachHYPERBRANCHED POLYOL
Low Mw polymer• Low VOC• Good flow
High crosslink density• Hardness• Solvent resistance
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Hyperbranched Polyols
• High functionality, low viscosity• Lin, et al compared 2 hyperbranched
polyols A2 and P2 in alkyd coatings with traditional alkyd resins – equivalent or better properties at lower
VOC
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P2 PolyolOHHO
OHHOHO
OH
HO
OH
HO
HO
OH HOOH HO
HO
OH
HO
OH
HO
HO
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A2 Polyol
O
OH
OH
O
O
OH
OH
O
OHOH
O
O
OH
OH
O
OHO
O
O
OHOH
O
O
OH
OH
O
HO
OH
O
O
OH
OH
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TxState Approach
• Phosphate Acid Ester–Water dispersible for low VOC–Reacts with metal
•No residual surfactant•Adhesion to metal•Protects metal
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TxState Approach
Soybean Oil Backbone– Renewable resource– Inexpensive– Versatile
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Soybean Oil
O
O
OO
O
O
(9%)
(51%)
(25%)
15% Saturates
Not Shown
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Epoxidized Soybean Oil
Versatile industrial raw material• Co-resin with cycloaliphatic epoxies in
cationic cured epoxy formulations• Acrylate esters used commercially in
UV cured free radical formulations• Converted to the corresponding
glycol by hydrolysis to make a variety of polyols
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Epoxidized Soybean Oil
O
O
O O
O
O
O
O
O
OOO
Mw 950
average about 4.5 functional
15% Saturates
Not Shown
Commercial Product
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O
O
OO
O
OOH
OH
OH
OH
OH
OH
OH
OH
OH
OH
OH
OH
Soy Polyol S1
15% SATURATES
NOT SHOWN
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H+H2O
HC CHO
OHC CH
H
+
HC CHO
H2O
HC CH
OH
O
CH CH
OH
HC CH
OH
OH
H2O
COMPETING REACTIONS
Hydrolysis Oligomerization
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PO
OH
OH
PO
OH
OH
O
O
OO
OO
OH
OH
OH
OH
HO
OHOH
HO
OH
HO
O
O
O
O
O
O
O
O
HO
OH
HO
OH
HO
HO
OH
HO
OOH
OH
Phosphate group-water dispersible- good adhesion to metal
Hydroxyl groups-Crosslinking-adhesion
POLYOL
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KEY FEATURES & BENEFITS
PHOSPHATE GROUPS :
• IMPROVED ADHESION
• CORROSION RESISTANCE
• WATER DISPERSIBILITY
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HYDROXYL GROUPS
KEY FEATURES & BENEFITS
• CROSS-LINKING SITES
•ADHESION TO METAL SUBSTRATE
• ENHANCED COMPATIBILITY WITH WIDE RANGE OF RESINS / SOLVENTS
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ABSENCE OF UNSATURATION
• NON-YELLOWING • UV RESISTANCE
LOW VISCOSITY
• LOW VOC COMPOSITIONS
• GOOD FLOW AND LEVELLING
KEY FEATURES & BENEFITS
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Objective
Investigate Effect of %PO4 on:
• Dispersibility of Soy Polyol
• Salt Fog Resistance of Soy Polyol Coatings
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Goals
POLYOL Hyperbranched Resins with 1%-10% Phosphoric Acid Ester
INVESTIGATE:
• Dispersibility vs. [% PO4 Acid Ester]
• Corrosion Resistance of Coatings
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Experimental• Polyols with 0-32% phosphate substitution
were made. • Alkyd Resin. The conventional linear alkyds,
Beckosol 12-054 (50% solids), 12-021 (60% solids), and 11-045 50% solids, air dry, medium oil) were supplied by Reichhold, Inc. The waterborne alkyd Chempol 810-0432 71% solids, AV=47) was obtained from Atofina.
• Crosslinker. Aminoplast crosslinker Cymel 303 (Cytec) and Resimene 747 (Solutia).
• Substrate. Test panels were B-1000 from Q-Panel, • Cure Conditions. 130-170°C for 15-30 minutes in an
electric forced air oven.
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ExperimentalCoating characteristics and dry film properties
were determined with the following tests: • Dry times determined according to ASTM
D1640-83 using a B-K Drying Recorder• Weight per gallon (ASTM D1475), Non Volatile by
Weight (ASTM D2369), VOC (ASTM D3960-87), Pencil Hardness (ASTM D3363-74), Crosshatch Adhesion (ASTM D3359-90), Impact Resistant (ASTM D2794), and Viscosity (Brookfield viscometer) were also determined.
