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Additives | Crosslinkers | Resin Components | Resins Issue 10 | March 2013
Smart Formulating Journal
Editorial
Matting agents with a higher polishing resistance –introduction of a suitable testing methodpage 6
Hot stamping – a printing process using methacrylate resinspage 5
TEGO – Adding AdvantagesTEGO additives and specialty resins for functional coatingspage 3
Environmental issues are increasingly becoming important in managing any public or private operation today. Recognition for the potential of Green Public Procurement (GPP) as an eff ective instrument for stimulating sustainable public or private operation today. Recognition for the potential of Green Public Procurement (GPP) as an eff ective instrument for stimulating sustainable public or private operation today. Recognition for the potential of Green Public
development has grown.
Minimizing the Carbon Footprint of Road Markings
GPP guidelines implemented by the European Union, for example, are calling for the consideration of environ-mental aspects based on solid scientifi c evidence when deciding various product alternatives. Green purchasing is not only limited to the public sector and appears to be increasingly used as a corporate practice. Hence, decisions about product portfolio are shi� ing to more environmen-tally friendly products as the business strategy for future sustainability and competitiveness. Evonik points how to use Life Cycle Assessment (LCA) as a guideline for the development of more sustainable road marking solutions with reduced environmental impact. This method allows both an analysis of particular product options with respect to the total environmental impacts as well an assessment of the signifi cance of the individual phases of a product life cycle.
As a major supplier of road marking binders, Evonik Industries has conducted a comprehensive analysis of road marking systems based on the four major road marking material technologies used in the European market: solvent-borne (SB) paint; water-borne (WB) paint; ther-moplastic (TP) and thermo spray plastic (TSP); and cold plastic (CP) and cold spray plastic (CSP) [1,2]. Impacts originating from both the marking material and the glass beads broadcasted onto it during application to achieve retro-refl ection, respectively night-time visibility of the road marking have been taken into account. The method for this analysis is the life-cycle assessment (LCA) as out-lined in ISO 14040 and 14044. This method is evaluating the environmental impact of a product considering all raw material and energy inputs throughout its entire life from cradle to grave.
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Dear Readers,
You are holding the tenth issue of our customer magazine for the coatings and paint market in your hands. With this magazine, we want to inform you about the latest developments from Evonik for this important market.
As an innovative industrial company, Evonik gears its business towards the key megatrends. For us, they are the global social issues of the future and with our business we want to make a real contribution towards fi nding solutions. In our eyes, these megatrends are not only social developments that bring with them great change, they are also business areas with exceptionally high growth potential for both us and our customers. Evonik has identifi ed three global megatrends: resource effi ciency, health and nutrition, and globalization. Within the megatrend of resource effi ciency, for example, an essential goal is to be the number one cooperation partner when it comes to developing new paints in collaboration with our customers or improving existing formulas in close cooperation with our customers.
In order to implement this cooperative approach with our customers – the manufacturers of coatings and paints – on a global scale, we have set up application labs in all regions, most recently in Brazil. We are also establishing new plants around the world, such as the isophorone production facility which is currently being set up in Shanghai. In addition, we are investing in our network of paint experts who develop new formulas in close collaboration with you, our customers, as well as new methods, for example the life cycle analysis featured in our report in the current issue.
We look forward to receiving your comments and continuing our intensive dialog.
We hope you enjoying reading this issue!
Best regards,
Dr. Thomas Haeberle Member of the Executive Board of Evonik Industries AG
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Smart Formulating Journal | Issue 10 | March 2013
Impacts such as the Global Warming Potential GWP (so-called carbon footprint) are calculated in equivalent mass of a reference substance e. g. kg-CO2 Equiv. In total 8 impact parameters have been studied including acidifi -cation potential, eutrophication potential, ozone creation potential and eco-toxicities, for instance. The environ-mental impacts of road markings was studied considering a typical German federal road bearing an average traf-fi c of about 10,000 to 15,000 vehicles per day, whereby the road pavement may typically last about 10 years giv-en this traffi c. Consequently, in this study, the lifecycle of the road marking has been evaluated for a period of 10 years per kilometre road section.
Raw materials used in the formulation of road mark-ings include binders, solvent or water in (case of paints), fi llers, TiO2 pigments and additives. Typical material for-mulations in characteristic application scenarios have been modelled using the data of corresponding offi cial approval test certifi cates issued by the German Federal
Highway Research Institute (BASt – Bundesanstalt für Straßenwesen). These approvals exactly define, for instance, both the marking material and the broadcasted glass bead aggregate mixture along with the proper spe-cifi c consumption per square metre that must be applied in practice on the road to comply with German perfor-mance standards (ZTV M 02). According to these stan-dards, safety markings with high wet night-time visibil-ity are characterised by a coeffi cient of Retro-refl ected Luminance RL measured at a wet condition of at least 35mcd / m2lx. Thus the service life of such road markings is given by the time during which retro-refl ection remains above this threshold under traffi c conditions.
