An Article on

Approaches to develop waterborne acrylic binders for low VOC Paints

By:Shasanka Sekhar Borkotoky Parag Choudhury

(M. Tech. Polymer Science & Technology)

Department of Chemical Sciences

TEZPUR UNIVERSITY
NAPAAM, TEZPUR 784028 DISTRICT- SONITPUR (ASSAM)

1|Page

1. INTRODUCTION

The development of new elastomeric waterborne acrylic resins for use in surface tolerant maintenance coatings will be described. These coatings are resistant to mud cracking, and form an excellent barrier coating for the protection of steel. Elastomeric coatings based on waterborne Acrylics have excellent water and corrosion resistance, adhesion, flexibility (even at low temperatures), and tolerance to application over both clean and rusty steel surfaces. In addition, these coatings have very low levels of volatile organic compounds (VOC), and offer an environmentally-friendly and VOC compliant alternative to traditional solvent borne coatings. The development of a waterborne acrylic binder that can be formulated into zero VOC paints requires the tuning of film formation under difficult conditions, hardness, and flexibility properties. To meet these requirements, a model of the ideal film was developed and polymers were synthesized to comply with this model. The choice of particle size and glass transition temperature (Tg) of the polymer phases were the key parameters in producing the desired film morphology. However, to ensure good mechanical properties, it was also crucial to optimize the interaction between the polymer phases by varying both the polymer composition and the stabilization of the latex.

Today, most interior and exterior paints are found to have high levels of VOCs, which help them to dry faster. But, these VOCs emit smog-forming chemicals into the air and thus. Become the major contributor to ground-level ozone pollution. These release low-level emissions into the air for years after the application. And the major source of these toxins is a variety of volatile organic compounds, which, until recently, were essential to the performance of the paint. The new environmental regulations have resulted in alternative solutions Low VOC and Zero VOC paints. Lower VOC paints preserve both indoor and outdoor air quality and reduce the incidence of eye or respiratory irritation from exposure to VOC fumes. [1]

2|Page

Types of non-VOC paints:

1. Natural Paints and Finishes These are paints made from natural raw ingredients such as water, plant oils and resins, plant dyes and essential oils; natural minerals such as clay, chalk and talcum; milk casein, natural latex, bees wax, earth and mineral dyes. Water based natural paints give off almost no smell. The oil based natural paints usually have a pleasant fragrance of citrus or essential oils. Allergies or sensitivities to these paints are uncommon. These paints are the safest for ones health and also for the environment. 2. Zero VOC paints According to the EPA (Environmental Protection Agency) standard, any paint in the range of 5 grams/litre or less can be called Zero VOC paint. Adding a colour tint usually brings the VOC level up to 10 grams/litre, which is still quite low. 3. Low VOC paints As described above, the level of harmful emissions are lower than solvent-borne surface coatings, as they carry water as a carrier instead of petroleum base solvents. These certified coatings also contain no, or very low levels, of heavy metals and formaldehyde. The amount of VOCs in paints should not exceed 200 grams/litre and in varnishes, it should not exceed 300 grams/litre. Low VOC paints tend to emit odour until dry. To avoid this, one should buy paints that contain VOCs less than 25 grams/litre. [7]

3|Page

2. Waterborne Acrylic Binders

Acrylics began life early in the 20th century and have gone on to produce a wide range of products. Long before there was any Acrylic artist's paint Acrylic was replacing glass in World War 2 fighter planes and acrylic fibers were being woven into textiles. Acrylic emulsions were first used as house paints which were made famous artistically when they were used by Jackson Pollock, but it was not until after Pollock's death that the first artist's acrylics became widely available. Making Acrylic paints is not so simple as the traditional products like oil and Tempera. However very serviceable paints can be ground in the prepared Acrylic mediums. As these come in a wide range of viscosity and other properties it is easy to vary the mixtures to suit individual needs. Taking this approach makes making Acrylic paints little more difficult than making Tempera. Unlike Tempera, however, a far wider range of paints can be made from thick impasto paints to tough thin vehicles for glazing and iridescent coatings.

