2024 Agenda

Surfactants and Rheology: Chemistry, Theory, Mechanism and Application

This short course initially reviews the various types and chemical structures of commercially available surfactants. We then dive into an understanding of the role of inter-atomic and inter-molecular attractive forces as it relates to surface tension. The course progresses to a better understanding of various surface activities including surface area, surface tension, surface pressure, wetting, surface transport, and micelle formation. We will explore the world of foam with respect to how surface-active agents stabilize and de-stabilize bubbles at the surface or as entrained air. Finally, a review of surfactants as an aid to the dispersion process and the measurements of surface tension in both static and dynamic conditions.

The second part reviews the basic principles of rheology, including its definition and its influencers  chemical structure, morphology, and environmental conditions. The impact by various deformation forces, including compression, tension, torque, and, particularly, shear will be reviewed to demonstrate the resulting flow profiles of viscosity as a function of shear and time. The chemistry and ancestry of current rheological agents will help clarify the appropriate selection of products for various formulation types including waterborne, solventborne, aliphatic, aromatic, and polar systems.

While targeted to formulating chemists, this course is also well suited for marketing, sales, and production personnel. Managers and supervisors would also benefit by having a better understanding, and appreciation, of the important role surfactants and rheology play to the production, storage, transport, and application of quality paints and coatings.

Instructor

Powder Coating Fundamentals

This abbreviated version of the popular “PC Kitchen” course will introduce new formulators, chemists, and customer-facing personnel to the basics of powder coating. The presenters will discuss how powder coatings are formulated (resin/crosslinker selection, pigments, and additives), important processing details (premixing, extrusion, grinding, and particle classification), and laboratory test methods that are commonly used to evaluate powder coatings for performance. Participants will also be given a brief overview of where powder coatings are used, as well as their benefits and drawbacks compared to liquid coating technologies.

Instructors

Rheological Additives in Latex Paint Formulations: How to Select Them and Adjust Viscosity to Obtain the Best Workability and Stability

A practical guide to rheological additives in latex paints, including cellulose ethers, clays, HEUR, and HASE/ASE thickeners. Step-by-step discussion of the selection of rheological additives based on research procedures, taking into account obtaining initial viscosity, and stabilizing viscosity over time, including storage stability, tintability as tint viscosity stability, as well as viscosity in the entire area of shear forces (Brookfield, Stormer, ICI-CAP), with attention to secondary rheological properties such as brush/roller drag, spattering, sagging, leveling.

Instructor

Resolving Resin and Coating Defects

This course will cover coatings resins; resin chemistries and selection; different curing mechanisms [including oxidative cure, two-component, energy cure (UV and baking) and coalescence]; and common coatings defects (what they are, what causes them and how to cure them). The course is intended for beginner to intermediate chemists.

Instructor

Water-Based Polyester Polyol Dispersion for VOC-Compliant, Ambient-Cure Polyurethane Floor Coatings

This study aimed to broaden our understanding of our new water-based polyester polyol dispersion for VOC-compliant, two-component (2K) waterborne (WB) ambient-cure polyurethane coatings, responding to the dynamic demands of the floor coating industry. We examined new exterior starting point formulations, emphasizing the inclusion of light stabilizer additives to enhance durability in UV and weatherability testing. Our research ventured into assessing these coatings' efficacy on bare concrete and over epoxy primers, including evaluations for hot tire pickup and resistance to hydrocarbons such as Skydrol and motor oil.

The investigation extended to experimenting with different isocyanate types, varied A:B ratios, catalysts, and additional additives to fine-tune performance attributes, pot life, and drying times. We also focused on optimizing the surface quality of the coatings by achieving improved leveling to eliminate occurrence of crater and foam defects. Additionally, this work allowed for exploring dry film thickness (DFT) limitations, multicoat layering, and recoatability aspects.

To highlight our competitive advantages, we set new benchmarks by comparing our formulations against leading industry standards, including 2K polyurethane dispersions (PUDs), various polyaspartic coatings, and other high-performance floor coatings. Finally, we showcased the practical application of WB 2K PU coatings derived from our novel polyester dispersion in real-world scenarios. These included applying clear, matte, and pigmented paint to a range of floor types: a previously coated garage floor, a stained interior wood floor, and a direct-to-concrete plant floor. In so doing, we demonstrated the coatings’ ease of application, versatility, and performance in situ.

Speaker

Ceramic Microspheres for Epoxy Formulations with Improved Flow and Abrasion Resistance

will discuss the use of solid ceramic microspheres in 2K epoxy formulations. Because of their almost spherical shape and good packing, the microsphere fillers included in the study improved flow of the epoxy system, which make it adequate for flooring applications. Consequently, these functional fillers allow for the development of lower-cost formulations still with good appearance. Conversely, higher filler levels can be used, resulting in still lower cost per volume, while keeping current performance characteristics. In addition, tests have shown that the solid aluminosilicate microspheres help improve the abrasion resistance of these formulations, compared to other fillers.

Speaker

AI - Where It Can (and Can't) Give You a Competitive Edge in R&D

We are in the middle of an AI boom, with new advances constantly being made in the field. But how can R&D teams take advantages of these developments? In this talk, learn where AI can make a difference today, where it might not be ready, and how you can best prepare your organization to utilize AI over the coming decade.

Speaker

New surface appearance measurements to match consumer perception

For many decades, the visual perception of surfaces has been an important research topic. Newest studies found that the human vision system subconsciously considers multiple visual cues when judging or comparing surfaces. This company’s technology adopts a similar approach – capturing multiple surface images that represent the optical characteristics of the surface modified for different viewing conditions. Internal software uses state-of-the-art perception algorithms to calculate parameters that predict the human visual response to important surface characteristics. NEW measurement parameters to determine the perfect surface finish, exactly as your eye sees it.

Speaker

The Green Monster: Baseball Lessons in Carbon Economics and High-Speed Powder Coil Coating

In the face of global decarbonization efforts, industries are urgently seeking innovative solutions to achieve net-zero carbon goals while maintaining product quality and performance. This challenge is especially prominent in the manufacturing sector, particularly in the use of materials like steel and aluminum, which are essential in various consumer products. This presentation will describe a technology that uses advanced powder coatings in a continuous, high-speed process, enhancing the performance, durability, and corrosion resistance of coated materials.

Speaker

Deploying AI and DOE in Real-Time at the Bench

AI and AI-driven DOE are finally being used in real-time at the bench by chemists and materials scientists, creating a dramatic leap forward from a productivity perspective. In this presentation you will be able to see and hear how you can:

• Explore your problem space holistically, while still creating the most efficient test plans possible.
• Leverage formulation recommendations with high predictive accuracy of technical and functional performance targets.
• Do all this without a statistics or data science degree. Once deployed, the business benefits of AI are tremendous. It is reducing product development timelines, increasing market responsiveness, and accelerating time to revenue. The presentation will conclude with two case studies, so you can see examples of actual problems and how they were addressed.

Speaker

Optimizing the Air-Liquid Interface of Waterborne Coatings

Interfacial interactions between air and coatings formulations can create manufacturing challenges and compromise the performance of the coating through surface defects. Interactions with the air can lead to the formation of flaws in the surface such as poor wetting, cracking, bubbles, craters, orange peel, fish eyes, blistering, voids, pinholes, or uneven coating layers. These defects reduce the quality of the coating application, cosmetically or more substantially, and can negatively impact the overall performance of the coating. This presentation will discuss air entrapment and its stabilization within coatings due to unfavorable air/liquid interactions during production and application.

