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[…] products and services to advance a Sustainability commitment. View The Stories Economic Contributions The U.S. paint and coatings industry employed 306,000 workers in 2021. Total industry employment increased 20% over […]

2023 CoatingsTech Conference Highlights

[…] at the state level, such as PFAS initiatives and Washington State activities around PCBs in Paints and Inks and Anti-Fouling coatings. David F. Darling Prize On the last day of […]

2022 American Coatings Conference: Technical Highlights

By Leo Procopio, Paintology Coatings Research, LLC The entire North American paint and coatings industry met in person for the first time in four years during the American Coatings Show and Conference, held April 5–7 in Indianapolis. The last in-person exhibit and conference were held in 2018—two years prior to the COVID-19 pandemic. By all accounts, the 2022 conference and exhibit were overwhelming successes. People in the industry have been missing the in-person interaction for more than two years due to pandemic-related restrictions and were ready to get together to discuss all things concerning paint and coating. The American Coatings Conference consisted of nearly 760 attendees, all engaging in 90 presentations describing the latest advances in coatings technology. This article includes technical highlights from many of the sessions, which were held concurrently in four tracks. Further details can be found in the papers available in the proceedings of the conference. Some papers will also be published in future issues of CoatingsTech after peer review. The papers highlighted in this article will be presented according to some overarching themes that they addressed: Sustainability, Functional Coatings, Paint Fundamentals, and Additive Technologies. These brief summaries will hopefully serve to interest the reader to seek out the full papers and learn more about the thought-provoking topics presented during the conference. Sustainability Sustainability and sustainable development are concepts that are front and center for every business today. While sustainability can be defined as the long-term goal, as in achieving a more sustainable world, sustainable development is the process through which we achieve that goal. One definition of sustainable development comes from Our Common Future (aka, the Brundtland Commission Report), prepared in 1987 by the World Commission on Environment and Development.1 It defines sustainable development as “development that meets the needs of the present without compromising the ability of future generations to meet their own needs.” The concept of designing products which have lower impact on the environment and society is not new for the paint and coatings industry. Goals such as lowering volatile organic compounds (VOCs) in coatings and finding alternatives to surfactants that contain alkylphenol ethoxylates have been industry concerns for decades. More recently, innovation efforts have focused on additional topics such as removing other materials of concern (e.g., PFAS), using biobased raw materials, and lowering carbon footprint.  The impact of sustainability trends in innovation were clearly displayed at the exhibit and conference at booths, product presentations in the exhibit hall, and conference papers and presentations. One such paper, “The use of levulinates as coalescing agents in water-based coatings,” by Steven Block of NXTLEVVEL Biochem, received the American Coatings Award for most outstanding paper. Block described how NXTLEVVEL Biochem has commercialized a line of products derived from levulinic acid, which the U.S. Department of Energy has identified as one of the top 12 renewable chemicals. The products include levulinate esters and levulinic ketals (Figure 1), and are derived from non-food biomass such as corncobs and bagasse from sugar cane. Block described how the biobased content of the derivatives could be up to 100% biobased. For example, butyl levulinate can be produced at either 58% or 100% biobased content, depending on whether or not the source of butanol is biobased. In addition, they have a lower carbon footprint compared to petrochemical-based solvents. The example given was for ethyl levulinate (0.347 kg CO2-eq/kg) vs typical petrochemical based solvents (2 to 5 kg CO2-eq/kg). The levulinate esters (R = ethyl, butyl) are readily biodegradable, and the ketals are ultimately biodegradable. The use of derivatives including butyl levulinate and ethyl levulinate propanediol ketal as coalescing solvents for waterborne coatings was investigated. Due to their low water solubility and slow evaporation rates, it was proposed that they could be good coalescents for latex coatings. They were compared to some common coalescents, such as 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate (aka Texanol). Evaluations in waterborne coatings based on several acrylic and acrylic/fluoropolymer emulsion polymers were conducted and demonstrated that the levulinate derivatives gave comparable or better compatibility, MFFT reduction, gloss and hardness development and water-resistance properties compared to the standard coalescing solvents. On a weight basis, the levulinate derivatives were more efficient at lowering MFFT compared to the standard solvents. A second presentation discussing biobased raw materials was “Lignin as a raw material for production of biobased resins,” by Mojgan Nejad of Michigan State University. Nejad explained that after cellulose, lignin is the second-most abundant natural polymer, and is a byproduct of pulp and paper and bioethanol production. Lignin is a random polymer derived from phenolic precursors (p-coumaryl, coniferyl and sinapyl alcohol), and its composition varies based on the biomass source as well as the isolation method. Because it varies so widely, Nejad stressed that analytical methods are necessary to characterize the lignin being evaluated. For example, 31P NMR is used to measure hydroxyl content (following conversion to phosphate derivatives). Molecular weight, polydispersity