This is the pure acrylic resin without modification so it is a thin milky liquid that dries to a tough flexible film that is the strongest and most durable of the Acrylic paint films. Pigment can be ground directly into Binder Medium, or the binder can be freely mixed with other mediums to increase resin content. On its own this makes fabulous glue that is perfect for gluing canvas to panels because it is nice and thick, and is great as general purpose glue as well as a medium for making paints. Gel Medium Thick, transparent, and glossy makes a good strong paint film with maximum brilliance of colors. The addition of spreader medium will increase flow property. Impasto Medium The base for thicker paints Impasto medium does not dry perfectly clear as it has a solid content already. So it is the starting point for making acrylic gouaches with the addition of precipitated chalk or for adding calcite to make thick modeling style pastes.

4|Page

Iridescent Medium For special effects Iridescence can be added to any pigment by using Iridescent medium. It is basically Acrylic binder with Mica Titanate added that gives the iridescent sparkle to any color ground in this medium. Transparent pigments will have a greater iridescence and opaque pigments less so.

Modifiers Retard, spread, break surface tension etc Retarder Retarder mediums adjust drying speed by replacing water with a liquid that drys more slowly than water. Useful up to a point but too much can create a paint that won't dry properly. Spreader or Thickener This adjusts the flow and leveling qualities of the paint (technically called rheology). Thickeners are available with both short and long rheology. Defoaming agents These are silicones that combat the surficants within the Acrylic which have a tendency to foam during dispersal by popping bubbles as they form. Overuse causes 'cratering'. Matting agents This is silica and in the case of making Acrylic paint the naturally derived crystaline version is better than the synthetic 'amorphous' type. Wetting agent Often called Surface Tension Breaker's these are valuable for wetting the synthetic organic pigments during predispersal of the pigments. Calcite Calcite can be freely mixed with the acrylic to make a modeling paste or paint that holds brushstrokes easily. Ammonia This can be just the Cloudy Ammonia from the supermarket. As you make paint the pH level may fall. Acrylic paint exhibits ideal paint qualities between pH levels of 8 5|Page

and 9 (water is 7) and if the pH gets too low the paint goes funny and can be ruined. A little Ammonia helps return the alkalinity the paint needs.[2] These are some industrially used Acrylic Binders.
Chemical Nature pH (0.05) Dry Cont. (2%) Cold Crac C
0

Film Properties

General properties and uses

Acrylic Emulsion

6.5

35%

Hard Clear Transparent Glossy

General used as a topcoat for resin as well as glazed finishes. It produces a bright, lustrous and a radiant gloss with a pleasant touch. It can be used as an intermediate binder for plate release. Self-crosslinking binder used for general plated resin finishes. It has excellent surface build up and surface smoothness. Self cross Linking general-purpose med-soft binder used as a major binder for bottom as well as intermediate coats...It has moderate surface build up. Soft binders with low tackiness, good gloss, filling, anchorage and possesses good fastness properties. Non-Tack Med. Soft, elastic resin with low tack, good flow and embossing properties. Excellent fastness to light.

Acrylic Emulsion

7.0

38%

12 0C

Med-Soft Glossy Elastic Non-Tack

Acrylic Emulsion

6.0

35%

-15 0C

Med-Soft Elastic Glossy

Acrylic Emulsion

6.5

38%

-12 0C

Soft Good Filling Glossy

Acrylic Emulsion

6.5

38%

-12 0C

Med. Soft, Good Filling, Glossy

6|Page

Acrylic Emulsion

7.0

35%

-25 0C

Very-soft Strongly Filling Glossy Soft, Fine Glossy,

Acrylic Emulsion

4.5

35%

-18 0C

Slight Tack Soft binder with fine particle size used for sealing coat in finishing splits.

Soft, fine elastic binder with low tackiness for full grain/garment leather. Improve adhesion without overloading the grain.