All four system options can be considered as an option for spraying of thin-layer road markings. Compared with a SB paint, which needs to be reapplied together with cor-responding amounts of broadcasted glass beads 10 times to maintain retro-refl ection of the marking in-spec for 10 years. In contrast to that CSP made of DEGAROUTE® 661 reactive acrylic resin needs to be applied only four times within 10 years (see fi gure 1). Because of its high durabil-ity and thus also long service life, CSP provides an attrac-tive option to reduce GWP. TSP has a comparatively long service life as well, but GWP for this material option is higher compared with CSP because of the inherently high-er marking material consumption and its application in the molten state at about 200 °C. It becomes obvious from this
study that durability (lifetime) of the actual road marking system under traffi c wear is most decisive for the overall environmental impact. The eff ects of usage on the road overturn the relation of the impacts when looking at the production of the various materials up to the formulator’s gate. However, such cradle-to-gate evaluation reveals that specifi c contributions from binders (solvents if any) and TiO2 are generally higher than those from inorganic fi ne fi llers, wheras TiO2 (and some additives) are signifi cantly contributing to eco-toxicity. Hence all materials have a certain impact on eco-toxicity irrespective of their statu-tory hazardous-substance classifi cation.
With the methodology and scenarios established in this study a highly fi lled cold spray plastic formulation based on new DEGAROUTE® 655 binder technology can be evaluated and compared to the established DEGAROUTE® 661 technology to assess the environmental performance of new development (see fi gure 2).
For this article we have specifi cally focused on carbon footprint [kg-CO2 Equiv] of diverse road marking systems, taking into account the current broad public involvement in reducing human impact on climate change. For the fi rst time comprehensive environmental impact data on all four major road marking systems has been made available by life cycle assessment with expert panel review according to ISO 14040 / 14044. It can be concluded that among all phases of road marking life cycle it is the phase of usage on the road that is the most signifi cant phase. It is the durability (lifetime) of a road marking system that largely determines the overall ecological impact. Mainly due to savings of raw materials thanks to high durability cold plastic road markings result in a rather more resource-effi cient, more environmentally friendly solution as com-pared with other binder-based road marking systems. With advanced DEGAROUTE® 655 binder technology for highly fi lled cold spray plastics even further carbon footprint savings can be materialized. This illustrates how LCA can be employed as a guideline for development of sustainable road marking solutions.
ContactDr Alexander Klein
References[1]: “Lifecycle under the lens” Annual Showcase 2012,
Intertraffi c World, P202.[2]: “Vergleichende Ökobilanzstudie für Straßenmarkierungssysteme”,
77. Lacktagung, GDCH, 2012.
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Figure 1: GWP per 10 years per km
GWP: Global Warming Potential
Thickness, mm
CSP TSP Water Solvent
0.6 1.2 0.6 0.6
2.5 2.0 1.0 1.0Lifetime, years
thermo spray plastic
solvent based cold spray plastic
water based
154 %
178 %
100 %
180 %
transports
marking materialdrop-on material disposal
application
The global warming potential (GWP) of four different road marking types per 10 years and road kilometre, broken down to contributions from mark-ing material, glass beads, transport, application and disposal according to [1]
Figure 2: GWP per 10 years per km
GWP: Global Warming Potential
Thickness, mm
DEGAROUTE 661(40 wt%)
DEGAROUTE 665(30 wt%)
0.6 0.6
2.5 1.0Lifetime, years
100%87%
transports
marking materialdrop-on material disposal
application
Binder type/content
The global warming potential (GWP) of cold spray plastic road markings formulated with 40 wt % DEGAROUTE® 661 versus such formulated with formulated with 40 wt % DEGAROUTE® 661 versus such formulated with 30 % DEGAROUTE® 655 per 10 years and road kilometre, broken down 30 % DEGAROUTE® 655 per 10 years and road kilometre, broken down to contributions from marking material, glass beads, transport, application to contributions from marking material, glass beads, transport, application and disposal
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Smart Formulating Journal | Issue 10 | March 2013
TEGO – Adding AdvantagesTEGO additives and specialty resins for functional coatings
Various additives and specialty purpose resins that are used to adjust the selective functionalities of coatings are marketed under the TEGO brand name. By using innovative coatings, our customers can clearly distinguish themselves within their respective markets.