Defoamers are essential tools in addressing foam-related issues at the air/liquid interface in coating formulations. Defoaming additives used to correct these issues by breaking down or preventing the formation of bubbles will be examined, along with potential repercussions of under or overuse. Achieving the right balance is crucial to maintaining the desired coating properties without introducing unintended side effects. Guidelines for selecting the appropriate chemistry, dosage, and point of addition will be reviewed with the goal of creating ideal defoaming for production, storage, application, and film formation without creating surface defects. Finally, current compliance challenges for defoamers in different coating markets will be discussed along with green formulation strategies and additives that meet these challenges, some with substantial bio-based renewable content or other sustainability benefits.

Speaker

Rapid Reformulation of APEO Containing Surfactants Using AI-Guided Techniques

To meet ever-shifting market, customer, and supply demands, leaders in the coatings industry have adopted artificial intelligence to accelerate formulations development. Historically, intuition-based knowledge has been a key element of R&D in new coatings development. Through AI-driven development, historical data alongside expert domain knowledge is captured, preserved, and deployed in the service of accelerated new product development.

In this presentation, we discuss the core concepts enabling the successful deployment of AI to coatings problems. We provide an example of the application to address a common coatings reformulation problem: removing harmful materials. In this case, removing outdated surfactants to achieve regulatory compliance while maintaining product performance in solution and on application.

Speaker

Who Needs Liquid Paint? Re-Inventing Surface Protection

There is growing concern in some companies about the high cost of maintaining the paint spray booth lines that are an integral part of their operations. Not only do spray booths consume lots of energy, but they must comply with strict environmental regulations for ventilation and worker exposure to harmful fumes and materials. As paint film technology has improved in performance and sustainability has become more of a focus in manufacturing operations, performance films are beginning to present a viable alternative to liquid paint. In this talk, we will discuss the evolution of paint film technology, the emerging trend of replacing films for liquid paint, and the potential impact on the coatings industry.

Speaker

The Dirt Pick-Up Resistance Battle

The exterior appearance of residential and commercial buildings has great importance to owners and property managers in influencing first impressions. However, airborne contaminants from pollution, and vehicle emissions that dirty the exterior are especially problematic in industrial and densely populated areas.

Dirt pick-up resistance (DPUR) is the ability of a coating to resist discoloration due to the deposition of particles from the environment. Companies dedicate a great deal of resources developing accelerated tests that simulate the real world, sometimes using blends of dirt and ash that are found in areas where the coating will be applied. Polymers that exhibit excellent dirt pick-up resistance, while maintaining other properties that are important for exterior coatings, such as flexibility and adhesion are in demand.

In this presentation we will discuss the testing and results of a polymer for exterior coatings with excellent performance.

Speaker

Measuring the Mass and Diameter of Pigment Particles - Towards a Universal Size Standard

The size of a pigment particle is a relevant parameter for the producers, consumers, and regulators. The broad range of particle shapes and optical properties poses a challenge for most particle sizing techniques. Ultimately, only electron microscopy imaging can detect any pigment material, but its application is limited by its high cost, low throughput and only provides a 2D-image.

A newly developed measurement instrument allows us to detect number-weighted distributions of the particle mass and diameter in less than 15 minutes. The particle mass is a fundamental and intrinsic property of a particle and, therefore, doesn’t require the assumption of spherical particle shape. The measurement concept does not rely on optical particle detection and is independent of material refractive indices. This makes the particle mass ideal to become a standard reference for the size of a particle. In combination with a diameter determination, the new instrument gives insights into the effective particle packing density and other structural parameters. For example, a typical iron red pigment has a median mass of 31 fg (10^-15 g) and a diameter of 274 nm. The resulting particle density of 2.9 g/cc indicates that the material consists of aggregated particles with a significant pore volume and not densely packed spherical particles (cf. true material density of Iron(III)-oxide is 5.2 g/cc).

From a number-weighted mass distribution, the total number of particles per gram ( e.g. 10^13 particles/gram) can be obtained. By simultaneously detecting the particle diameter, the nanoparticle content cannot only be expressed by a number-percentage but also by its absolute content (10^12 nanoparticles/gram versus 10% by number).

We deployed this analytical technique to investigate the mechanical stability of coated titanium dioxides. With increasing dispersion intensity, an increasing amount of the coating material is sheared off from the core particle. Firstly, this reduces the pigment performance in its final application and secondly, a majority of the released particles are nanoparticles. Total amounts of more than 1013 nanoparticles per gram were recorded. Similar observations were made for other coated pigments as well.

In coordination with the conference organizers, we will present data for titanium dioxide or colour pigments. Further we focus on the instrument as a potential size standard and/or on the regulatory implications of the release of nanoparticles.

Speaker

Bio-Hybrid Epoxy Diluent - Alternative to Nonylphenol

Nonylphenol is under increased environmental regulation due to its hazardous nature as a toxic endocrine disruptor and its persistence in aquatic environments. Specifically, nonylphenol has recently been subject to increased EPA regulations in the United States, and has been banned in the European Union, Canada, and various other countries. This study introduces the development of a new bio-hybrid resin that functionally replaces nonylphenol in 2K epoxy systems as an accelerator, plasticizer, and viscosity reducer. This bio-hybrid resin reduces both the gel time and the dry through time of epoxy by 25%. Testing was conducted on finished epoxy coatings formulated with this novel resin to assess the resin’s effect on flexibility, hardness, adhesion, impact resistance, and chemical resistance. This non-toxic epoxy additive is a light color, low-VOC alternative to circumvent current and future nonylphenol regulatory challenges in the coatings industry.

Speaker

Sustainability Trends in Epoxy Systems for Coatings

The first lab experiment to react epichlorohydrin (ECH) with Bisphenol-A (BPA) is recorded in Dr. Sylvan Greenlee’s laboratory notebook dated Dec. 12, 1942. Fast-forward more than 80 years and we find that epoxy systems (resins + curing agents) have become a preferred thermosetting technology for coatings that protect planes, bridges, automobiles, and even wind generation farms. Recognizing the need to address global climate change, raw material suppliers are developing new products and processes for epoxy systems. This presentation will describe several active developments that will enhance the overall sustainability of epoxy resin systems.

Speaker

A Bespoke, Non-Additive Approach to Anti-Microbial Coatings

Anti-microbials were brought to the forefront of the paint and coatings industry during the global pandemic, with several new products brought to market. The pandemic increased our awareness of the danger of the pathogens around us, but even now that the world is recovering, a demand and a need for anti-microbial materials remains. For example, it is critical to reduce the risk of disease transmission in high-risk areas like healthcare and food-processing facilities.

However, innovation in the world of anti-microbials is slow. Traditional anti-microbials are additives  coating manufacturers purchase the additive and mix it into their product, and the anti-microbial activity results from the controlled release of the ingredient from the coating. While this has the advantage of simplicity, increasing regulatory demands and the trend towards sustainability are making the application of these additives less and less acceptable.

We present a bespoke, non-additive approach to anti-microbials, utilizing well-known anti-microbial metals but in a unique composite system. The active ingredient is synthesized within the resin, resulting in the formation of a chemical bond between the polymer and the metal. This produces an anti-microbial polymer that is completely non-leaching, which means it is long-lasting, sustainable, and safe.

This process can be applied to a range of different polymer types including polyurethanes, acrylates, and epoxies, which means that bespoke anti-microbial solutions can be produced for a variety of coating systems. In addition to the longevity and sustainability advantages of the technology, creating a bespoke anti-microbial coating system removes issues with compatibility, it can be seamlessly integrated into existing manufacturing processes, and it has significant cost savings compared to traditional anti-microbial additives.