index, elemental analysis, and characterization of aliphatic and aromatic hydroxyls are all important information to gather. Lignin was evaluated as a replacement for phenol in phenol-formaldehyde adhesives. A relatively low molecular weight lignin was reacted with formaldehyde to produce a lignin-formaldehyde resin. In addition, glyoxal was used as a biobased alternative to formaldehyde to generate a completely biobased lignin-glyoxal resin. Using differential scanning calorimetry (DSC), it was found that the lignin-formaldehyde resin cured at the same temperature as a commercial phenol-formaldehyde resin, while the lignin-glyoxal resin needed slightly higher temperatures (165 °C vs 145 °C). A reactivity analysis of 20 varieties of lignin with phenylisocynanate was done to identify an appropriately reactive lignin to replace the polyol in polyurethane formulations. The lignin polyol was used in a wood coating and compared to a commercial polyurethane. Although there was initially some concern about color, such a lignin-based polyurethane appears to have suitable appearance over wood or could be used in applications where color is not an issue. Nejad also described replacing bisphenol A in epoxy resins by modifying lignin with biobased epichlorohydrin (from glycerol) to form an epoxidized lignin resin. The lignin-based epoxy resin was combined with a commercially available biobased curing agent (derived from cashew nutshell liquid) to form a fully biobased epoxy system. Nejad ended her presentation with the excellent question to the audience, “Isn’t it time to start thinking about using lignin-based resins to formulate more sustainable coatings?” In the presentation, “Aliphatic glycidyl  ethers as crosslinkers for high-performance NISO coatings,” Brendon Bohnert of Nagase Specialty Materials NA discussed new epoxy crosslinkers, made from biobased sorbital, which can be used in two-component, high performance non-isocyanate (NISO) coatings. Bohnert described how there is interest in coatings made without isocyanate for EH&S reasons, but that there are also challenges in meeting the high-performance requirements. Two tetrafunctional aliphatic epoxy crosslinkers were described, based on the epoxidation of biobased sorbitol (Figure 2). One is designed for waterborne coatings (EEW = 173 g/eq), and the other for solventborne coatings (EEW = 191 g/eq), with about 15% biobased content. Each was evaluated as a crosslinker for acid-functional acrylic resins in formulated 2K NISO systems and tested direct-to-metal (DTM) and as a topcoat over organic zinc-rich and epoxy primers. Comparisons were made to a 2K solventborne acrylic polyurethane and a commercial 2K solventborne NISO topcoat. The solventborne aliphatic epoxy crosslinker gave an ambient-cure NISO system with promising corrosion resistance and durability (gloss and color retention in accelerated Xenon arc testing) and improved flexibility/impact resistance compared to the commercial NISO and 2K polyurethane topcoats. Bohnert added that formulating work will continue, aimed at improving pot life and dry time and optimizing corrosion resistance. The waterborne NISO system displayed excellent pot life, dry time and impact resistance, and Bohnert alluded to further formulating work designed to improve gloss and corrosion resistance. The last presentation with a sustainability theme to be described here was “Improving the odds of success using a benign-by-design approach to product development,” presented by Ingrid Meier of Evonik Corporation. Meier discussed a unique strategy used in the development of new dynamic wetting agents. Dynamic wetting agents require molecules to quickly align at the air/water interface, especially after the system is disturbed. Key structural features include short, often branched hydrophobes, which prevent strong micelle formation. Dynamic wetting agents are also low molecular weight and can’t meet the U.S. Environmental Protection Agency (EPA) definition of a low-risk polymer under the Toxic Substances Control Act (TSCA), which in turn brings considerable risk to the registration process for a new molecule due to the significant time and cost for required testing. EPA uses quantitative structure-activity relationships to model potential ecotoxicity behavior, and has a publicly available model (EPI Suite™) that can be downloaded from its website and used to understand how the EPA might view the risk profile of a new substance in absence of data. The project team utilized the modeling to predict the ecotoxicity of “paper” molecules, and along with their understanding of structural requirements for dynamic wetting and low foam, drive the development process and minimize the amount of ecotoxicity testing needed. In a pre-concept stage, the team identified nine chemical classes which they predicted to perform well as low-foam dynamic wetting agents. Using the models in EPI-Suite to predict aquatic ecotoxicity and biodegradability, they were able to narrow the choices to three chemical classes: thioethers, hydroxythioethers, and N,N-dialkylglucamines. Examples were prepared and then all components present at > 1% were identified, and EPI Suite was used to predict their environmental, health, and safety profile. Meier explained that after further fine tuning for performance, the two leading candidates created by the benign-by-design process, a thioether and hxdroxythioether, were ushered through the registration process quickly and efficiently. Functional Coatings Another key trend in coatings technology has been the development of coatings with functionality beyond the typical protective and aesthetic properties of paints and coatings. For example, functional coatings that provide enhanced haptics, self-healing, thermal insulation, and anti-microbial properties are available. The topic of functional coatings was well represented at the conference, with a full-day session devoted to the subject. A discussion on coatings capable of removing formaldehyde from the air in a building was presented by Mark Langille of Angus Chemical Company in the