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Soy Phosphate Stoichiometry
• H3PO4 Mw 98 • ESBO Mw ~ 900
~7% Oxirane ~ 4.2 Epoxies per molecule
%PO4 1 3 8% Sub 3 9 25PO4/Soy 0.15 0.5 1.1
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Effect of Phosphate Ester Content on Resin Dispersibility% PO4
3.5% stable dispersion with amine
>8% dissolved in water with amine (clear solutions)
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Table 1. POLYOL Dispersibility vs. %PO4
%Acid Acid Value Dispersion Characteristics
Clear solution10.0Clear solution698.0
Stable465.04.0
Stable323.53.0
unstable212.5unstable131.0
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Formulation
• POLYOL Replaced Short-oil Alkyd– 0 to 100%
• Varied RESIN/MF ratios–20-50% MF for POLYOL–15-20% MF for short-oil alkyds
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Crosslinking
HMMM crosslinker-low tendency to self-condense, high-solid systems, and long shelf-life
N N
N N(CH2OR)2
N(CH2OHR)2
(ROH2C)2N
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Film Properties Of POLYOL / HMMM Solvent Compositions
POLYOL ALKYD% HMMM 50 40 30 20 18DFT (mils) 1.1 0.9 1.1 1 0.6Pencil Hardness 3H 3H H F 3HImpact (D/R) 80/10 85/10 160/85 140/140 160/130
Adhesion % 35 75 95 85 90MEK DR >200 >200 >200 50 >200
VOC, g/L 200 445
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Commercial Waterborne Alkyd Film Properties
% HMMM 20 15Dry Film Thickness 0.90 0.80Pencil Hardness 2H 2HImpact Resistance 110/30 130/40MEK Double rubs >200 >200Adhesion, % > 95 > 95
140ºC/30 min
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POLYOL CoatingPOLYOL-3.5 Container
Enamel*
Film Appearance -Both Smooth and Glossy--Free from any film defects-
Pencil Hardness H HImpact Resistance 160/100 160/140MEK DR (pass) 50 75Adhesion 4B 4BVOC, lbs/Gal 1.45 2.7
* Commercial product being used
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Effect of Phosphate Ester Contenton Corrosion Resistance
• Crosslinker Higher for POLYOL
– POLYOL (3-8% PO4) 30% HMMM(All Waterborne Formulations)
– Commercial resins 15% HMMM(One Solvent/ One Water Formulation
• Cured at 170 ºC
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Effect of Phosphate Ester Contenton Corrosion Resistance
Theoretically
• More PO4 = better adhesion and corrosion resistance until surface saturated with PO4/POLYOL
• More PO4 would lead to water sensitivity of the coatings
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Effect of Phosphate Ester Contenton Corrosion Resistance
• No corrosion inhibitors were used in this comparison
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SALT FOG CORROSION TEST (ASTM B-117, 96 hrs exposure)
A– Solvent ControlB- Water Control
C- SOPEP-3 D-SOPEP-3.5
E- SOPEP-5 F-SOPEP-8
A
C
B
D
E F
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ConclusionsSoy Phosphate Ester POLYOL
• Film-forming component of waterborne and solvent bake coatings
• Hyperbranched = performance, low VOC• Soy = reduced cost• Percent acid PO4 in POLYOL can be
optimized for good salt fog resistance
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QUV Results• POLYOL3.5 coatings
much better resistance to yellowing and chalking than commercial short oil alkyd
Absence of aromatic acid improves weathering resistance of POLYOL coatings
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Task Results Task 3- Commercial POLYOL Evaluations• Paint company representatives contacted re:
POLYOL sampling and test program
• Cooperating companies performed an initial evaluation of the performance of POLYOL
• Arkema/Cook Composites and Polymers, Precision Coatings, Rohm & Haas, Dunn Edwards, Valspar, Niemann & Associates, Sherwin-Williams, National Ink
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Task Results Task 4-POLYOL Modifications
Modifications made to POLYOL to improve:
• Adhesion
• Compatibility with resins
• Low temperature cure
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Task Results Task 4-POLYOL ModificationsModifications included
– Optimization of phosphoric acid content for adhesion
– Addition of aromatic acids and diacids to the oxirane group to make new resins
– Improvements to the process used to make POLYOL• solventless process for POLYOL validated• solvent process developed for high phosphate,
low viscosity polyol.