7|Page

3. Low VOC Paints

Volatile organic compounds are substances that evaporate from paint allowing it to dry and are very toxic to humans. Even after the paint has dried, VOCs can continue to be released from the paint for years, thus, harming the occupants. The easiest solution is to use paints that do not contain VOCs and instead contain a non-harmful drying agent. Low VOC paints are the ones which use water as a carrier and it contain reduced levels of volatile organic compounds (VOCs), which emit smog producing pollutants into the air. Formulation of a zero VOC polymer Choice of thickener When formulating the zero VOC binders, the careful choice of the thickener was considered to be crucial. The stability of the formulation during film formation is important to obtain the optimal balance in properties. Since the binder was optimized in its stabilization mechanism, certain thickeners can have a detrimental effect on the film-formation and application properties. Two thickeners that were found to be suitable were next to the Rheolate 350 from Elementis Coapur 3025 from Coatex. Both can act as the basis for further formulation. Choice of defoamer Defoamers are known for their strong effect on film properties and always have to be optimized according to the final formulation. Important in this specific formulation was the fact that they should not contain any organic solvent. Two defoamers which showed the best properties in the screening

8|Page

formulations were Foamex 805 from Tego and Drewplus S4386 from Ashland. BYK 022 was only used in the pigment paste.[8] Addition of solvent Although the intention of the binders is based on a completely zero VOC formulation, it is feasible to add some additional cosolvent. The binders are compatible with standard organic solvents such as butylene diglycol (BDG), ethylene diglycol (EDG), dipropylene glycol methyl ether (DPM) and dipropylene glycol butyl ether (DPNB). In these cases, the cosolvents did not have an additional function as a coalescent aid, but had an effect on the paint viscosity. One has to be careful that the solvents have no negative impact on other properties such as the hardness and the blocking tendencies, mainly due to retention in the film. Increasingly demanding environmental regulations for industrial maintenance coatings have put pressure on manufacturers and users of both solvent borne and waterborne coating systems. The lowering of volatile organic compound (VOC) levels to below 100 g/L is being considered for industrial maintenance coatings in many regions of the world. This article discusses the development of Waterborne acrylic latex polymers for use in high performance,VOC-compliant coatings applied to steel and concrete structures. Formulation and coating properties of these polymers are described, with an emphasis on comparisons of performance to traditional, higher VOC waterborne and solvent borne coatings. Environmental regulations have put increasing pressure on all members of the coatings industry to develop and use coatings that have lower impact on our environment. Raw material suppliers are constantly working to develop new resins and additives that allow paint manufacturers to produce coatings with favorable health, safety, and environmental profiles. In addition, painting contractors and end-users such as home owners and facility owners are constantly asking for higher performing products. Those two desires are often difficult to bring together in a new product, especially when it comes to lowering volatile organic compound

9|Page

(VOC) levels. Waterborne latex coatings are one technology which provides an opportunity to reduce VOC levels relative to traditional solvent borne technologies. However, technical challenges still exist, considering the low-VOC targets posed by many existing and proposed regulations. In particular, properties such as hardness, dirt pickup resistance, block and print resistance, and the ability to withstand freeze-thaw cycles, can be difficult to achieve. Using latex polymers with lower glass transition temperatures is an obvious route to coatings that require less coalescing solvents and have lower VOC demands. Industrial maintenance painting of steel and concrete structures is still done mainly with solvent borne coating technologies. It is estimated that about 80% or more of the coatings used in these applications are solvent borne, with epoxies, polyurethanes, and alkyds making up the bulk. Only about 16% by volume of industrial painting relies on waterborne acrylic latex coatings, while architectural applications today overwhelmingly utilize latex-based coatings. However, the use of waterborne coatings for industrial maintenance has grown considerably since the 1970s, when they were virtually non-existent. Waterborne acrylics now find use in a variety of light and medium duty industrial applications. Overall, the phenomenal growth of waterborne acrylic has been driven by a number of factors, including compliance with VOC regulations, ease of clean-up, less hazardous waste disposal and its associated costs, lower risk of health hazards due to exposure to solvents, less concerns with flammability and the impact on insurance costs, their one-component ease of use, and, finally, their proven performance capabilities in real world settings. As with architectural coatings, industrial maintenance (IM) coatings are coming under increasingly stringent VOC regulations in many areas of the world. Standard VOC levels for industrial maintenance coatings to 100 g/L. Such regulatory pressures will continue to move IM coatings towards waterborne, high-solids solvent borne, and other technologies that are able to comply with these strict limits. At the same time, end-users are unwilling to sacrifice coatings performance for these often high-performance coatings.[4]