Speaker

Plant-Based, Sustainable Propanediol as a Monomer Component in a Hybrid Powder Coating Applications

A hybrid epoxy polyester formulation for indoor white glossy powder coating used typically for appliances and white goods was chosen to evaluate. Two carboxy functional saturated polyesters were synthesized, a standard carboxy functional saturated polyester containing both ethylene glycol (EG) and 1,6-Hexanediol (1,6-HDO) and a polyester that replaced both polyols (EG and 1,6-HDO) with bio-based1,3-propanediol. The carboxy functional saturated polyesters with a type 3 epoxy resin in a hybrid powder coat for interior application. Properties of the two systems were compared.

The replacement of EG and 1,6-HDO with 1,3-propanediol (PDO) simplified the polyester synthesis, removed a toxic substance (EG), replaced a solid material (1,6-HDO) with a liquid (PDO) resulting in carboxy polyester system with 13% bio-content without significantly changing the raw material cost. The experimental white glossy powder coating showed excellent mechanical properties and had very similar properties to the standard hybrid powder coating containing both EG and 1,6-HDO with one exception. There a a visible improvement in the dark yellowing of the PDO-based system.

This project illustrated that the replacement of petroleum-based polyols with a renewable polyol is possible without impacting the performance of a white glossy hybrid powder coating while making the formulation easier to synthesize and more environmentally appealing.

Speaker

Biodegradable Chitin Nanowhisker: Sustainable Reinforcing Nanofiller and Additive for the Epoxy and Coatings Industry

Molecular dynamics is a better way to control the flow properties of any material, both at the molecular and nano levels, specifically if the source is bio-based. Nano-sized fillers are recognized as significant and promising additives for enhancing the physical and mechanical properties of any polymer matrix. Organic-based nano-sized fillers are a burgeoning field of research and a rapidly expanding technology sector in a wide variety of application domains. Transitioning from micro- to nano-fillers leads to superior reinforcement in nanocomposites, requiring significantly less filler material compared to their conventionally sized counterparts. Among all these organic nanofillers, chitin gained much attention due to high abundance, complete biodegradation, non-toxic behavior, and adequate intrinsic mechanical properties compared to other filler systems. With controlled synthetic approach, we were able to separate the intrinsic crystalline domains into higher and lower grade qualitatively, exhibiting different properties. Our initial studies were focused on exploring the potential of high crystalline structure, referred as chitin nanowhiskers (CNWs) to improve the thermal and mechanical properties of various grades of epoxy resin.

Our studies demonstrated the promise of CNWs as a sustainable and effective reinforcement for epoxy, highlighting their potential for various applications requiring enhanced material properties. Undergoing collaborative and inhouse research offered better insight towards the CNW optimizing dispersion techniques and the impact of functionalized CNWs on the nanocomposite's performance.

Speaker

Evaluation of UV-Resistant Epoxies for Protective Coating Applications

Protective coating system design requires consideration of desired properties alongside environmental criteria to select an appropriate formulation. While epoxy systems are highly regarded for their substrate adhesion, chemical resistance, strength, and durability, there are some inherent shortcomings due to their chemical structure. One such limitation is gloss retention and yellowing resistance, especially in the presence of UV exposure when compared to polyurethane or acrylic systems.

To formulate an epoxy system with the best UV resistance, cycloaliphatic epoxy resins and curing agents are often selected. With these systems, higher levels of gloss retention and reduced yellowing can be achieved, allowing the design of epoxy systems that do not need a PU or acrylic topcoat. This presentation will review physical properties and QUV-A accelerated weathering of UV resistant epoxy systems benchmarked against an industrial PU topcoat.

Speaker

Improving Water Resistance of Pure Acrylic Emulsions with Nonionic Reactive Surfactants

The replacement of conventional surfactants with reactive surfactants in emulsion polymerization is a promising strategy for improving the water resistance of waterborne coatings. However, the appropriate use of reactive surfactants in emulsion polymerization to balance stability and water resistance is still a challenge. With pure acrylic polymer emulsions, due to their higher polarity, they are more difficult to stabilize during the polymerization in comparison to styrene-acrylic polymer emulsions.

In this presentation, the properties and application of a new reactive nonionic surfactant will be presented. The molecule was designed to react with the key monomers used in emulsion polymerization and to present surface activity similar to conventional nonionic surfactants. Polymerizations of pure acrylic emulsion polymers were carried out using a combination of conventional anionic surfactant and the new reactive nonionic surfactant. The effect of surfactant composition on emulsion stability and water resistance was explored.

Emulsions polymerized with the reactive nonionic surfactant exhibited particle sizes in the range of 90-110 nm and excellent mechanical stability. Emulsions polymerized with the optimized composition of surfactants showed outstanding blush/whitening resistance. They absorbed about 85 % less water than the all-acrylic emulsion benchmark after immersion in water for 7 days. Using HPLC, we will also examine the incorporation of the reactive nonionic surfactant.

Speaker

Influence of Novel Multi-Functional Additive on Melt Rheology and Surface Control in Powder Coatings

Sustainability and energy conservation efforts in the coatings market are driving progressions in powder coatings technology to achieve lowest possible curing conditions, while maintaining the appearance characteristics of traditional coatings. Film degassing and leveling properties become increasingly difficult to manage at reduced curing temperatures, trying to overcome the high melt viscosity of powder coating systems. Technology advancements have led to the development of a multi-functional additive suitable for the use in powder coatings with strong efficacy for improving surface appearance. This gives the formulator a greater latitude to balance low cure performance to better meet the degassing, DOI and leveling requirements of the end application.

In this study, the paper reviews a range of additive technologies to influence surface appearance of powder coatings and highlights the new additive’s ability to positively influence melt viscosity and film characteristics, while maintaining important surface properties. Key powder coating attributes, such as color, gloss, leveling, DOI, degassing threshold, recoatability, overbake stability, compatibility among others will be highlighted in this performance benchmarking.

Speaker

Controlled Free Radical Polymerization (CFRP) Dispersant Technology

Pigments are a fundamental aspect of many coatings in many different industries. As such, they provide desirable features to the performance of a coating ranging from protective aspects to coloristics (tint strength, chroma, etc.). Dispersing pigments into a liquid vehicle is a critical part of formulation as the degree of pigment stabilization will directly impact the extent to which desirable features are met. Dispersing agents are the additives of choice to meet this need for dispersing and stabilizing pigments in liquid media. It is important to recognize that not all pigments are equal in terms of their ease of dispersing. In the same vein, not all dispersants are equal in performance. To meet the need of dispersing difficult to disperse pigments, BASF has developed a line of advanced, high-molecular-weight dispersants with unique polymeric architecture via Controlled Free Radical Polymerization. This dispersant technology provides the ability to efficiently disperse even the most difficult to disperse pigments such as high color carbon blacks and transparent organic pigments. This presentation will cover the unique features and values of CFRP dispersants. Additionally, some application case studies will be discussed to demonstrate the performance value of CFRP dispersant technology.

Speaker

Enhanced Corrosion Inhibition in Powder Coatings

Powder coatings have long been recognized for providing high-performance, durable finishes that can be utilized in various end-use applications. They have become a leading technology in the pursuit for sustainable coatings due to low waste generation and no utilization of volatile solvents, which are becoming increasingly scrutinized in every regulated region. The simplicity of powder formulations can generate manufacturing and formula development efficiencies as well. As companies drive to lowering the environmental footprint of their products, powder coating technology is an excellent avenue that can achieve that while providing high performance asset protection.