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Task Results
Task 6-Verification of POLYOL Performance• Quality and performance of POLYOL verified at
every scale-up operation • Process conditions affect POLYOL viscosity• Formulation properties, VOC levels, curing
properties, and physical properties of paints made from POLYOL were evaluated
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Task ResultsTask 7-Production of Prototype Resin• A prototype alkyd resin made from POLYOL
was produced• POLYOL is a suitable coating binder resin for
many applications. • Reaction of the oxirane group with aromatic
acids prior to hydrolysis to POLYOL was evaluated to make resin
• Process for making low viscosity, highly-branched alkyd resins from POLYOL by addition of aromatic acid
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Task ResultsTask 8-Prototype Paint Development• Prototype paints for metal and wood were
developed• Prototype paints formulated to meet
specifications for specific applications (i.e., drum coatings, wood coatings, direct to metal (DTM) were formulated at the request of the demonstration partners
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Task ResultsTask 15-Precision Coatings Demonstration
• Precision Coatings conducted a test program on commercial containers to demonstrate the feasibility of using coatings made with POLYOL
• A DEMONSTRATION was made on a container production line in the Southern California
• 1.45 lb/Gal VOC (174 g/L)
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Task Results
Task 16-Other Demonstrations• Valspar• Sherwin-Williams• Dunn-Edwards• Rohm-Haas• Cook, Composites, and Paints
Task 17-Data Reduction
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VISCOSITY (40OC) CPs BROOKFIELD VISCOMETER
85501192518450100
116-129116-128116-119RPM
Properties of SOPEP 3.5 Pilot Resins
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Acid value and % Oxirane
0.04104.53116-1290.0182.83116-1280.0155.62116-119
% OxiraneAcid Value, mg
KOH/gm
Sample Code
Properties of SOPEP 3.5 Pilot Resins
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Properties of SOPEP 3.5 Pilot ResinsThe scale-up procedure was supplied by Texas State University
•Oxirane was consistent•Viscosity and Acid number varied with solvent
removal procedure
•Baking 116-119 formulation 10º higher/10 min longer ~ matched properties of lab sample
•5 gallon sample was released to Precision Coatings.
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COMPARISION RESULTS OF THE ARKEMA SAMPLES
643536Salt-fog resistance(B-117/96 hrs.)
0.30.30.30.31.01.0DFT (mil)
4B4B2B1B3B4BAdhesion (cross hatch)
>20015050150>20050MEK double rub
104/28156/128160/136160/112110/30160/100Impact resistance D/R
2HHHH2HHPencil Hardness
Smooth semi gloss
Smooth glossy
Smooth glossy
Smooth glossy
Smooth glossy
Smooth glossy
Film appearance
Control116-129116-128116-119ControlLab
result
SOPEP 3.5LAB result
Properties
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COMPARISION RESULTS OF THE PILOT SAMPLES
Conclusions
Pilot sample has inferior adhesion in 1 mil coatings, comparable for 0.3 mil coatings.
The other physical properties are comparable
Curing the 1.0 mil coatings at higher temperature and longer time gave goodadhesion results.
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DemonstrationPrecision Coatings- Bake Coatings
• Low bake coatings– lab data looked good– <100 g/L VOC
• Precision Coatings – Confirmed Performance in Lab
• SOPEP1.0 confirmed• SOPEP 3.5 confirmed
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Demonstration #1Precision Coatings- Bake Coatings
• Arkema Scale-up POLYOL –10 gallon reactor
–SOPEP1.0• Good in lab tests
–SOPEP3.5• OK in lab tests with adjustments
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Demonstration ProjectPrecision Coatings- Bake Coatings
Precision Scale-up formulation– SOPEP1.0 Good for low VOC
– SOPEP3.5 Low VOCHigh Gloss MEK resistanceAdhesion
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Demonstration Project• Commercial Plant Line
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Demonstration Project
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Demonstration Project
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Demonstration Project
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Demonstration Project
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Demonstration ProjectEvaluation of Containers Off-Line
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Demonstration Project• Coating looked good
–Good gloss–Good flow–Good adhesion–Good MEK resistance–1.45 Lb/Gal VOLC
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Demonstration Project• Coating had some streaks
–Due to poor wetting–Will be corrected by re-formulation
• Precision Coatings Plans to Commercialize POLYOL Based Low VOC Coatings
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Project #2
• Niemann & Associates• Coatings and Adhesives for “Green”Products• Sampled 1.0 and 3.5• Requested Drum Quantities
– Not available for months• Gave NA POLYOL synthesis procedure• Customer Demonstration- canceled
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Project #3Cook, Composites, and Polymers (CCP)Evaluated POLYOL lab sample
• POLYOL evaluated as reactive diluent in high solids polyester baking enamel
• POLYOL drop-in:– reduced yellowing in QUV testing– reduced gloss retention– slower polyester cure
• needed +25ºC higher cure for physicals and salt spray resistance
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Project #4Rohm and Haas- Bake coatingsEvaluated performance of SOPEP1.0
• Tested as low VOC coalescent- did not lower the MFFT of latex
• Tested as as pigment dispersant- not much success
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Project #5
Dunn-Edwards– Air dry Direct-to Metal coatings– No interest in Bake coatings– No interest in 2-K– A 1-K PU formulation was prepared:
• Low MEK resistance (25)
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Project Milestones StatusCommercial Demonstration- done
Precision Coatings
Technology Transfer-Presentations
AOCSWaterborne ConferenceACSFSCT
Publications- 1 Published (JCT, April 2006)2 in progress
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Project Milestones StatusCommercial Demonstration- done
Precision CoatingsCommercial Plant Line