10 | P a g e

The major paint properties, which include an excellent film formation of zero VOC paints under difficult circumstances (e.g., drying at 4degreeC on a porous substrate), combined with a good hardness, blocking, and sufficient flexibility to follow dimensional changes of the wood, put a high demand on the design of the acrylic binder. For an excellent film formation at a temperature of 4degreeC, one would need a very soft polymer to ensure optimal polymer flow, even at higher pigment loadings. This implies that the polymer will need a glass transition temperature (Tg) that is well below 4degreeC. This will result in insufficient hardness and extremely poor block resistance. To achieve the required hardness and blocking, a high Tg is required. This will result in a poor film formation, because of the contradictory requirements for this low VOC application. Through the years, researchers have sought the ultimate balance in these properties by combining hard and soft polymers in a variety of ways.

11 | P a g e

4. Structure and Formation of low VOC Paints

Film Formation
Film formation using acrylic binders is a process that has been studied by many people over the years. When homogeneous latex is applied, the ultimate film should eventually result in a homogeneous polymer film. When one considers the contradictory application requirements, this homogeneous film would hardly ever be able to deliver the desired properties. Thus, for many years, attempts were made to synthesize acrylic dispersions that would give a heterogeneous film on drying, by combining hard and soft polymers. The most common way of obtaining a structured film was to apply a blend of hard and soft particles and/or to change the particle morphology of the single particles. By using this method; several film structures can be obtained. In the rest of the article, the terms hard and soft polymer will be used. The term soft refers to a polymer with a Tg < 0degreeC; the term hard refers to a polymer with a Tg > 50degreeC. A model is proposed that is believed to give the most desirable film morphology for a zero- VOC paint. It is thought that in an ideal case, the hard polymer builds an internal film structure along the edges of the particles of the soft polymer. The soft polymer is able to form a coherent film under ambient conditions, and the internal structure of a limited amount of hard polymeric material provides the required hardness.

12 | P a g e

An additional requirement is to obtain a flexibility of at least 100%. Flexibility, in this case, was measured using the percentage elongation of the film up to the point of failure due to the propagation of fractures in the film. For good elongation, the most flexible (i.e., soft) phase should form the continuous phase, in which case failure will occur in this soft, continuous matrix. The case where the fracture occurs along the interface of soft and hard material is undesirable, because this points to a weak interface between hard and soft particles and, therefore, reduced elongation. This all leads to the conclusion that the interface between the polymers has to be tougher than the soft polymer matrices.

Another important parameter that has to be taken into account is the fact that the polymer dispersions are being used as binders in paints. In other
13 | P a g e

words, the pigment ability of these formulations containing the polymers plays a major role in the overall performance of the material. This implies that the desired hardness/ flexibility balance has to occur in a pigmented formulation where the pigment binder interaction plays an important role. Therefore, in addition to the interaction between the different polymers, the interaction of the polymer with the pigment will also determine the properties of the final paint. Considering all these factors, it is clear that such systems require a careful balancing of parameters in the polymer binder.[5]

Structure of the polymer film

The first target was to obtain a film that had an internal structure, which resembled that shown in Fig. The most logical route to obtaining such a structure was through the use of a blend of two polymers. For this purpose, a range of polymers was synthesized, varying in both particle size and Tg. These polymers were blended in several ratios and evaluated. More experimental details regarding the polymers are clarified in reference. To clarify the internal film structure, atomic force microscopy (AFM) experiments were conducted on the films of the blends not only exhibiting the surface of the film (as is normally the case when applying AFM), but also studying the interior of the film. This latter set of experiments was performed by applying AFM on cryo-microtome crosscuts of the films. Since the AFM method that was applied was sensitive to the hardness of the surface, a picture could be obtained of the internal morphology of the film, where the dark regions indicated soft material (low Tg) and light regions indicated hard material (high Tg). By applying this technique, it became clear that the film morphology could be modified by varying particle sizes, hard/soft ratios, as well as particle morphologies. Table displays the three key parameters