presentation, “Creating functional coatings with formaldehyde-scavenging additives.” Formaldehyde has been identified as a key chemical species that negatively affects indoor air quality, and which has detrimental effects on human health. As Langille explained, there are many sources of formaldehyde, such as cigarette smoke, particle board used in furniture, and carpeting. A French study was cited that showed that formaldehyde is a high concentration contaminant of indoor air, and the World Health Organization has set a threshold where a formaldehyde level above 80 ppb (100ug/m3) is considered contaminated air. Tris(hydroxymethyl)aminomethane (TRIS AMINO™), an aminoalcohol additive, was evaluated as an additive for paints and coatings which have the ability to react with airborne formaldehyde and remove it as an indoor air contaminant. The reaction of TRIS-AMINO with two equivalents of formaldehyde proceeds through a mono-oxazolidine to eventually produce a bis-oxazolidine and water (Figure 3). Although the reactions are reversible, harsh conditions (i.e., acid) are needed to regenerate the starting materials, and under ordinary circumstances the oxazolidine products are quite stable. TRIS AMINO was incorporated into a model architectural paint formulation at levels of 0 to 0.8% on total formulation weight, and dried paint films were evaluated according to the method of ISO 16000-23 to demonstrate the ability to remove formaldehyde. Coated panels were placed in a chamber and air containing formaldehyde (at 80 ppb) was circulated through the chamber, and formaldehyde concentration was measured for air exiting the chamber. Without a scavenger, only 0 to 10% of the formaldehyde is removed from the air after 21 days, while approximately 50% is removed by the sample containing TRIS AMINO. Other paint properties were similar to the control with no additive. Andrew Bartlett of Chromaflo Technologies examined bringing the functionality of electrical conductivity to coatings in the presentation, “The use of single-walled carbon nanotubes in coatings colorants.” Nanoparticles can be difficult to handle and disperse in a manufacturing environment, and Bartlett explained how Chromaflo Technologies has created single-walled carbon nanotube (SWCNT) dispersions to take the potential issues of handling and dispersing SWCNTs out of the paint manufacturer’s facilities. The SWCNT dispersions are already used in thermoset applications, and studies were initiated to understand their potential utility in paints and coatings. For waterborne coatings, the addition of SWCNTs to phthalo green and bismuth vanadate colorants was investigated, with levels of 0, 40, 400, and 657 ppm for the phthalo green colorant, and 0, 40, and 400 ppm for the bismuth vanadate colorant. Coatings with electrical resistance in the range to allow static dissipation could be achieved at 400 ppm and above, but electrical resistance was not quite low enough for the coatings to be considered conductive. Color is sacrificed at the higher levels of SWCNT, i.e., the color becomes darker. However, a comparison with carbon black at the same 400 ppm in the yellow bismuth vanadate colorant shows that the carbon black causes much more darkening compared to the SWCNT. In a solventborne acrylic clear base, addition of 400 ppm SWCNT achieved conductivity, but was lost on addition of phthalo green colorant. Bartlett proposed a few possible reasons why the clear base with only SWCNT was conductive while the pigmented base was not, including interactions of dispersants with the SWCNT, steric interference of the SWCNT conductive pathway by the pigments, and possible affinity of the SWCNT for the pigment surface. Further study with inorganic pigments (red iron oxide and TiO2 ) and an alternative additive package demonstrated the ability for pigmented bases to remain conductive. Overall, Bartlett stressed that these were early studies, and more work needs to be done. However, the initial results show promise that color spaces with conductivity can be achieved by using SWCNT dispersions. In another interesting presentation on functional coatings, a unique anti-microbial additive was discussed by Avantika Golas of Corning Incorporated. The paper, “Key considerations for functional virucidal paints,” described the use on a novel copper-glass ceramic additive as a sustainable delivery system for Cu+1 ions with high anti-microbial efficacy. Golas first described how surfaces facilitate the spread of microbes through both indirect contact (touching a previously contaminated surface) and aerosol spread, and that spread can be very fast. As an example, it has been shown that a contaminated surface can lead to spread throughout a building within 2 to 4 hours. Disinfection techniques, such as liquid spray, are prone to errors (surfaces missed during cleaning) and are episodic in nature, while contamination occurs constantly. Therefore, surfaces with residual efficacy can provide an additional layer of protection. Golas noted how testing of products claiming to be bactericidal and virucidal needs to be conducted to simulate realistic environmental conditions and contamination. Wet testing has strong incumbency, and uses test conditions at elevated temperature (37 °C) and humidity (>95% RH). However, there is a slow trend towards regulatory adoption of dry test standards, which are done at room temperature (20-24 °C) and ambient humidity (40-50% RH). To pass the dry test conditions, a truly bactericidal/virucidal product must demonstrate a > 3 log kill of microbes on the surface within 2 hours, i.e., greater than 99.9% reduction in the number of microbes remaining. The study compared interior latex […]

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ACA 2024 Industry Awards Dinner

[…] $125 To reserve a table for eight (8), please contact ACA’s Shelby Ferguson at sferguson@ paint.org or 202-290-5415. HOTEL INFORMATION Indianapolis Marriott Downtown 350 W. Maryland Street Indianapolis, IN  46225 […]

Current Trends in Interior Architectural Coatings

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