When antistatic additives are used, for example, fl oor coatings become electrically conductive, creating a path for charge dissipation.
Silica nanocomposites provide increased scratch and abrasion resistance in high gloss coatings for wood and plastics. These products simultaneously improve the bar-rier eff ect against water vapor, gases, and solvents.
Some surfaces can be given an easy-to-clean eff ect, while exterior paints can be fi nished with a water repel-lent eff ect, thereby increasing the longevity of buildings.
By providing release properties, blocking can be adjusted so that two coated surfaces, such as window frames, do not stick together. In a similar manner, bake-ware can be treated to allow the easy release of cakes and other naturally adherent foods.
When reactive resin modifi ers are used, silicone elas-tomer particles can be incorporated into the resin matrix of coatings, whereby the impact strength can be signifi -cantly increased, e. g., the rotary blades of wind turbines. Even during continuous use, coatings with high heat and cold resistance can be created with the help of TEGO’s specialty purpose resins.
The feel of surfaces can also be selectively adjusted with TEGO products. Touch modifi ers on leather and plastic give the surface a comfortable feel and a high-quality look.
The TEGO product line is backed up by more than 27 years of experience in the research, development and marketing of additives and specialty resins. By placing great emphasis on close collaboration with our custom-ers, we will continue to provide innovative technologies to optimize coatings in the future.
ContactMarcus Freyer
Silicone rubber
Shell
Reactive group
ALBIDUR® – Liquid Silicone Elastomer Particles for Improving the Impact Strength of Coatings Systems
Structure of the ALBIDUR® Core-Shell Particle
The use of ALBIDUR® products signifi cantly improves the impact strength of coatings without impairing the modulus or the glass transition temperature. Addition-ally, internal stresses caused by thermal shock are signifi -cantly reduced. These reactive resins are eff ective over a temperature range of –100 °C to + 180 °C.
The recommended usage level for optimal performance of the ALBIDUR ® products is between 8 to10 percent.
These liquid dispersions in resins are available for all normal 1-pack and 2-pack coatings systems. Their remarkably low viscosities simplify handling during coat-ings manufacture without signifi cantly increasing viscos-ity of the formulation.
Coatings systems modifi ed with ALBIDUR® products can be overpainted without problems a� er curing and, due to their characterization as solvent-free dispersions, are highly recommended for use in pigmented coatings.
ContactMarco Heuer
ALBIDUR® products are core-shell silicone elastomer particles of defi ned size (0.1 – 3 μm) which have an organic shell with reactive groups. These particles are dispersed in a reactive resin without settling or fl oating.
Heat resistanceSILIKOPHEN®SILIKOFTAL®SILIKOPON®
Scratch resistanceNANOCRYL®NANOPOX®NANOPOL®
HydrophobingTEGO® Phobe
Release propertiesTEGO® GlideTEGO® Rad
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Smart Formulating Journal | Issue 10 | March 2013
Higher Resistance Against Water and Corrosion for Aqueous Coatings Using TEGO® Dispers 757 W
Wetting and dispersing additives are essential for the production of pigment concentrates with high tinting strengths and suffi cient storage stability. Some additives, however, reduce the resistance of the fi lms due to their hydrophilic structure. This is especially true of aqueous coatings. We investigated whether it is possible to create high quality, waterborne coatings with pigment concentrates without signifi cantly degrading the anti-corrosive eff ects of the coating. The result is our latest product: TEGO® Dispers 757 W for perfect pigment concentrates in resistant aqueous coating materials.
Wetting and dispersing additives enable productive dispersion processesDuring the dispersion process, pigment agglomerates are crushed. This increase in surface area heightens the tint-ing ability of the pigments, making them maximally effi -cient in meeting demands for optical properties in terms of hue, tinting strength, chroma, gloss, and transparency. Wetting and dispersing additives are incorporated in the pigment surfaces (wetting) and prevent the pigment par-ticles from reagglomerating (stabilizing).
High quality aqueous coatings use polymeric wetting and dispersing additives that anchor themselves on the pigment surfaces by means of their functional groups, thus ensuring – due to their macromolecular structure and their electrostatic repulsion – suffi cient stabilization in the coating matrix1).
Compared to low molecular weight products, coating fi lms with polymeric wetting and dispersing additives generally have greater mechanical and chemical stability. However, the benefi t added by these polymeric additives is not without some adverse eff ects as they negatively impact the resistance against water and corrosion of aque-ous coatings.
With TEGO® Dispers 757 W, we have developed a polymeric wetting and dispersing additive for aqueous pigment concentrates that is intended for use in coatings with a high degree of resistance against water and cor-rosion. In addition, this new product exceeds the per-formance of commercially available products in terms of reducing viscosity and developing color intensity.