14 | P a g e

that were chosen to judge the applicability of the binder. AFM internal morphology images of these four samples are also displayed in Fig. From the AFM pictures and the application results, it can be concluded that the control of the internal film morphology clearly influences the final properties of the film. When a homogeneous film is obtained with a limited internal structure (sample A), the properties are quite poor. The hardness and elongation properties are inadequate and film formation at 4degreeC is not optimal. Introducing a separation in hard and soft material, where both hard and soft components are present in equal amounts, results in a sort of bi-continuous phase (sample B). This has a positive effect on both the hardness and the elongation. When the particle-size ratio between the soft and hard particles is increased (sample C), an internal structure starts to develop and appear, resembling the model presented in Figure. The elongation immediately increases. However, film formation at 4degreeC is still not optimal, because of a relatively large amount of hard material. Decreasing the amount of hard material (sample D) surprisingly did not influence the measured hardness much and had a very positive effect on the film formation at 4degreeC. A closer inspection of the AFM picture of the interior of the film still revealed an internal structure in the film,

15 | P a g e

16 | P a g e

where the hard material was present at the outside of the soft particles.[6]

Interaction between the different polymers

Although there is a clear relation between the film morphology and application properties, it was immediately clear that the internal film structure was not the only parameter determining the properties. The elongation properties and the ability to formulate the binder are determined by the chemical buildup of the polymer and the stabilization mechanism of the polymer emulsions. Changing the composition of the polymer backbone and changing the stabilization mechanism can have a dramatic effect on the mechanical properties of the film. Where scanning electron microscope (SEM) images of the fracture surfaces, after failure in the elongation experiments, are presented. Here, three blends of polymers with the same ratio hard/soft material were investigated. The particle sizes of both the hard particles and the soft particles were identical, so no effect of the film structure was expected. The only differences between the three samples were the composition of the soft material (Tg was kept identical) and the stabilization mechanism. The hard polymer was kept the same in all cases. What can be seen in the first

17 | P a g e

sample is that there has been very poor interaction between the hard and soft polymer phases. It appeared that the hard particles and the soft matrix material were completely separate from each other. Furthermore, due to poor stability during film formation, the hard polymer particles exhibited clustering, resulting in large hard domains. This resulted in a brittle fracture over the interfaces between the two polymer phases. The second sample contained the same soft polymers and hard polymers, only with an improved stabilization of the polymer particles. The system also showed typical surface features associated with a brittle fracture. It appears that this system also failed at the interface between the hard and soft particles. However, no large clustering of hard polymer particles was observed, indicating better stability during film formation. The third sample contained a soft polymer with similar stabilization to that of polymer. However, this polymer was designed to have better compatibility with the hard polymer phase. The fracture surface was more ductile in nature. The failure appears to have occurred through the main, soft, polymer matrix because fewer hard particles were visible. This indicates a better interaction between the soft and hard phases. As a result, there was a significant improvement in the hardness-flexibility balance, as shown in Table 1. When the results in Table are compared, it is clear that good interaction and good stability during film formation are very beneficial for the overall performance of the system. It is also evident that when the hard and the soft polymers exhibit excellent interaction, the hard polymer strengthens the soft polymer phase. When this is combined with the positive effect that one can obtain with an internal structure in the polymer film, the result can be that relatively small amounts of hard polymer have a very positive effect on the mechanical properties of the polymer film. It is clear that the complete domination of the polymer film by the hard phase resulted in a decrease of the measured elongation. The balance

18 | P a g e

between hardness and elongation was clearly very sensitive. It is usual to add as much hard material as possible to obtain the highest possible hardness. However, too much hard material will have a negative effect on the film formation properties and on the elongation characteristics of the film.[7]

