Document k6LDmKrkOXNOkbJvxR543bQBO

HlOJBCTiiD LABORATORY DKVbLORMTTS I. IIITRODUCTION \ "Rrojeoted Laboratory Developmentsn is the designated title of this talk* The objective is to discuss some of .the problems that faco us in the development of coatings for tue noar future and the approaones and solutions to bo found in the laboratory. At a recent joint Teelinical-Manufacturing Conference of the Gliddon-Durkee Comany in Baltimore, Mr. William D. Kinsell Jr., vioe-presi - dent of the Coatings and Rosin Division put the challenge in tnese wordsi nio wnat extent is Rosenrch and Development time, money and effort being dovoted to the maintonanco of yesterday* s product which is already doom ed to extinction by the noods of tomorrow* s market? Are the product development and technical service functions seeking to determine the cutomer*s noods of the immediate and long term future, or are they dovoted to the solutions of today's and yesterday's p^blems?" GLD006437 II HIOBL&IS To meet there challongos then it is nooeoGory to define these un stated problems, to consider possible approaches and proceed to the labor atory for confirmation and to establisn tne validity of that solution* The problems that face' both the formnlator and the end usor of today1s coatings are many and varied. These problems may range form the com ponent raw materials that go into the coating to its final appearanoe after application to its ultimate performance. Tuis problem Gnectrum :is superimposod on the continuing need for and expected improvements in the protective and cosmetic values. Tftiat are these additional requirements? Ecology is not a novr word but not"Until refe.ently has it "become a common word in our daily vocabulary. It needs no definition but its impact on the socio-economic f?dttorns of our lives has been great. For example, what had started out as local legislation to meet local con ditions duo !;o a unique meteorological phenomena in Los Angolos County as Rule 66 and in San Francisco as Regulation 3 is now spreading across the country. The probability of increasingly stringent Federal, Stat and local reflations in the area of controlling solvent omission is fast becoming a roality. HtOBLKM JJ0.1 nOVT BliST TO SOLVn TnJS SOLVj'JiX HUSSION FROBLhf.lt Gt000b8 Related to tuo ecological problem of solvent ernmission is tho con cern c'f.'the uso of heavy metals, specifically, that of lead and mercury in coatings. Uso of mercurials is wide spread in the ooating industry as an in-can preservative of many laiices and emulsions as well as a mold inhibitor in the ozeposed dried film, hot only is tho ooating manufacturer faced with the problem of replacing tho mercurials with effective non-mcrcurial, ho is also facod with the disposal of rash wash solutions both solvent end water, used in the cleanup of equip- usod to produco tiiose products wnica contain merourialB. Lead pigments aro widely usod as colored pignonts as well as anti - corrosive pigments. Tho Gist Congress recently passed an Act to pro vide financial assistance to nolp cities and communities to develop arid carry out intensive local programs to uliminato tho cause of lead paint poisoning. This, of course, covers only paint already applied. Title IV of tho same Act deals with the future of lead paints. In short and terse terms it directs HJSW to tai.e suen steps and impose such conditions as may be necessary to prohibit the use of lead paints in residential structures constructed or inhabited after the date of the enactment of this Act. Full details majr bo found in the February 16th issuo of the American Paint Journal. This Act is narrow in its present coope.but itB ban of lead into ot.ner areas is almost a prodiotable certainty GLD006439 II. PROBLEMS To moot tnese challenges tnefri it is necessary to define these un stated problems, to oosidcr the possible approaches ^ -J J GLD0064A0 Perhaps more problomgpxist and continually arise in the aroa of application than in any other area. The coat of application per coat or better yet tuo cost per mil dry film is pernaps tne largest single cost factor to be considered in maintenance painting# It ia also true that there is a