Powder coating performance, along with liquid coatings, is driven by the resin chemistry selection. But powder coatings differ from liquid systems in that they historically rely on fewer additives to optimize film properties. As the industry continues to migrate to powder technology, competition will grow, and the optimization of these systems will be essential to extend performance and achieve a competitive advantage. A case study evaluating the use of corrosion inhibitive pigments in a polyester/TGIC powder coating will demonstrate the performance advantages that can be achieved in a non-traditional metal protective system.

Speaker

Novel Waterborne Silicone Resin Emulsion for High Temperature-Resistant Protective Coatings

The use of silicon-based materials in architectural and industrial markets continues to expand from niche utility to being viewed as premium technology for high-performance coatings. Silicone resins and intermediates can offer improved resistance to temperature, moisture, corrosion, electrical discharge, and weathering for heat resistance paints, and industrial maintenance and protective coatings. With demanding performance requirements, formulators often utilize proven, superior performing solvent borne technologies; however, the increase in environmental, health and safety, and regulatory restrictions has excited an interest in more sustainable and regulatory compliant raw materials. Dow continues to drive cleaner, innovative solutions to address unmet market needs across the globe, and the high-temperature coatings market is no exception. In addition to introducing a novel, low volatile organic compounds (VOC), heat-resistant silicone resin emulsion, this presentation will outline formulation flexibility in performance, delivery, and cure requirements for demanding applications.

Speaker

Comprehensive Stabilizer Systems for Water-Based Coatings

Stabilizers, such as organic UV-absorbers (UVA), sterically hindered amines (HALS), and anti-oxidants (AO) find widespread use as coatings additives to prevent degradation during outdoor weathering and/or thermal exposure. In water-based (WB) coatings, many of the well-established non-polar stabilizers are difficult to incorporate due to insolubility and/or incompatibility with the aqueous coating or paint formulations. Getting a stable, uniform mixture, leading to homogeneous coating formulations upon storage and use without separation of stabilizers is critical. Several undesired phenomena such as sedimentation, and exudation may occur if the stabilizers are incompatible in WB coatings, leading to inadequate protection, or even detrimental coating performance.

A new emulsification technology was developed to make traditional stabilizers water dispersible. Optimized combination of several synergistic water-based UVA/HALS blends were designed to meet varying enduse performance expectations of different waterborne coating formulations. A water-based anti-oxidant was also developed to improve performance of water-based coatings under high thermal exposure.

A new waterborne non migrating light stabilizer system, containing a reactable non-basic HALS and a reactable photo permanent UV absorber was developed, for use in waterborne one component acrylic melamine coatings and waterborne two component acrylic/ polyisocyanate crosslinked coatings. This unique stabilizer system was designed to prevent migration issues in WB plastic coatings. It could also meet the high performance and durability requirements of water-based automotive and industrial coatings.

These new water-based light stabilizers and anti-oxidants thereby address the VOC and HAPS concerns, while maintaining the efficacy of conventional additives with the benefits of water miscibility, ease of incorporation and handling.

Speaker

Branched Vinyl Ester Copolymers for Intumescent Emulsion Paints

Viscoelastic characteristics of polymeric binders are known to greatly influence the foam expansion of intumescent paints. These organic resins also contribute to char formation. Furthermore, the thermal stability of the foams depends on the chemical structure of the char and thus on the chemical mechanisms governing the thermal decomposition of the polymer.

Polyvinyl acetate copolymers are known to undergo an autocatalytic deacetylation reaction where the elimination of acetic acid from the polymer backbones leaves unsaturated polymer backbone or polyenes with conjugated carbon-carbon double bonds. At higher temperatures, the polyenes undergo slower allylic chain scission reactions than non-conjugated polymers that would derive from other thermoplastic polymers such as polyacrylates. This step is then followed by complete degradation. The kinetics of polyvinyl acetate in this process has been found to yield optimum intumescent properties.

To improve other coatings performance aspects, such as storage stability, film formation, abrasion resistance, and durability, co-monomers such as ethylene or acrylates may be introduced in the polyvinyl acetate backbone. Yet, these co-monomers do interfere with the deacetylation process and subsequent allylic chain scission. Research has demonstrated that ethylene monomer has a negative impact on the deacetylation process. The autocatalytic effect mentioned earlier is slowed down and may even disappear at elevated ethylene concentrations.

Branched vinyl esters comonomers for vinyl acetate such as vinyl neodecanoate are well known to efficiently improve overall coatings performance. It is also known that paint formulations with these copolymers exhibit excellent intumescence development. The present study compares the performance of various vinyl acetate  vinyl neodecanoate copolymers with waterborne binders of different chemical natures: vinyl-ethylene, acrylics, and styrene-acrylics. It shows that, unlike the other monomers, vinyl neodecanoate significantly enhances intumescent properties via improved foam expansion and foam stability.

Speaker

Navigating ‘Materials of Concern’ in the Coatings Industry

In recent years, PFAS and other chemicals of concern have come under heightened scrutiny by regulatory agencies in the United States and Europe, leading to increased restrictions, expected bans, and a push to develop replacement products. Join us as industry experts from across the coatings value chain collaborate to discuss the debate surrounding these materials, how the restrictions are affecting their business, what innovative replacement products are under development, and what the future holds for some of these highly irreplaceable chemicals.

Panelists

Painting a More Sustainable Future – Bio-Based Binder for Interior Architectural Paints

Growing consumer awareness regarding personal health, indoor air quality, and environmental responsibility, coupled with support from government and non-governmental organizations, are fueling innovations in the development of safer and more sustainable materials. Within the coatings industry, the ongoing challenge lies in developing paints that achieve a harmony between sustainability, performance, and affordability.

Herein, we will discuss initiatives from Dow Coating Materials (DCM) aimed at creating durable solutions for more sustainable paints. DCM is incorporating plant-derived ingredients directly in 100% acrylic binders with measurable bio-carbon content in the final product. Preliminary internal LCA analysis, demonstrates that paints with these resins have lower carbon footprint and deliver equivalent or better performance than the existing acrylic-based wall paints. Additional studies indicate they can be formulated into high-performing, low-"materials of concern" paints with low emission from VOCs and without the need for purposefully added PFAS. These coatings can potentially contribute towards improved air quality and healthier living. This technology can also enable paint formulations to qualify for USDA BioPreferred certification and contribute to LEED and green building credits. Overall, this initiative aims to provide formulators with solutions to develop affordable coatings with more favorable sustainability profiles that integrate performance, safety and environmental benefits.

Speaker

High-Performance Materials: Introducing PEI Resins for Coating Applications

Polyetherimide (PEI) resins are high-modulus, high-strength, inherently FR thermoplastics that are available in a variety of powder formats. Recent work with PEI powders has shown that they are compatible with standard electrostatic coating methods. In this talk, we produce PEI coatings using ULTEM™ resins with Tg greater than 215˚C demonstrating high gloss and topcoat compatibility with epoxies. Fused PEI powder also demonstrate impressive adhesion to a variety of metal substrates and creates durable coatings with characteristics that reflect the properties of the base polymer.

Speaker

Unsaturated Polyester Resins as Adhesion Promoters in Coatings

This presentation investigates the use of amorphous unsaturated polyester (UP) resins as adhesion promoters to enhance the adhesion of solventborne coatings. Adhesion is a critical property, and its mechanisms in polymeric coatings are complex, involving factors such as surface morphology, wetting, mechanical interlocking, diffusion, acid-base interactions, and chemical bonding. The article explores the potential of UPs as effective adhesion promoters for the coating industry, focusing on their role in strengthening the bond between coatings and substrates. The study involves incorporating these adhesion promoters into solventborne coatings and then evaluating the resulting coatings' adhesion properties. The results demonstrate that UPs can significantly improve the adhesion of coatings. Their effectiveness depends on several factors, including the type and amount of UP used, as well as the substrate type. These findings have significant implications for the development of high-performance coatings with enhanced adhesion properties.