19 | P a g e

5. New developments and technologies in Water based Polymers

A Driving force in the development of water based binders has been, and still is, the introduction of legislation to protect the environment and increasing legislation to protect our safety and health. Acceptance of new technology depends much on such practical factors as the ease of coating production, the ease and speed of application, drying methods and the final properties of the finished material. But such, new technologies should not lead to a decrease in the capability of the finish to beautify wood or furniture. The development of water based binders has always concentrated on this aspect, but so far, the trouble-free replacement of solvent based coatings by water based systems has not been too easy. Recent developments in acrylic emulsion and polyurethane dispersion technology give coating manufacturers the possibility of formulating paints and lacquers which perform very near to the quality furniture producers are used to. With the introduction of surfactant-free emulsions, a new generation of urethane/acrylic copolymers, fatty acid modified polymers, water based UV curing technology and the increasing know how in controlling emulsion particle size and shape, formulators can now develop coatings fit for the new age.[8]

Development need Intensive discussions and co-operation with paint producers and end users made visible what the shortcomings of the water based technology are and which coating aspects should be improved making a higher penetration of the market share of water based technology possible. The following table lists these aspects or points of improvement:

20 | P a g e

It Improves Wood wetting Stain resistance Scratch resistance Block- and imprint resistance . Transparency Filling properties De-foaming properties Grain-raising resistance Flow- or stretch of the applied coating

Technologies
The various technologies used are Self cross linking one component acrylic emulsions; Fatty acid modified urethane dispersions; Controlled particle size morphology and distribution emulsions; Surfactant free acrylic technology; New urethane acrylic polymerization technology Various coatings used in the industrial wood coating sector, such as those for tables, kitchen cabinets, office furniture, etc. require a high level of resistance. A resistance level that preferably is obtained by using one-component coating systems, since the use of polyaziridine nor the addition of cross linking formaldehyde releasing urea resins is no longer wished and the addition of poly isocyanates is possible only under strict conditions and some application methods, such as curtain coating, do not allow their use, due to the relatively

21 | P a g e

short pot life. Improved resistance of one-component systems can be obtained by various techniques.

Self Cross Linking Resins By incorporating self cross linking capability into an acrylic copolymer it is possible to improve the chemical resistance. Self cross linking is obtained at room temperature but optimal cross linking is reached at elevated temperatures of 50 to 60 Centigrade. The temperature increase improves the molecular mobility and furthermore leads to a faster optimal acidity of the emulsion system, enabling quicker and more intense cross linking. These systems, now in use for many years, have caused wider and easier acceptance of water based systems due to the higher resistance level .

Fatty Acid Modification Fatty acid modification of waterborne polyurethanes or acrylic/urethane copolymers is yet another way of increasing resistance to chemicals, stains and solvents. By building in fatty acid, auto-oxidation is introduced, leading to increased resistance, but also offering improved scuff resistance, comparable to that of a water borne polyurethane cross linked with an aziridine or solvent based oil modified urethane. Interesting side effects of this fatty acid modification is offered towards the improvement of filling properties, transparency, gloss, wood wetting, hardness and flow. In some European areas, where deep gloss, excellent wood wetting and flow are desired, the use of this material can replace solvent based products in furniture and flooring application.

22 | P a g e

Novel Morphology The performance properties of acrylic copolymer emulsions can be drastically improved by altering the shape of the polymer. Acrylic emulsions synthesised by conventional free radical polymerisation have usually lacked the clarity, block resistance and durability necessary for end users such as furniture and kitchen cabinets. The use of new polymerization techniques, such as sequential polymerization, offers acrylic emulsions with improved clarity, sand ability and better block resistance.

The segregation of the different monomers into distinct phases by sequential polymerization can produce a polymer with glassy or rubbery regions. Reduced film former demand, improved block resistance and improved adhesion is obtainable depending on the sequence in which the monomers are polymerised.Copolymers designed with a hard, glass like core and a soft rubbery shell will show a lower minimum film forming temperature at a comparable coalescent level than a physical blend of the same composition.

23 | P a g e

Reversing the structure will lead to improved block resistance. Sequential polymerization can mask a particular monomers weakness while playing to its strength.

Water based UV curing Industrial wood finishing is an application area where water based UV curing coatings are used in increasing quantities. Application methods vary from conventional air spraying, airless spraying, air mix spraying, curtain coating application and even roller coating application. The advantages are numerous: No- to very low - coalescing solvent need, Ease of obtaining low gloss levels, Ease of application and physical drying properties.