direct correlation between performance and film thick ness. Thus to reduce the numbor of coats required to produce a givon film thickness: snould result in a lovror per mil appliotion cost# How ever this must be achieved without lar.s of performance# PROBLEM HO.5 HOW CAJ! -.IGjtHM BuILD BE OBTAINED IN LESS COATS VTiTJi 8QUAL PERFORMANCE? GL0006441 As stated in tno beginning of our discussion improved performance vrijfhin a gonoric typo of product is inherent in all development work* Thus, improved allyds, urethanes, epoxies, etc, are constantly intro duced, These are hard earned incremental but expected improvement. On the other hand certain resins exuibit outstanding properties cucaas for estomplo cneraical resistance but frith relatively poor gloss retention. Still another rosin may have these same properties in revorse. PROBLEM NO. & . CAH THIS DESIRABLE PROPERTIES OP A GIVEN RfiSTIf BE COM* Bln ED WiTrt DSHlHAHLci FEATURES OF Ah Ot USSR AiD AT Til e, SM& TIME MihIMttZE tneir respective WioknesseeT GL00064A2 Conditions at the tine of application have immense effect on the ultimato performance of a coating. Rain, dew, enibie^t temperature, surface temporature, hum'dity, etc. are impossible to control com pletely. Climatic conditions limit the exterior application season. PROBLEM UQ.'b. iiOW TO idClMID TilB APPLICATION SAiSASOIT ANDTOR BUROV* AELICATION UNDER LESS Tj l Ai-I DESIRABLE OR IDEAL CONDITIONS VTITnOUT AD* VERSE EFFECT 0)! THE PERFORIA'CE? GLD006443 1'he nature of maintcncncepainting is sucii tnat its needB relate to t a# Fractival dolloars and cents economics. VTliat are the cost advantages of painting over the cost of replacement of a substrate or structure# b# Koquirod or self imposed standards suoh as light reflectance, safeth and nealtn codes# c# subjective values associated with overall appearance, color, etc. All of tnose requirements placo an obligation or responsibility on both the manufacturer as vrell as the buyer of coatings# HtOBLEH liO# 6 HOW GAJT T E RfiQUIRffi.WnTS OF TliE MAliUFACTURER TO HtODUCE A:;D Th H BUYER TO HIOCUHB BEST BE MET FOR MUTUAL BEi EFIi A-lD SATISFACTION? GL0006AAA Ill APPROACH TO SOLUTIONS To logically find solutions "bo these problems it is necessary to establish %Yhere vro are and use that hnse as the starting point. Solutions must ho found within 'the matrix of tne oomporent parts that go to make up a coating, namely, 1. Vcuiclo solids. 2. Pigment solids. 3. Solvent volatiles. For purposes of roviovr let us briefly list the generic jtypes of vohiolo or rosin solids in use today* 1. Alkyds a. linseed b soya o. castor oil d. saffloner e. fish f. tung g. mixed oils 2. Modified Alhyd.s a. acyrlic b* rosin C. pnonolic d. silicone e* styrono f. vinyl touleno GL 0006445 3. Acrylics a* homopo lymors b. interpolymers 4. Drying oils a. same as those listed under alkyds. 5. Olooresinous 6. Urethanes a. moisture owed b oil modifiod c prenolynor d. blocked 7. Silicones 8. Vinyl Chloride copolymers 9. Latices a. acrylic b. vinyl acetate o. st;.-rone bnbndiono 10. Kpoxy n o st or s b. amino catalyzed c. amide catalzyed 11. Asphaltic and coal tars 12. fcShellno, collulosic, chlorinated rubber, inorganics, GLOOOb^^b Tnis list is by no moans axnnustive or all inclusive. It is In tended to be used as a guide in aur approach to the problems posed. Of the typos listed the alkyd is still the "work horeo" by accounting for hotter than 50 % of all maintenance coatings. Projections of raw material consumption indicate tuat aljryds will continue in a position of strength but being strongly challenged by the various laticos. the others string out boivind tlie two unquestioned leaders* In the pigment field titaniums continue to be a front runner, particularly witu the availability of tne chloride process type. Zinc oxide is a poor second. In the solvent group tho principal types are1. Aliphatic hydrocarbons 2. aromatic hydrocarbons 3. terpones. 