Speaker

Reducing the Carbon Footprint of Paint and Coatings with Soy

As one of the most abundant plant-based oils, U.S. soybean oil plays a pivotal role in coatings formulations. The United Soybean Board is committed to offering valuable insights to companies aiming to fulfill sustainability and supply chain goals through the utilization of U.S. Soy. Soy presents multiple advantages beyond its renewability, including economic benefits, consistent quality, and widespread availability. With stable year-round production volumes and processing infrastructure, soybean oil streamlines supply chains, reducing transportation costs and carbon footprints.

Soy derivatives empower resin manufacturers to create a diverse range of sustainable, renewable, technically advanced, and cost-competitive products. This presentation emphasizes soy's crucial role in expanding resin portfolios to incorporate biobased feedstocks, aligning with company and industry sustainability targets such as NetZero Carbon 2050.

Furthermore, the presentation outlines USB-funded research comparing the performance of commercially available soy-based versus petro-based materials, including the preparation and testing of coatings formulated with soy alkyd dispersions in applications ranging from wood deck stains and sealers to direct-to-metal coatings. The resulting data will equip coating formulators with additional tools necessary for the development of sustainable coatings with high bio-based content.

Speaker

Pigment Selection Process: Balancing the “MUSTs, WANTs and the NICE TO HAVEs”

In today’s fast-paced world, we do not want to “go down the rabbit hole” when selecting pigments for an application. If you are the color formulator, then you have the not so envious job of reaching the color design ideas provided by your marketing team yet meeting the technical requirements of the formulation and the performance requirements of the application process. Combining the complex function of the color formulator with the current pigment industry of mergers, SKU reductions, and less and less knowledgeable sales forces can result in a difficult and possibly an inadequate choice of pigments. Can you identify with a mouse in a maze looking for the cheese, or the list maker identifying each item with its importance? Pigment selection is a process, but it is a known process, and working with a knowledgeable manufacturer can make the process smooth and efficient. In the end, a pigment is only technically valuable to a customer if it performs in the correct manner required for the application it is used for. Each market segment has unique technical requirements and in every class of pigments, one will find at least one grade with higher performance characteristic(s). The degree of performance for a pigment depends on the demands imposed upon it for its intended application.

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Novel High-Performance, Waterborne, Oil-Modified Urethane for Wood Flooring and Furniture Application

The growing global emphasis on environmental sustainability has spurred a significant transition within the wood flooring and furniture market from traditional solventborne urethanes, notorious for their high Volatile Organic Compound (VOC) emissions, towards more eco-friendly waterborne alternatives without compromising on performance. Currently, the waterborne sector predominantly utilizes aromatic and aliphatic oil-modified urethane (OMU) technologies, each catering to specific property requirements due to limitations in performance. For example, aromatic urethanes demonstrate high hardness but limited flexibility and durability, rendering them vulnerable to cracking and wear. In contrast, aliphatic OMUs provide excellent flexibility but may lack the necessary hardness to meet the evolving demands for high performance. This presentation demonstrates the recent breakthrough in the development of a novel, NMP-free aliphatic OMU approach that achieves comparable hardness development to aromatic OMUs while maintaining the flexibility of an aliphatic system for wood flooring and furniture applications.

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Enhanced Robustness and Durability: Next-Generation Matting Agents for Waterborne Coatings

With the changes of people’s taste in aesthetics, there is a trend towards deep-matte and natural-looking finished coatings, especially in the furniture and flooring markets. On the other hand, as EPA requirements increase, waterborne coatings are becoming more attractive in the market. However, the development of deep-matte waterborne coatings, especially 1K systems, remains a challenge because of loss-of-film properties such as chemical resistance, transparency and mechanical integrity.

In this presentation, two new silica matting agents with special organic treatments and unique particle structures are introduced. One silica provides excellent matting efficiency as well as good chemical resistance, transparency and burnishing resistance. While the other silica exhibits outstanding chemical resistance and transparency with maintaining good matting efficiency. Both grades will provide formulators an additional tool to meet the ever-growing performance needs of waterborne coatings.

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High-Solids TEA-Free Waterborne Polyurethane Dispersions

High-solid-content polyurethane dispersions (PUDs) can help deliver both sustainability and performance features in waterborne polyurethane coatings. The highest attainable solid content for waterborne polyurethane dispersions is lower than what can be achieved in acrylic emulsions. In this paper, we show our journey using novel technology to guide the development of several high solids waterborne dispersions with over 50% solid content, approaching the limits of acrylic emulsions while maintaining a high performance polyurethane. The increased solids content has several benefits for coatings applications, including the elimination of a coating step, thicker coatings, reduction of dry time, and lowered coalescing solvent need. These products were also designed with regulatory needs in mind and have been developed without the use of TEA or NMP. The combination of these advantages and the well-known high performance of the polyurethanes is expected to be a valuable benefit to a large variety of coating applications.

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Powder Coating Resins from Recycled PET

The large amount of plastic waste ends up in in the landfills and the natural environment is a major global issue. Among many types of plastics, polyethylene terephthalate (PET) accounts for 70% of the global synthetic fibers and approximately ¼ of all packaging materials. Therefore, recycling PET would significantly reduce the plastic waste end up in the environment. Moreover, recycled PET will also reduce the use of virgin raw materials originating from the diminishing petroleum resources and reduce the greenhouse gas and carbon emissions. In recent years, allnex has successfully developed the capabilities and the know how to use recycled PET in powder coating resins. This presentation discusses these recycled PET-based powder resins and their impact.

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High-Performance Wood Coating Additives

There are increasing demands for higher performance, more sustainable coatings employing more natural materials with substantial health, safety, and environmental properties. To address those challenges, raw material suppliers and coatings manufacturers are increasingly turning to water-based solutions of that require efficient, environmentally friendly emulsion technologies. The science behind key wax and silicone additive technologies to meet these needs will be presented.

Innovative technologies will be presented that utilize unique waxes, silicones, and wax – silicone hybrids. These additives are used to disperse pigments, reduce foam, and provide coating advantages including wetting and leveling, water and oil repellency, block resistance, water beading, scratch and abrasion resistance, haptic properties, and both slip and anti-slip performance. Novel coating additive features will be translated into specific advantages and benefits for coating formulators and end users.

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Silicone Resins for Breathable, Long-Lasting Exterior Architectural Paints

The exterior architectural coatings industry has a paradox: the requirement of a film to be both water-repellant and moisture-permeable. Particularly when coating porous substrates that may contain moisture such as wood and concrete, a paint must breathe to reduce damage from water build-up behind the film and maintain hydrophobicity to prevent damage from water incident on the film. One such way to accomplish this is by use of silicone resin emulsions. The unique Si-O bond that comprises these silicone resins allows for the transmission of vapor through the coating matrix while still preventing the absorption of water from the paint surface. The breathability of the film and water resistance of the silicone resin is a powerful combination that can produce a highly durable coating that lasts for generations, as evidenced by years of real-world exposure data.