Flat panels as well as three dimensional surfaces, in the case of e.g. the coating of chairs, are coated with water based UV curing coatings, replacing two-component solvent based systems, Obtaining high quality coatings with superior properties is not difficult by the use of the available Water- based UV curing chemistry. Combining aliphatic- or aromatic, acrylic terminated, polyurethane technology with polyester and/or acrylic materials offers advantages such as quick water release, wood wetting, physical drying, surface hardness and resistance. Blending with acrylic emulsions leads to improved leveling. Water based UV curing dispersions can be formulated into transparent and pigmented low and high gloss coatings. Surfactant-free Polymers Polymerization of polymers without the use of surfactants or emulsifying agents, offers various interesting features as e.g. lower polymer particle size, less

24 | P a g e

foam formation during coating production, increased wood wetting properties, coating transparency and improved water resistance. Formulating surfactant free materials into coatings does not differ much in comparison with formulating with conventional acrylic copolymers. As we are used to with our standard emulsion programme the choice of film forming agent needs attention, not only because of compatibility but also because of the, by legislation, limited choice of coalescing agents in various countries. The following table shows the compatibility results of a surfactant free copolymer with various coalescing agents. Recent development in surfactant-free polymerization has shown that combining the advantages of low molecular weight binder solutions (offering improved wood wetting, ease of film formation and better flow properties), with higher molecular weight free radical polymerization technology will offer us the best of both systems. This new method of producing acrylic emulsions enables the formulator to produce water based furniture coatings offering high transparency, wood wetting, superior pore wetting and touch, excellent de- foaming properties and application properties.

New Urethane Acrylic Polymers Again economics and the wish for increased properties, as resistance to butyl acetate and acetone as required in the British Standard BS-6250 Severe, excellent block resistance and hand cream resistance, made a search for new polymerization techniques necessary. A new generation of urethane acrylic copolymers was developed and is now used by formulators to create waterborne clear and pigmented coatings for kitchen cabinets, table tops, chairs and panels, replacing conventional solvent-based coatings such as acid curing coatings and in some cases even 2 component coatings.
25 | P a g e

Wood & Grain Raising Grain raising caused by water contact is a well known, but not much desired effect by the wood processing industry. The swelling of the wood fiber results in a rough surface which requires extra sanding will it not lead to visible defects in the topcoat. A subjective method was determined to assess grain raising. Factors influencing grain raising were listed and literature study was done. Grain raising is not a very well described nor understood phenomenon. It depends on the following : Grain Raising Influence Wood Type Co solvent use , type and quantity pH level Solids content Coating thickness Surface tension Solubility of the polymer Emulsifier type used for polymerization ( cationic/anionic) Tg, MFT(Melt Flow temperature) Drying speed and method Surface preparation Particle size Viscosity Application method It is cleared that grain raising made clear that the type of grain raising will be different by the selected wood type. The grain raising of oak, mahogany, pine, beech, etc, is not equal. There are no standard test surfaces nor special

26 | P a g e

laboratory equipment known which can be used to qualify grain raising. The wood quality and type of grain raising differs too much in wood panels to make use of equipment which measures the roughness of the coated wood by means of laser technique/digital surf, inter-ferometry or con-vocal microscopy. [3]

27 | P a g e

6. Advantages of Low VOC Paints for Water borne Acrylic Binders

Major advantages of low VOC paints using water borne Acrylic Binders are Environment friendly, as there are lower levels of ozone pollution Fewer emissions of smog-forming chemicals. Better indoor and outdoor air quality Allergies or sensitivities to these paints is uncommon Ideal for commercial applications, and offer excellent scrub ability Quick Drying Low Odour Non-yellowing Increased UV resistance, flexibility