4. oxygonatod solvents a. alcohols b. etners o. ostern d. kebones 5. nalogonatod Hydrocarbons 6. nitroparaffins 7. water. Against bills background lot us consider tho solutions to the porblems, CLD00644? iV. SOLUTIONS Problem Wo. 1 How to solvo the solvent emission problemt SOLUTIOIT A. An obvious solution is to replace the non- con forming solvent frita a solvent that does comply nitn tue require ments# In tiie case of mineral spirits tjiis nas been rolfcively simple.in as much as a single direct replacement was readily available. Those mineral spirit replacements were of lower aromaticity tnor ofor of lor/nr solvency widen resulted in sligntly uigner viscosity anci at times sligntly slower set up times# Additional formulation adjustments minor in nature had to be made to compensate. To roplaco aromatics such as xylol or branohed ohained solvents s u c j i as M1BK is a little more difficult because a single direct ireplacement was not available# Instead combinations of solvents had to be blended to individual requirements# At the outset of the solvent emission regulations the replace ments were vrorked out empirically# Today tne replacomait com binations aro derived form sopnisticatdd computerised programs based on solubility parametershydrogonbonding factors, fete. With this tool'avai lable solvent emmisiion problems should not be critical to solve. GLD006448 SOLUTION B. Still anotuor solution is to eliminate tins solvent entire ly by resorting to solvent free or 1007* vohiole solids ooatings* This would require sgme roformul&tion of the base resin to adjust for good application. Suon coatings are feasible as i8 witnessed by various epoxy formulation^ Otnor rosins are being oondidardd fbr adaptation to this technique. ssabtnaoif o. If a replacement solvnot is not available or does not produce thxa desired result, consideration should be given to converting trie reftin from a solvontusolution to a water soluble resin. Many of the resins listed can be solubilized in vrator by the use various coupling agents tp eliminate the objectionable solvent or solvents. Thid solution is adequate in some cases wneruas in otnors is may introduce water sonsitivity or residual odors. Many alkyds and acrylicB have boon converted by this mechanism to satisfactory water roducibility . S0LUT10H D. If vmter solubility is not the comploto answer another teonique to consider is tne omulsification of tne resin, 'inis nas boon successfully psed with epo.xjr esters, chlorinated rubber and oven with two paokago catalyzed epoxy systems. This technology is boing refined daily and may veil be tne best answer for manjr of today's solvent ooati' gs. SOLUTION JS. GLD0064 49 Another solution to sfilvcnt emmsion is a variation of 100/5 solids^.M* rtfi" ' ' r ^ coating^ however, it is applicable to production line finishing. It is cited only as sn oxsjn.pl c of now such problems can be approached GL0006450 HtQBlfcM HO* 2 Wj iAT TO DO AlJO.jI MKRCURi' AiiD LhAD RtPLACl^toTI Solution; Many non-mercuriils are available and on testand in many cases already in formulations. Current literature is devoting a lot of spaoe V to this problem towct can readily be referred to In any case no one non- mercurial has emerged as the outstanding replacement, however,as tests and exposures continue the problem will be resolved. Lead pigments have served long and fiithfully in the coatings industry both as a colored nif^ient and even more importantly as an anti -corrosive. The objection to? the use of lead is its toxicity especially during application and tne potential danger during the life bf the film by accidental ingesting. Where load pigments have been used for their chromoticity they have boon largely replaced by non toxic organiss. In the anti-corrosive field the lead replacement Ass been more difficult because of its long rooord of roliable performance. The potential replcomento such as calcium chromate, onlcium molydate, eino phosphate, iron phosphate and barium metaborate have much shorter field exposure hence their performance is sjjill under consideration. lioYrover, the rpports are encouraging. Kach nas some merit and in tne case of tne last four an additional advantage is gained by the faot that they are white. This nay herald a new series of colors for primers other than'the tradional rods, oran gos and olive drabs. CLD006A51 HtOBlJa-.! NO. # now CA*! nlGnKl BUILD BS OBTAInJSD IN LttSS COATS ffiTn