Transcript T7B) Breakthrough Waterborne Alkyd Technology

Breakthrough Waterborne Alkyd Technology
for Interior Wood Stains
Michael Knight
PCCR USA, INC.
Technical Service Manager
October 9, 2014
AGENDA
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BACKGROUND
ALKYD DEVELOPMENT
EMULSIFICATION PROCESS
EMULSION STABILITY
STAIN FORMULA OPTIMIZATION
PENETRATION TEST
LAPPING RESISTANCE TEST
GRAIN RAISE RESISTANCE
EXTERIOR STAIN
CONCLUSION
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BACKGROUND
 SOLVENTBORNE CONVENTIONAL SOLIDS LONG OIL
ALKYDS USED FOR WOOD STAINS
 AS VOC REGULATIONS TIGHTENED, HIGH SOLIDS
ALKYDS INTRODUCED
 SLOWER CURE DUE TO LOWER MW
 THEN WATER REDUCIBLE LONG OIL ALKYDS
INTRODUCED
 HYDROLYSIS ISSUE
 ALKYD EMULSIONS
 SAME PENETRATION INTO WOOD NOT SEEN AS WITH
SOLVENTBORNE
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BACKGROUND
 ALKYD EMULSION DEVELOPED TO OVERCOME
SHORTCOMINGS OF EARLY OFFERINGS
 VERY GOOD HYDROLITIC STABILITY
 EXCELLENT PENETRATION INTO WOOD
 EXCELLENT LAPPING RESISTANCE
 EXCELLENT GRAIN RAISE RESISTANCE
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ALKYD DEVELOPMENT
 EMULSION OF TRADITIONAL LONG OIL ALKYD
– POOR PENETRATION, LAPPING AND GRAIN RAISE
RESISTANCE
 ALKYD BACKBONE WAS MODIFIED TO IMPROVE
– LONGER OIL LENGTH
– RESULTANT LOWER MW
– FASTER DRYING OIL
 STAIN PERFORMANCE WAS IMPROVED
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EMULSIFICATION PROCESS
 CRITICAL PARAMETERS
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SURFACTANT TYPE
SURFACTANT LEVEL
SHEAR RATE
RESIN AND WATER TEMPERATURE
WATER ADDITION RATES
 OBSERVATIONS
– VERY FORGIVING PROCESS
– HIGH TO LOW SHEAR
– ADDITION OF SURFACTANT CRITICAL
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EMULSION STABILITY – 140 F HOT BOX
 LAB HIGH SHEAR
– BEWOID BLADES
– ~500 NM – 10 WEEKS HOT BOX STABLE
 PILOT HIGH SHEAR
– ROTOR STATOR
– ~300 NM – 10+ WEEKS HOT BOX STABLE
 LAB LOW SHEAR
– NORMAL PADDLE BLADES
– ~600 NM – 8 WEEKS HOT BOX STABLE
 PILOT LOW SHEAR
– SAME STABILITY
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BEWOID BLADE
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STAIN FORMULA OPTIMIZATION
 OPTIMIZATION FOR OPEN TIME AND LAPPING
– PROPYLENE GLYCOL AS SOLVENT
– CAN BE FORMULATED TO AS LOW AS 50 G/L VOC
 OPTIMIZATION FOR COLOR ACCEPTANCE
– ADM 750 DISPERSANT
 OPTIMIZATION FOR GRAIN PENETRATION
– WHITE STREAKS IN STAINED WOOD
• ENVIROGEM® 2010 SURFACTANT
 OPTIMIZATION FOR DRY TIME/URETHANE
CLEARCOAT ACCEPTANCE
– 3% BORCHI® OXYCOAT 1101/0.3% CA (HYDRO-CEM®)
– 2% BORCHI® OXYCOAT 1101.0.2% ZR/0.2% CA (HYDROCEM®)
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50 g/L VOC TINTABLE STAIN FORMULATION
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PENETRATION TEST
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NO QUANTITATIVE TEST METHOD
DESIGNED OUR OWN QUALITATIVE TEST
COUPLE DROPS OF STAIN PLACED ON BOARD
COVER 15 MINUTES WITH WATCH GLASS AND
OBSERVE
– EXTERIOR ACRYLIC STAIN – SITS ON SURFACE
– INTERIOR ACRYLIC STAIN – MORE CONTACT WITH WOOD
– ALKYD EMULSION – SPREADS ON WOOD AND PENETRATES
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PENETRATION TEST
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LAPPING RESISTANCE TEST
 COMMON APPLICATION PROBLEM
– STOPPING MID-FLOOR OR MID-BOARD
 WIPE STAIN ONTO 9 INCHES OF 12-INCH OAK
FLOOR BOARD
 AFTER TWO MINUTES, WIPE OFF EXCESS
 WAIT 20 MINUTES
 APPLY STAIN TO OTHER END OF BOARD WITH
3-INCH OVERLAP
 AFTER TWO MINUTES, WIPE OFF EXCESS
 OBSERVE
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LAPPING – 20 MINUTES BETWEEN COATS
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GRAIN RAISE RESISTANCE
WOOD IS POROUS SUBSTRATE
WATER SWELLS THE WOOD GRAIN
ROUGH TO TOUCH
SOLVENTBORNE STAINS DO NOT HAVE GRAIN RAISE
ISSUES
 TYPICALLY, WATERBORNE STAINS DO
 ALKYD EMULSION STAIN HAS EXCELLENT GRAIN
RAISE RESISTANCE
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EXTERIOR STAIN
 FORMULA TRANSFORMATION
 FOR WATER BEADING
– SILICONE AND PARRAFIN WAX EMULSIONS ADDED
 FOR UV DURABILITY
– TINUVIN® 1130 AND TINUVIN® 292 ADDED
 FOR FUNGUS CONTROL
– A FUNGICIDE WAS ADDED
 GLOSS WAS FLATTENED WITH SILICA
 COMPARED TO 6 COMMERCIAL DECK STAINS
 ONE YEAR OUTDOOR EXPOSURE TO DATE
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EXTERIOR STAIN – ONE YEAR OUTDOOR
EXPOSURE – CARPENTERSVILLE, IL
GLOSS RETENTION
20 DEGREE
GLOSS RETENTION
60 DEGREE
DELTA E
ALKYD EMULSION
100%
65%
3.8
STAIN #1
100%
44.4%
3.0
STAIN #2
50%
34.2%
4.05
STAIN #3
50%
44.9%
3.6
STAIN #4
100%
22.5%
2.5
STAIN #5
100%
92.3%
4.0
STAIN #6
50%
83.4%
2.3
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SUMMARY
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“HOLY GRAIL” FOR REFINISHING WOOD FLOORS
EXCELLENT STAIN PENETRATION
EXCELLENT LAPPING RESISTANCE
EXCELLENT GRAIN RAISE RESISTANCE
VOC AS LOW AS 50 G/L, LOWER POSSIBLE
FEASIBLE AS EXTERIOR DECK STAIN
 ANY QUESTIONS……
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