A recent study was conducted by incorporating silicone resin emulsions as both a sole and co-binder in an exterior waterborne acrylic latex paint formulation at various levels. Properties such as water vapor permeability, water absorbance, contact angles, and accelerated weathering performance were evaluated against an acrylic latex control. The results indicate silicone resin emulsions provide an eco-friendly, water-resistant, and breathable binder option to improve coating and substrate lifespan in architectural coatings beyond what it is possible to achieve with acrylic binders alone, or even with low doses of silicone additives.

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Design and Implementation of a Digitalization Strategy for Coatings Industrial Research and Development

Coatings are highly formulated products with vast potential design spaces and many complex interactions. In large organizations like Eastman Chemical, copious amounts of data are generated daily that theoretically can be harnessed to enhance the quality of decision-making and speed up innovation in today’s rapidly evolving industry. In practice, this data is often generated and stored in a variety of locations, not easily accessible, poorly organized, and not consistently structured. That’s not very F.A.I.R. and makes it difficult to take advantage of machine learning, data visualization tools, and other powerful data analytics. Therefore, an organization needs to develop a comprehensive digitalization strategy. Here, we discuss our approach to digitally transform our coatings division through implementation of a database management system across various stages of our workstreams and processes. We share our experiences with what has and hasn’t worked for us, including development of in-house relational databases, adoption of commercially available software and services, and challenges with getting a bunch of humans to adopt a change in the way they work. Finally, we highlight our efforts in developing a machine learning platform to aid innovation in resin design and coatings formulations using both internal resources and external partnerships.

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UV LED-Curable Dichroic Coatings Based on Structural Color Copolymers

In the search to reduce carbon emissions, the contribution of pigments is commonly overlooked, however they can contribute up to 60% of the carbon emissions of formulated coatings. Brush block copolymers offer a lower carbon footprint option to improve sustainability while providing eye-catching, highly chromatic colors based on structural color. In this presentation Cypris will review UV LED-curable formulations and methods to assess their color performance.

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Characteristics of Styrene Sulfonates and their Application in Coatings

Sodium p-styrenesulfonate (NaSS) has proved valuable as a unique reactive emulsifier. Sodium p-styrenesulfonate is a unique sulfonated monomer having the highest reactivity among the sulfonated vinyl monomers. TOSOH produces the hemihydrate form of NaSS, which provides more storage stability and better handling. Key properties include low toxicity, high reactivity, sulfonate functionality and good surface activity, which lead to its use in varied and unique applications.

Recently, we have established an industrial method for producing ammonium styrene sulfonate (AmSS). Ammonium salts have the following three additional characteristics when compared to sodium salts. The first is that it is metal-free, the second is that it is soluble in organic solvents, and the third is that it has high purity. In particular, the fact that it is metal-free has the potential to solve the problems of water resistance and corrosion caused by alkali metals, making it ideal for producing higher quality emulsions.

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Waterborne, Environmentally Friendly Omni-Phobic Coatings for Sustainable Application

Waterborne coatings/additives are of great importance not only due to the growing restrictions on VOCs, but also because of the growing awareness of sustainability. Acrylate emulsions are used for many coatings applications such as architectural coatings, automotive refinish, and industrial applications, to name few. At SCOPS, we are developing an omni-phobic additive for acrylate emulsion. SCOPS is using a state of art to create PFAS-free waterborne omni-phobic additives. SCOPS prepared a modified acrylate emulsion that can be used as an additive to other acrylate latex to impart hydrophobic and oleophobic characters. Our additive was tested in a number of benchmark products, including acrylate emulsions and polyurethane emulsions at different weight percents. The hydrophobicity/oleophobicity was tested by the sliding speed of water and oil on the coated substrates. The coating was applied to various substrates including glass, wood, tiles and plastic. SCOPS also tested the solvent-based analog of the prepared additives to assess the performance of both waterborne and solvent-based additives. The experimental details and more data will be presented in the presentation.

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Sustainable Materials, Energy Demand Reduction and Process Optimization. Impossible Trilemma or Opportunity in Disguise?

The pressure on paint and coatings organizations to transition to water-based coatings is substantial, yet challenging. Reformulation and R&D efforts require significant financial investment, resulting in a slow transition for most organizations. Finding alternative bio-based feedstock materials and determining suitable quantities pose major challenges, particularly considering the historical reliance on the petrochemical industry.

While the decorative segment has transitioned relatively quickly, industrial applications are encountering difficulties in making the switch. Consequently, powder coatings have emerged as a preferable alternative for industrial applications, despite remaining relatively expensive and presenting application challenges. Moreover, debates persist regarding the extended drying times of water-based paints in winter, often necessitating the use of gas-based heaters.

Faced with these necessary changes, the elephant in the room remains energy consumption. While organizations have predominantly transitioned to renewable energy for lighting loads, production loads are still largely sustained by mixers. The iteration of batches during the production process, often required to achieve targeted color and viscosity, consumes significant energy too.

A comprehensive, three-prong approach to carbon footprint reduction by raw materials substitution, optimization of the process and reduction of energy consumption is the solution we present.

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Low-Cure Applications in Powder Coatings – with Particular Focus on Formulation

The conversation about low-cure powder coatings has been well discussed in recent years. In this presentation, we provide a coherent overview and analysis on how to achieve a robust formulation in low-cure powder coatings  from additive selection to mechanism of action in specific powder coatings systems. We further provide some unique headway into this new and emerging technology in powder coatings.

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Innovative Calcium Carbonate for TiO₂ Extension

This presentation will discuss the use of calcium carbonate as a TiO₂ extender, where it can displace 10-15% by weight of TiO2 in a decorative architectural coating without negatively impacting performance. Lab data will be provided to show how partial displacement is possible, along with optical property comparisons in terms of gloss, contrast ratio, brightness, and tint strength. The influence of particle size distribution of calcium carbonate and its impact on performance when partially displacing TiO2 will be discussed. The challenges of creating such a technology and the means to overcome hurdles such as particle agglomeration upon storage due to moisture pickup will also be reviewed. Carbon footprint values of calcium carbonate will be discussed as well, and how the overall carbon footprint of a coating can be reduced when partially displacing titanium dioxide with calcium carbonate.

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The Next Step in Production: Using AI to Achieve Better Results

There is a lot of talk and information about the possibilities of AI. But we need a discussion about how we can make this happen in the paint and coatings Industry. Our industry is unique, and that is why we cannot just adopt solutions from other industries. The presentation will describe the approach in paint production and point out prerequisites for making AI do its work in paint production and the lab, but also raw materials and paint applications.

The presenter has made hands-on experience on that topic and is one of the founders of the Smart Paint Factory Alliance, who is aiming to orchestrate a discussion about digitalization and AI in the industry.

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The Scientific Balance - Bridging Fundamental Chemistry with Empirical Work for Optimized Coating Formulations

"The Scientific Balance" presentation explores the potential synergy between fundamental chemistry principles and empirical knowledge in the formulation of paints and coatings. In the coatings industry, empirical approaches often dominate formulation practices, relying on trial and error and historical experience. While effective, this approach may limit innovation and overlook underlying mechanisms that could enhance paint and coating formulations.

This presentation advocates for a holistic approach that integrates a deeper understanding of chemistry, physics, mathematics, mechanisms, and theories to potentially guide the formulator’s empirical work. By revisiting fundamental concepts (i.e. molecular interactions, material properties, etc.), formulators can gain insights into the underlying principles governing a coating’s performance. A few examples will be presented to demonstrate how "The Scientific Balance" can inform, complement, and enhance empirical practices. From a clearer understanding of various concepts including surface tension, rheology, pigment dispersion, and film formation, the presentation will highlight how chemistry, physics, and mathematics addresses common challenges most formulators experience.