Test systems and investigative methodsThe new TEGO® Dispers 757 W dispersing additive was tested with a variety of pigments in various aque-ous coating systems. In this article, results with PR 101, iron oxide and PB 15:4 (phthalocyanine) are compared to a market standard for pigment concentrates. The for-mulations of the binder-free pigment concentrates can be found at www.tego.de. Rheological tests were performed in accordance with DIN EN ISO 3219 (RotoVisco1 vis-cometer type, Thermo Electron, cone / plate (CP 35 / 2 °), D = 0 –1000 s –1).
For the investigation of the colorimetric properties and of corrosion protection, a corresponding pigment concen-trate was added to an aqueous 2K PU industrial coating that was cured at room temperature (PR 101: 8 %, PB 15:4: 4 %). Spectrophotometric investigation: X-Rite, type SP62 with 2K PU coatings on Leneta cards (wet: 150 µm). Salt spray test according to DIN EN ISO 9227 over 1,200 hours (2K PU coating on steel). Gravimetric analysis of water absorption relative to the initial value: 1K acrylic fi ller, 7:3 mixture with the corresponding PR 101 concen-trate on aluminum a� er 24 hours storage of the sheets in a water bath at room temperature.
Higher stability of pigment concentrates using TEGO® Dispers 757 W
Figure 1: Viscosity (mPas, D= 100 s –1) of the pigment concentrates for various dispersing additives
immediately a�er 7 d @ 50˚C
140
100 110
160
Market standard
PR 101 PR 15:4
TEGO® Dispers 757 W
325
520
145210
Market standard TEGO® Dispers 757 W
Table 1: Coloristic properties at the highest level
PR 101 PB 15:4
Market standard TEGO® Dispers 757 W Market standard TEGO® Dispers 757 W
Tint. Strength 476 500 710 745
Haze 50 20 90 85
Gloss, 20 ° 79 83 89 90
Coloristic properties of 2K PU coatings on the basis of pigment concentrates with full shades of various dispersing additives
Figure 2: Aqueous 2K PU coatings based on the diff erent pigment concentrates PR 101 (le� ) and PB 15:4 (right) a� er exposure to the salt spray test
PB 15:4
Market standard Market standard
Figure 1 above shows the viscosities of diff erent pig-ment concentrates before and a� er storage at 50 °C for seven days. In general, TEGO® Dispers 757 W has a good and stable viscosity profi le. The decrease in viscosity a� er storage of the blue pigment concentrate based on the mar-ket standard can be explained by subsequent wetting of the pigment and indicates slower wetting. In the case of the PR 101 concentrate with the market standard, the sig-nifi cant increase in viscosity a� er storage is to be viewed negatively.
TEGO® Dispers 757 W allows the tinting strength to be increased by up to 5 %. In practice, this makes it possible to use less pigment concentrate. The gloss and haze prop-erties are at a similar level in both dispersing additives.
TEGO® Dispers 757 W sets new standards for corrosion resistanceFigure 2 shows various aqueous 2K PU industrial coatings a� er undergoing the salt spray test. For both the organic phthalocyanine blue and the inorganic iron oxide red, the
PR 101
TEGO® Dispers 757 WTEGO® Dispers 757 W
5
Smart Formulating Journal | Issue 10 | March 2013
coatings with the market standard have the highest level of damage. Blistering and tunneling can be seen, providing a mediocre result.
On the other hand, the coatings with TEGO® Dispers 757 W demonstrate outstanding results: the coating was largely unchanged over the entire duration of the salt spray test.
Figure 3: Reduced water absorption improves stability properties
Market standard TEGO® Dispers 757 W
20.0
17.5
15.0
12.5
10.0
27%
Water absorption (%) of a 1K acrylic fi ller with PR 101 pigment concentrates on the basis of various dispersing additives
The investigation of water absorption (fi gure 3) con-fi rms the results obtained in the salt spray test: using TEGO® Dispers 757 W, the coating has signifi cantly lower water absorption. In practical terms, lower water absorp-tion is equivalent to higher mechanical resistance dur-ing and a� er exposure to water as o� en swelling results in so� er and thus more vulnerable fi lms. Furthermore, changes in the appearance (e. g. blushing) cannot be seen with TEGO® Dispers 757 W.
ConclusionsTEGO® Dispers 757 W is a polymeric wetting and dispers-ing additive for aqueous pigmented coatings with excel-lent resistance against water and corrosion; it also meets the highest demands in terms of coloristic and rheological properties.