28 | P a g e

7. Conclusions
A high-performance, zero-VOC acrylic topcoat has been formulated based on a new innovative acrylic resin that has a fine particle size and a proper Tg without adding solvent or additives that contain VOCs or HAPs materials. The new development offers excellent corrosion resistance, weathering durability, early moisture resistance, freeze-thaw resistance and dirt pick-up resistance that is suitable for protective coating applications. The performance properties of the new zero-VOC acrylic topcoat are comparable to the commercial high-VOC, high-performance acrylic. We have described the development of a new waterborne acrylic latex polymer designed for both low-VOC and high performing industrial maintenance coatings. The improved performance relative to currently available binders and commercial coatings is based on the use of a novel technology which enhances the pigment distribution in both the wet paint and dry film. The formation of latex polymer-pigment composite particles in the wet state leads to better pigment dispersion in the dry film, and results in significantly improved gloss, durability, hiding, and corrosion resistance. In addition, self cross linking via an oxidative cure mechanism leads to improvements in dirt pickup and solvent resistance, and also contributes towards the excellent durability. Direct evidence for the formation of polymer-pigment composites and improved pigment dispersion in the dry film comes from centrifugation and microscopy (FE-SEM, AFM) techniques, and correlates with the observed properties. The technology exploited in this work represents a new method for controlling the wet paint and dry film structure of waterborne acrylic latex coatings, and the demonstrated benefits suggest potentially broad utility and value in both industrial and architectural coating applications.

29 | P a g e

New developments in elastomeric waterborne acrylic polymer technology provide coatings for industrial applications that possess a number of desirable attributes. Benefits over solvent borne coatings include the user-friendliness, low VOC levels, low toxicity, and easy cleanup that are already key properties of waterborne coatings. This study has also shown that the performance of the elastomeric waterborne acrylic coatings can equal or exceed that of commercial solvent borne and waterborne coatings. Maintenance coatings for steel based on the elastomeric technology exhibit excellent performance properties, including corrosion resistance over clean and marginally prepared steel, adhesion to difficult substrates such as galvanized and rusty steel, flexibility, and dirt pick-up resistance. In addition to the protection of steel, the same coatings have shown promise as coatings for the protection of industrial concrete. Good adhesion properties and protection of the concrete from freeze/thaw cycling, water and deicing chemicals suggest that the elastomeric waterborne acrylics could find utility in the maintenance of our transportation infrastructure, as well as for other industrial maintenance of concrete. The ability of the same coating to perform well over both concrete and steel surfaces is a key benefit, and would allow the use of a single coating system for both of these very different substrates. It was found that the combination of zero VOC, flexibility and sufficient hardness could be reached by designing a polymer film that contained a specific internal film structure. In addition to this, the interaction between the different hard and soft polymer phases must be optimized to obtain the required balance of properties. The internal film structure could be regulated by using a combination of particle types with different glass transition temperatures and particle sizes. The interaction between the polymer phases can be optimized by choosing both the right polymer backbones and an optimal stabilization mechanism for the polymer latex.[9]

30 | P a g e

BIBLIOGRAPHY
(1) U.S Paint & Coatings Market Analysis (20002005), National Paint and Coatings Association, Washington, D.C., October 2001. (2) Rosano, W.R., Bleuzen, M.N., Garzon, A., Gebhard, M.S., Larson, G.L., and Procopio, L.J., Improved Performance of Waterborne Coatings through Polymer-Pigment Composite Particle Formation, Proc. of the 28th FATIPEC Congress, 2006. (3) Braun, Juergen H., Titanium Dioxide A Review, J. COAT. TECHNOL., 69, No. 868, p. 59 (1997), and references therein. (4) Hegedus, C.R. and Kamel, I.L., Polymer-Filler Interaction Effects on Coating Properties, J. COATING. TECHNOLOGY., 65, No. 822, p. 37 (1993). (5) Richey, B. and Wood, T., Use of Ambient Temperature Crosslinking to Improve the Performance of Architectural Latexes and Enamels, JOCCASurf. Coat. Int., Vol. 77, No. 1,p. 26 (1994). (6) Speece, D., Monaghan, G., and Richey, B., Acrylic Ambient Temperature Crosslinking Technology in VOC Compliant Gloss Paints, Proc. of the 2004 International Coatings Expo, Chicago, IL, October 2004. (7) www.wikipedia.org (8)www.google.com (9) From various Internet Sources

31 | P a g e