Additionally, "The Scientific Balance" emphasizes the importance of ongoing education and professional development. By fostering a culture of scientific inquiry and continuous learning, practitioners can unlock new avenues for innovation and drive advancements in coatings technology. Embracing "The Scientific Balance" can empower formulators to create more effective, sustainable, and high-performance paints and coatings that meet the evolving needs of industry and society.

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Bio-Based, PFAS-Free Additive for Powder Coating Texturing

The use of powder additives based on PTFE is a well-established approach to imparting a range of texturing and tactile effects in powder coatings. With the current regulatory activity growing around the use of PFAS substances, which includes PTFE, there is a desire to find alternate approaches to texturize powder coatings. This presentation will introduce a new bio-based powder that can provide a range of texturing effects in powder coatings.

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New Developments in Emulsion and Dispersion Stability Analysis

Dispersions are multi-phase mixtures consisting of substances that are insoluble in one another. One phase is the continuous phase in which small particles of the other phase are dispersed. A suspension consists of a liquid continuous phase and dispersed solid particles. In an emulsion the dispersed particles are small droplets of another liquid, and a foam consists of a liquid continuous phase and dispersed gas bubbles. Instruments using optical scanning methods for stability analysis of emulsions and dispersions have been available for the past 25 years but before today, were not capable of true particle size analysis since they generally operated with only a single-wavelength light source. This lecture will introduce a new optical scanning capability whereby the same sample can be tested with two different wavelengths of light, both near-infrared and near-ultraviolet. This is a significant development because comparing measurements made on the same sample at two distinctly separate wavelengths of light will be shown to give higher sensitivity to smaller particles. It therefore gives the opportunity to yield more accurate particle size distribution, a capability long-desired by the coatings industry. In addition, 'freeze and thaw' impact on the stability of coatings is becoming increasingly important as new coatings are being created, targeted for very specific extended temperature-range environments. This lecture will also introduce a new and unique capability for fully-automated freeze and thaw emulsion and dispersion stability analysis experiments.

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Next-Generation Organic Rheology Modifiers

Conventional first- and second-generation organic rheology additives are finely micronized waxy powders based on castor oil derivatives and their combinations with fatty acids and/or amides. Such organic materials are used as thixotropic additives in solvent-based and solvent-free (100%) liquid coating and adhesive systems. They deliver specific storage stability and help to avoid settling and enable the application of the required layer thickness to vertical surfaces.

In addition to the rheological properties, sustainability and environmental compatibility, as well as the ease of handling, are ever more important. The new generation of organic rheology additives allows incorporation and reliable activation at significantly reduced temperatures compared to conventional rheology additives, which significantly reduces energy demand and increases process reliability.

This presentation shows how the latest-generation organic rheology additives meet the requirements for environmental friendliness, performance, and ease and safety of handling increasing overall effectiveness, while also being FDA-compliant.

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Waterborne Silicone Resin for High-Temperature-Resistant Coatings

Silicone-based polymers and additives are widely used for formulating highly durable coatings due to their inherent resistance to heat, UV, and chemicals. For automotive, industrial, and other specialty coating markets that require very high temperature resistance up to 600 C, cross-linked silicone resins with phenyl functionality are preferred to meet target performance and hardness. Such coatings are typically solvent-based, and one contributing factor is that suitable silicone resins are primarily available as solutions in solvents like xylene or toluene. These solvent-based silicone resins usually exceed volatile regulatory requirements, which are not sustainable solutions in today’s market. It is very challenging to produce silicone resins that are solvent-free due to their high viscosity and reactivity. Also, producing these as waterborne emulsions or dispersions pose challenges related to high reactivity in water and lack of shelf-life stability.

In this presentation, a new silicone resin emulsion will be introduced that overcomes these challenges and can be used to prepare waterborne and low-VOC coatings. Model formulations using this waterborne silicone resin were developed using multiple pigments like titanium dioxide, iron oxide, aluminum, etc. These formulations were easy to process, with excellent application profile, and became tack-free at room temperature in short time. After thermal curing above 150 C ,the resulting coatings demonstrated excellent performance like thermal resistance, hardness, adhesion, and corrosion resistance.

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Why Using Defoamers in Latex Paint Formulations Can Be Quite Troublesome

Defoamers in latex paints have the task of keeping bubbles down that appear both during the production process (grinding, let-down) as well as during packaging, mixing before application and the application itself using various techniques. The operation of defoamers is well known, however, the theory of defoaming still requires appropriate application knowledge regarding the selection of the type of defoamer, dose and method of incorporation, e.g. in the grinding, let-down stage or divided between these processes. The presentation will discuss issues related to solving problems and properly building recommendations for defoamers and their use in latex paint formulations for walls and wood, using research on the development of such formulations and defoamers dedicated to the U.S. market.

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Introduction to LED UV Curing Coating Applications  Customer Case Studies

North American manufacturing is a very competitive landscape, and LED UV-cured technology offers a low-energy consumption and sustainable coating solution. Customer case examples will be presented outlining the energy savings and VOC reductions based on several unique customer applications.

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Eliminating VOC Emissions in your Manufacturing Process and Much More with UV LED Coatings Technology

Imagine being able to eliminate all VOCs in your manufacturing process – thousands of pounds of VOCs per year, while producing faster, using a smaller physical footprint, and less overall energy costs.

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New Generation of Sustainable Alternative Resin Systems for High-Performance Coatings

There has been increasing pressure on industries to develop and offer high-performance resin systems that are sustainable while maintaining or enhancing their performance benefits. Many of the incumbent resin systems are based on hazardous components that are challenging their future usage. For example, isocyanate compounds in polyurethanes, Bisphenol-A in epoxy resins, and the use of per- and polyfluoroalkyl substances (PFAS) in fluoropolymers make them targets for their replacement.

Building on our patented sol-gel coating technology and by harnessing developments in novel cross-linking chemistries, our research group at Coating Research Institute of Eastern Michigan University has developed sustainable alternative resin systems for high-performance coatings. This new generation of environmentally friendly resin system is meticulously designed with alkoxysilane (and optionally other types of) reactive functional groups onto a robust polymer backbone of varying chemical structures, morphology, and molecular weights. One of the most interesting attributes of this novel resin system is its capability to cure under ambient conditions, by UV exposure, or by thermal curing – significantly expanding its end-use application space. This presentation will highlight polymer design, cure-study, and some test results that demonstrate this technology’s potential for high-performance applications.

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Using Temperature to Simulate Thixotropy in 100%-Solids Coatings

Thixotropy is a very valuable property widely exploited in modern coating formulations to control the flow out in the film. This is usually achieved with rheology modifiers that create this “shear-thinning” behavior.

In conventional solventborne and waterborne coatings, this is virtually the only way to achieve this behavior as temperature simultaneously affects both viscosity and solvent evaporation (including water). In 100%-solids coatings however, temperature can be used to simultaneously modify viscosity, reduce the need for monomer thinners, and control the flow out in the film.

In this presentation we will:

• define thixotropic behavior and why it is important in coating applications to achieve the desired surface finish;
• introduce the “temperature hierarchy” in a coating operation;
• compare and contrast key similarities and differences between conventional and energy cure coatings;
• identify the unique properties and behaviors of 100%-solid UV/EB coatings that allow temperature to generate “thixotropic-like behavior” in film formation;
• contrast the leveling times available in conventional and energy cure coatings and the influence of the shortened cure cycle.