ContactFrank Kleinsteinberg
1) Evonik Industries AG, The Big TEGO, Issue 4, 2012, Essen, Germany
Hot Stamping – a Printing Process Using Methacrylate Resins
Hot stamping is a printing process in which a negative image consisting of various individual coating layers is applied onto a PET fi lm, with the last layer consisting of a contact adhesive. For further processing of this prepared template, the printed fi lm is then turned 180 degrees and transferred to plastic, metal, or paper substrates under heat and pressure. As a result of the heat and pressure, the PET fi lm can then be peeled away from the coating layer, which bonds with the substrate as a result of the transfer process. A release layer applied to the fi lm facilitates the separation of the PET fi lm from the transferring coating layer.
This printing process is characteristically used for prod-uct analyses and package customizing, but also for creat-ing security emblems, including holograms that protect valuable items such as banknotes against counterfeiting. Applications range from imprinting pencils to decorating chocolate boxes or whisky bottles all the way to forgery-proof security characteristics for event tickets or credit cards.
DEGALAN® is a methacrylate-based bonding agent that achieves a particularly reliable release of fi lms and coatings, ultra-sharp image motifs, clear and refi ned contours, and high color brilliance in the printed image.
The fi nal coating layer typically requires hard, medi-um-molecular, thermoplastic methacrylate resins. In the case of printing ink layers, methacrylate resins with medium or low molecular weight yield the best results in terms of pigment crosslinking, pre-printing and metal
bonding. Formulations for holograms usually rely on hard, low-molecular methacrylate resins, while meth-acrylate resins with low hardness and low molecular weight improve the adhesive bond.
In contrast to gravure, off set, or digital printing, this printing process therefore off ers a much broader spec-trum of applied printing layers, especially for products with a high-quality or highly detailed look as well as for metallic eff ects, high-gloss designs, or security features such as holograms and raised surfaces.
ContactAndreas Olschewski
CA-AC-RC + -
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Smart Formulating Journal | Issue 10 | March 2013
Matting Agents with a Higher Polishing Resistance – Introduction of a Suitable Testing Method
Matted OEM Topcoats have been used for their Eye Catching, novel appearance at car exhibitions. In recent years, trends are to have fully matted automobiles or high gloss exteriors accented by matted side panels and accessories.
The challenge of matted top coat technology is when the coating is scratched; it cannot be polished out like a usual high gloss clear coat. In the case of a matted fi nish, the polish will make the matted topcoat shiny and will still be obvious to the observer. In future the demands on the matting agent development will be focused on a higher resistance against polishing. This paper will address a new method to test polishing resistance. Suitable matting agents are recommended.
Looking for a suitable procedure for testing the polishing resistanceCurrently, there is no standardized test method avail-able to assess and quantify polishing resistance and this is the fi rst issue to address when trying to develop mat-ting agents with better effi cacy and functionality. For the time being industry accepts coating manufacturers and suppliers providing their own test method and defi nition of polishing resistance, which can be used for market-ing purpose. With this background Evonik Industries AG developed a reliable and reproducible method to deter-mine polishing resistance. Based on this procedure the development of a special polishing machine by the Otter-stätter GmbH, Bretzfeld (Germany) was commissioned by the Evonik Industries AG.
In case of the new developed machine the polishing procedure takes place in one stroke forward movement. The polishing body takes off , when going back to the start-ing position and does not touch the substrate. A double stroke polishing with a change of the direction of rotation is avoided. That means the polishing is performed only in one direction. The pad is rotating, while it is horizontally moved. The rotation and forward speed is variable (simu-lation of a hand polishing). Also the weight of the polish-ing pad can be adjusted from 100 g to 1 kg.
b)
way back, no polishing
a)
polishing track
polishing body with a defined mass
polishing body with a defined mass
3M polishing pad (diameter: 40mm)
Figure 1: Operation principle of the “Otterstätter” polishing machine (topview)
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Smart Formulating Journal | Issue 10 | March 2013
At the beginning, we had a lot of questions about the polishing resistance of silica matted coatings. Do we need hard or so� silica for a better polishing resistance? What is better – a silica gel or a precipitated silica or a thermal silica? Is the polishing resistance also aff ected by the par-ticle size of the matting agent?
Testing of the silica hardness by the grinding stability Along with several of our ACEMATT® matting agents, we chose for this comparison a product with a high (Comp. 1; silica gel) and low grinding stability (Comp. 2; precipi-tated silica).
Grinding stability is a term for the hardness of the mat-ting agents. A high grinding stability means a high resis-tance against mechanical (grinding) stress, e. g. a� er a long or intensive dispersion at high grinding stress.