JS^UAL PERFORM.':Cii? SOLuTIOn A. Tno solution suggested as an answer to the solvent emnission problem can also be used to obtain higher buidf namely, the 100% solids or solvent froo coating. Properly formulatod thd solvent free coating can give higner fiifan build, inis has been demonstated as being praotical in certain opoxy coatings. This may result in higher costs per unit pur chased volume but could concicvably result in lower oost per mil dried film. Solution B. nighor build application may be attained by the use of thixo4 0vL-y> tropes witjiout sag. To do so tne coating must be formulated for complete through dry and good solvents el ease so aB not to give surface dry and a soft cure below the surface which would eventually lead to cheek ing and alligatoring. SQLUl'ICi; G. Veniclos witu high gel structure have been developed* These iu turn nave boon formulatod to give pigmented products of excellent structure that readily break down under the shear of the brush, roller or spray but recover rapidly to permit high mil application without sag. Aljryds are particularly amendable to tiAs teciinique. GLD006452 PROBLEM MO. CAN i1,* DaSIHABLu FROPERTI&S OF WTO GEHiRIC RaSIllS BB COM* BII'IJiD 1.1MT7 AiiD AT THE SAJLE TU.'E MINIMIZE THE LESS DESIRABLE IORPEKTIIES OF EACH? CAM WE HAVE T`:ii BEST OF TITO RBSIhS IN ONE FINISH? SOLHTiOuj T110 coalings industry is no longer as beholden to naturally occuring oils end rosins as it nad once bean. T110 loosening of tnis dependence on nature has been a long and continuing process of evolution as coating technology moved from on art to a science. Today t]u*6ugh the expertise of our rosin chemists the genetics of a resin oan bo controlled and designed to produce a desired resin. It can bo "tailormade". Tnu3if an epoxy resin is selected because of its superior chemical and solvent resistance it wan be designed to oombine vdth ati acrylic with good gloss and color retention properties by grafting a functional group for escamplo an isocyanate fcn one of the polymers and a corresponding reactive group such as a iiydroxyl to tne other. True, this re suitd in a two package system but the finish has properties not obtainable in either individually. GLD006453 HtOBLM HO. 5 nOYI `1*0 EXTii.D TnE ATPLlCAXiUn SEASON AiiD/OR D.imOVfi APPLlCAxIOiM UnDhR. Lk SS it Ah IDjAL COnDIXlOnS./t SOLUXlOu t /tt A similar approach to tnat proposed in the last problem is suggested, namely, specifically designed two package systems* Since such systems cure chemical orosslinking they are not as dependent on favorable atmospneric conditions as Mimmmm/mmif/ tnose dependent on air oxidative mechanism. CLD006454 PROBLEM 1(0. 6 now can THE REQUIREMENTS OF 'l'TTJB MAUUFAC'i'UBKB TO PRODUCE PROFITABLE AMD TriE BUYER TO PROCURE COMPETITIVELY BE MET? SQLUTlQn .This perhaps is not a quetion to be entirely resolved in the laboratory it snould nevertaoless bo considered. hitn consumer or ganizations growing stronger in their demandsa possibility that Washington Trill intensify efforts to sot product standards for con sumer goods. Some tnougat cnoyld be given to performance standards tnat vrill tnlyy reflect tny roods of the user. GLD006455 V. SUM-'JffiY Briofly some of tbo problems onifitewed for the soventies were discussed and solutions suggotfced. Ecological considerations loom largo in tue near future* in our industry tueso arc concerned with solvent cmicolon and tho elimination of load. Solutions to these problems not Vv>% only rccolvc i;lio ecology conflict but lead tn improved polymor systems and higher l>"ild coatjugs* additional j l u concludion iwoulO, 111 o to montioa topics of interest but not, discussed* fho concept; of aiding wiwiout pigments is coming up more and more* Thie development colud result in somo significant changes fin the industry* One resin syntom bnat 1 ranrants watching is the fluocarbons* i'hoso uavo boonomxnontly successfully in coil coatings with long rango durablity Witn t.'io o:q>onsive sandblasting costs in the field , tho pro blasted stool become3 nci'c attractive* If this develops intio a trend fast dry woldablo shop primers willbo como s hmjor row dcbolopnont. 8uou coat GtD006^5fc