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Sustainable Technology Enhances the Future of Colorant Tinting Systems

Sustainability is becoming increasingly important in the architectural waterborne coatings industry, whether to meet regulatory requirements or growing customer and consumer demands. One of the primary issues facing traditional colorants is the ever-increasing pressure to provide products free of biocides, volatile organic compounds (VOCs) and other additives. Meeting these requirements without compromising coating performance is an ongoing challenge for colorant producers. VOC-free colorants, while more environmentally friendly, come with their own set of challenges, including mold and bacteria formation, sedimentation, extended colorant drying times and the necessity for additional thickening in the waterborne coatings system.

Various challenges of traditional VOC-free colorants can also extend to the point-of-sale equipment systems used for dosing. These systems can lead to extended downtimes due to colorant changes, increased colorant consumption driving up ownership costs, issues like mold formation, tube clogging and tip drying, as well as syneresis-related problems. These obstacles can cause significant and untimely delays for coatings companies, result in higher ownership costs, and ultimately increase the carbon footprint within the supply chain.

To address these challenges, Vibrantz Technologies developed a novel breakthrough technology, a high-performing and sustainable solution that revolutionizes the colorant tinting process. As the architectural waterborne coatings industry’s first and only volumetrically dosed tinting system of solid colorants designed for use in architectural and industrial waterborne paint applications, this technology offers several key sustainability benefits, many performance enhancements, and a decrease on the carbon footprint of traditional liquid colorants.

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Improved Coating Performance with Gas Blacks

Carbon black is one of the earliest synthetic materials and certainly the oldest synthetic carbon modification. The colloidal properties and performance of carbon black pigments depend heavily on the manufacturing process. Gas black is a unique process developed to produce a deep, rich black color with special surface characteristics, leading to unique colloidal properties. As a highly engineered paracrystalline carbon material, dispersing and stabilizing carbon black can be challenging, especially high jetness pigment grades with blue undertone. Due to the unique surface chemistry and high area-to-volume ratio associated with the gas black process, grind time can be reduced with good dispersion properties, as well as outstanding weatherability. Additionally, higher gloss and improved color properties are enhanced with more finely controlled particle size distribution. This presentation will focus on new developments with the gas black process and their use as high performance pigments in coatings.

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A Revolution in Color Management – Prediction of Color Stability

With color being a key criterion in the purchasing decision, color harmony and long-term color stability are a must. Long-term exposure to sunlight can fade a product’s color resulting in the decay of the fluorescent ingredients affecting the appearance of the product.

The outdoor durability of polymers is directly related to color fastness to light, which refers to a dyed polymer’s ability to resist fading when exposed to light. Many modern car interior parts are made with polymers, including lightweight seats, instrument panels, durable upholstery, sound control fabrics, the headliner, dash, and door panels. These parts are often manufactured in different locals and then assembled into one automobile. If over time, the customer’s vehicle interior does not match due to exposure, the customer satisfaction rating could plumet, causing the return of the vehicle. This is why the prediction of color stability is so important.

The combination of color, 60° gloss and fluorescence influence the entire color experience. The prediction of lightfastness, detection and quantification of fluorescence is the next step in the evolution of color measurement. The combination of a spectrophotometer and a fluorimeter in one instrument provides the technology to predict the degradation of fluorescence that affects color stability.

In this presentation we will cover:

• How to predict color stability with elimination of fluorescence over time;
• Different geometries used to measure color;
• Definition and principle of fluorescence;
• How to evaluate fluorescent energy;
• Explanation of stokes shift;
• Fluorescence indices ∆Fl and ∆Ezero;
• Quantitative examples of degradation of florescence over time and its effects on color harmony.

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Polycaprolactone Polyols Designed for Polyurethane Dispersions

Polycaprolactone (PCL) polyols can also be used as building blocks in the manufacture of polyurethane dispersions (PUDs). A study will be presented that highlights the how the performance of a PUD can be improved with low-molecular-weight PCL polyols. The work shows that flexibility and toughness can be achieved with minimal effect on other important physical properties of the coating (such as hardness). This study will also demonstrate the performance benefits that can be obtained when using novel PCL diols to create high-performance PUDs developed to create more stain and chemically resistant waterborne coatings. This study will also focus on other additional properties that the novel PCL diols can help improve, such as early hardness development, early water resistance, and adhesion of the coating film.

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2K Bio-Based Binders for Wood Floor Finishes

As two-component binders for coatings are continually pushed to be more environmentally friendly to meet increasing sustainability requirements, resin suppliers have responded with a variety of solutions. These efforts have resulted in a wide variety of new and innovative polymer designs to meet environmental compliance while maintaining performance. Increasing developments in renewable bio-based products have led to new and exciting possibilities in various market sectors including decorative, architectural, packaging, and automotive coatings. The scope of this presentation will focus on the application of floor finishing using resins derived, whole or in part, from bio-based sustainable sources. These two-component resins will allow the formulator the ability to make “greener” finishes than previously possible without compromising durability and high performance. A range of bio-based products will be discussed for two-component systems for interior flooring finishes, and performance benchmarked against traditional products made from petroleum-based raw materials.

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Crystal Glass Pigments Revolutionizing the Visibility of Colors

Up to now, increasing (LiDAR) visibility of traffic participants could not be achieved in industrial form-free application. Enter crystal glass pigments, the first in class of a new and innovative type of effect pigments. In a perfect symbiosis with existing metallics and pearlescents, these pigments open up a new color landscape and play with light, enabling stylists with a new design freedom to incorporate increased visibility for both humans and sensors (e.g. LiDAR) in any design. Setting the stage for the AIPOV (Angular Independent Point-of-View) Visibility Model.

By integrating crystal glass pigments in styling opportunities in cars, motorbikes, bicycles, and accessories, their current color perception is changed as the technology champions the way to a second paradigm shift beyond the existing effect pigments in the color and safety landscape, culminating in the tunable twin-flop aesthetic effect.

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Advanced Polymer Strategies for Enhancing the Performance of Water-Based Exterior Coatings

Polymers used to formulate modern exterior decorative coatings must meet performance challenges that arise from exposure to a broad range of environmental conditions – temperature extremes, sunlight, wind, and air quality. Exterior paint must be hard yet flexible, give strong dirt pickup resistance, maintain color and gloss uniformity, and produce strong water barrier performance.

Modern polymer design techniques offer numerous approaches to meet the exposure challenges of water-based exterior coatings. Key emulsion polymer attributes include multi-phase polymers with hard and soft domains, nanoparticle size emulsions, incorporation of specialty monomers, and use of polymerizable surfactant technology. Polymer design considerations to optimize coating performance are discussed in the framework of low-VOC decorative exterior coating formulations. Featured characteristics, including water resistance, elongation, dirt pickup resistance, and accelerated weathering, demonstrate the capabilities of innovative emulsion polymer design techniques to achieve high-performance exterior coatings.

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Enhancing White Pigments for Innovative Coatings

Coatings formulators are commercializing innovative white pigment “enhancers” into new growth applications like architectural decorative surfaces, advanced flooring covers, and cool roof coatings. Specifically, an ultra-pure and engineered silica is being adopted into existing industrial formulations in order to achieve titanium dioxide independence as well as improving the economics and the performance of final applications. This presentation shows the latest research into how these pigment enhancers are offering a unique aesthetic as well as thermal and durability advantages.

Important to all coatings formulators is understanding how they can apply new minerals into their specific formulations. Insights will be shared about how the high surface energy of these white pigments will promote particle dispersion and stabilization of formulations in both water- or solvent-based coatings.  In addition to this, updated research will be discussed around the durability performance, weathering, and stain resistance as compared to titanium dioxide and other white pigments. Finally, beyond these technical aspects, an overview on the economic impact of a reformulation will be considered.  

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