For the testing of the grinding stability a coil-coating system was used. The matted coil coating lacquers were fi lled into PE-beakers, which contained glass beads. A� er-wards, the beakers were dispersed in the Skandex dis-perser for 90 minutes. The process was interrupted every 15 minutes to collect an “intermediate sample.” Each “intermediate sample” was applied to steel panels by a spiral fi lm applicator and dried in the oven. This was
followed by the determination of the refl ectometer-values at 60 ° and 85 °. Before starting this procedure, all matting agent samples were adjusted on the same gloss; refl ec-tometer value 20 at the measurement angle of 60 ° (gloss 20 @ 60 °). In this test, gloss should remain low with high grind stability. If gloss dri� s upward with grinding, this indicates lower grind stability.
Testing of the polishing resistanceThe polishing tests were done in an Alkyd-Melamine Black Baking Enamel, because the hardening process of the lacquer is fi nished directly a� er baking. The matt coat-ed (gloss 20 @ 60 °) Gardobond 722 W steel panels were polished with 100 polishing strokes by the “Otterstätter” polishing machine. Furthermore, the stroke speed was adjusted with 7.14 m / min and the rotational speed with 50 rpm. The weight of the polishing pad was 460 g.
As polishing medium Evonik AERODISP® W 1824 (AERODISP® W 1824 is a waterbased AEROSIL® disper-sion with a solids content of 24 %) was selected. In addi-tion, the gloss was measured each 20 polishing strokes.
The results of Table 1 show that the polishing resistance did not depend on the grinding stability. Competitor 2 (prec. Silica) had less grind stability but a similar polish-ing resistance compared to all matting agents with similar particle size. Contrary to conventional thinking, the mat-ting agent with the best grinding stability (Comp. 1; silica gel) showed no especially high polishing resistance.
Based on this testing, the hardness of silica, appears to be secondary. Experience shows us that generally; the coarser the matting agent, the better the polishing resis-tance, and, interestingly, the silica type (silica gel or pre-cipitated silica) does not play a role.
Silica gel, precipitated silica or thermal silica? Options for a better polishing resistance.This last fact was the subject in the next test series. Well known silica gels of the competition were compared with Evonik’s precipitated and thermal silica types. For this purpose, matting agents of diff erent particle sizes – fi ne, medium, coarse – were selected. As already described, the polishing resistance was tested again.
The following facts were confi rmed by the results of the 2nd series:
• The polishing resistance does not depend on the hardness of the silica.
• Furthermore, the silica type only plays a secondary role.
• The particle size has the main infl uence on polishing resistance. Generally, the coarser the matting agent, the better the polishing resistance.
• The polishing resistance of so� thermal silica obviously increases by the absorption of the lacquer inside the particles.
An important factor for matt coatings with a high pol-ishing resistance is the usage of coarse matting agents. With this background especially the coarse matting agent types like ACEMATT® HK 440, ACEMATT® 810, ACEMATT® TS 100 – but also ACEMATT® HK 460 – are recommended.
ContactAndreas FellerIM-SI-SRC-AC
Table 1: Relationship between grinding stability and polishing resistance
Matting agentParticle Sized 50 % [µm]
Grinding stability Relative mean gloss change (60 ° reflectometer-value)
Polishing Resistance mean value ∆ gloss 60 ° for 20 strokes
Comp. 1 (silica gel) 6.1 – 0.3 8.1
ACEMATT® 810 10.8 2.9 4.8
ACEMATT® HK 460 7.0 7.1 6.4
ACEMATT® HK 400 6.3 8.7 8.7
ACEMATT® OK 500 6.3 9.3 8.9
ACEMATT® OK 607 4.5 9.6 9.3
Comp. 2 (prec. silica) 6.1 11.5 5.8
Table 2: Polishing resistance depended on silica type and particle size
Matting agentParticle Sized 50 % [µm] Silica-type
Polishing Resistance mean value ∆ Glanz 60 ° for 20 strokes
Polishing Resistance mean value ∆ Glanz 85 ° for 20 strokes Ranking
ACEMATT® HK 400 6.3 1 8.7 3.8 ▯
ACEMATT® HK 440 14.5 1 2.6 3.2 ++
ACEMATT® 810 10.8 1 4.8 4.2 +
ACEMATT® HK 460 7.0 1 6.4 3.2 +
ACEMATT® OK 500 6.3 2 8.9 4.0 ▯
ACEMATT® OK 520 6.5 2 7.5 3.6 +
ACEMATT® OK 607 4.5 2 9.3 3.5 –
ACEMATT® TS 100 9.5 5 5.1 4.2 +
ACEMATT® 3300 9.5 6 5.2 3.1 +
Thermal Silica EXP product (very coarse)
13.0 5 2.9 3.2 ++
Comp. 1 6.1 4 8.1 4.4 ▯
Comp. 2 6.1 1 5.8 5.5 +
Comp. 3 4.3 3 9.4 3.7 –
Comp. 4 5.7 4 8.9 3.5 ▯
Comp. 5 6.8 4 8.4 4.4 ▯
Comp. 6 7.0 3 5.7 4.5 +
Comp. 7 11.0 3 4.5 4.6 +
Silica-Typ:1: precipated silica; not treated2: precipated silica; treated3: silica gel; not treated4: silica gel; treated5: thermal silica; not treated6: thermal silica; treated
Ranking (evaluation scheme):++ very good suitability for polishing resistance+ good suitability for polishing resistance▯ limited suitability for polishing resistance limited suitability for polishing resistance– poor suitability for polishing resistance
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Smart Formulating Journal | Issue 10 | March 2013
Dynasylan® SIVO 140 – A Novel Binder for Water-Borne Zinc Dust PaintsIn 2011 over half of the worldwide coating consumption was based on water-borne systems. Most of the zinc dust paints are still solvent-borne but increasing environmental awareness and new statutory provisions are putting pressure on the use of solvent-borne systems.
Corrosion can be extremely costly and it is not just limited to metals; other materials such as glass, plastics and con-crete can also be aff ected. Therefore corrosion protection is of great importance and a lot of research and develop-ment is done in this fi eld. Nearly all metals or metal alloys like aluminium, magnesium, iron and steel need to be pro-tected against corrosion.
Iron and steel are usually protected against corrosion by using zinc in diff erent forms. For hot dip galvanized steel the steel components are chemically cleaned by an acid to remove rust and millscale before being immersed in a bath of molten zinc at approximately 450 °C. When the steel is withdrawn, a layer of molten zinc remains on the surface. In the electrogalvanizing process (zinc plat-ing) the zinc coating is deposited onto the cleaned steel from a solution of zinc salts. This process is usually used for smaller parts like nuts and screws.
Zinc-rich paints are formulated with a binder and zinc dust. The concentration of the zinc dust is high so that the zinc particles are connected resulting in a dry fi lm which is conductive. The layer acts to some degree as metallic coating. The zinc dust paint is mainly used on ship’s hulls, parts of the car body and also for protection of factory steel work. The steel has to be cleaned before the appli-cation of the reduced zinc or zinc rich paint by abrasive blasting.
Diff erent binders can be used for zinc rich paints. Apart from organic binders such as polyester or epoxy resins, inorganic binders based on silicic acid esters are used. Zinc dust paints based on silicic acid esters are heat resis-tant in contrast to their counterparts based on organic binders. Zinc dust paints formulated with inorganic bind-ers are available as two-pack and one-pack systems. The one-pack system e. g. Dynasylan® MKS is stable for at least half a year when formulated and cures with the help of moisture at room temperature. Zinc rich paints based on inorganic binders do have a good chemical resistance, heat resistance and UV stability. The advantages of inorganic binders like silicic acid esters are obvious but formulations based on these inorganic binders still contain organic solvents.
The first water-borne zinc rich paints based on organic binders are entering the market; however these new systems do not have good heat resistance. Therefore Evonik developed Dynasylan® SIVO 140, a novel water-borne organic-inorganic binder for two-pack zinc rich paints with a higher heat resistance than water-borne organic binders.
Zinc rich paints based on this novel binder are nearly VOC-free, heat resistant and cure at room temperature. Dynasylan® SIVO 140 is an improvement for the environ-ment as there is almost zero organic solvent emitted to the atmosphere.
Dynasylan® SIVO 140 is the result of the latest SIVO SOL Technology and combines diff erent silanes in a water-
borne, stable and defi ned binder. The combination of dif-ferent silanes used in the hydrolysis and co-condensation process opens the way for a water-borne binder system with a designed reactivity, fl exibility and a good compat-ibility with fi llers and polymers.
Dynasylan® SIVO 140 is fully hydrolysed, can be thinned with water and is almost VOC-free. The active silanol groups are stabilized and the system can be for-mulated with fi llers and pigments. The pot life of such a formulation depends on the fi ller type and fi ller con-
centration but typical pot life times exceed 7 hours. The Dynasylan® SIVO 140 formulation has to be applied on a clean iron or steel surface. Alkaline cleaning can be done on production lines but outdoors an abrasive blasting of the iron / steel surface is necessary. Depending on the for-mulation, Dynasylan® SIVO 140 systems can be sprayed or brushed. The drying time is approximately 5 minutes for an 90 µm wet fi lm thickness at 20 °C and 50 % relative humidity. The silanol groups are activated when the water evaporates but full curing takes more time. The layer is
Figure 1: Cold rolled steel panels coated with a formulation based on the water-borne binder Dynasylan® SIVO 140. Procedure: Alkaline cleaning (60 s, pH 11, 60 °C). Corrosion protection formulation: 17 % (w / w) Dynasylan® SIVO 140 with a solid content of 25 % (w / w), 83 % zinc dust. The curing was done at 20 °C for 1 day (dry fi lm thickness ~ 35 µm). The right panel was coated with the Dynasylan® SIVO 140 formulation, cured for 1 day (dry fi lm thickness ~ 35 µm) and overcoated with a two-pack epoxy coating cured at 60 °C for 2 hours (dry fi lm thick ness ~ 60 µm). The coated panels were placed in the salt spray chamber and tested according to EN 9227.
235 hours SST
SIVO 140 formulation
KJ / V18 / 11_97 KJ / V18 / 11_101
SIVO 140 formulation +two-pack epoxy coating
870 hours SST
9
Smart Formulating Journal | Issue 10 | March 2013
VISIOMER® Methacrylate Monomers – Sustainable Solutions for the Coatings Industry
Sustainability and resource effi ciency are the focuses in the Acrylic Monomers Business Line. Apart from analyz-ing and optimizing the carbon footprint throughout the supply chain and using and developing processes with the highest possible degree of resource effi ciency, another key area is using sustainable, bio-based raw materials.
Evonik Industries already has bio-based methacrylate monomers in its product portfolio. VISIOMER® IBOMA and IBOA (isobornyl[meth]acrylates) even have a double eff ect on sustainability: On the one hand, the special monomers are excellent for formulating paints with a low VOC content and on the other hand, they are manufactured using the raw material camphene. This is recovered from α-pinene, a secondary product in paper and pulp production.
VISIOMER® THFMA (tetrahydrofurfuryl methac-rylate) and VISIOMER® C17.4-MA (a long-chain alkyl methacrylate) are also bio-based. VISIOMER® THFMA improves the adhesion properties of adhesives and goes easy on resources because the raw material used in its manufacture is recovered from waste products from sugar and starch production. VISIOMER® C17.4-MA is a main component in polymers that are used in oil additives. The raw material used to produce VISIOMER® C17.4-MA is recovered from palm kernel oil.
Evonik is also working intensively on developing more methacrylate monomers based on renewable sources. Both monovalent and multivalent alcohols from bio-technological processes are used as starting materials for methacrylate monomers. Our motivation is not only to use a sustainable raw material basis, but also to off er added value in the end applications. There are two factors that also unite the latest development product from our pipeline: Because of its low vapor pressure, VISIOMER® GLYFOMA makes it possible for highly volatile reactive diluents in resin systems to be substituted. This is a bonus, for example, in various reactive adhesives, diff erent types of coatings, and composite materials. Glycerol, the build-ing block used to synthesize VISIOMER® GLYFOMA, comes from canola oil.
Evonik would also be happy to help you develop indi-vidual solutions for your special requirements with cus-tom-made and sustainable methacrylate monomers.
ContactDr Gerold Schmitt
Sustainable development and careful use of the world’s resources are among the key issues for the future. Sustainability is also a focus of the development work in the Acrylic Monomers Business Line.
touch-dry a� er 5 minutes and can be overcoated a� er one day. Dynasylan® SIVO 140 is fl exible and formu-lations can be done for thin and thick fi lm corrosion systems. Overcoating is possible with diff erent coating systems. Especially coatings show a very good adhe-sion.
Figure 1 shows two cold rolled steel panels coated with a water-borne zinc rich paint based on Dynasylan® SIVO 140 (le� side) and a cold rolled steel plate coated with a water-borne zinc rich paint based on Dynasylan® SIVO 140 overcoated with a two-pack epoxy system (right side).
In fi gure 1 the coated cold rolled steel panel at the le� side shows some white rust a� er 235 hours in the salt spray test. The cold rolled steel panel coated with the water-borne zinc dust paint based on Dynasylan® SIVO 140 and a two-pack epoxy coating doesn’t show any red or white rust at the scribe a� er 870 hours in the salt spray test. There are also no signs of coating delamination. These results demonstrate the high potential of this new water-borne organic-inorganic binder.
Dynasylan® SIVO 140 is a novel water-borne organic-inorganic binder designed for two-pack water-borne reduced zinc or zinc rich paints. The binder offers many formulation options with fi llers and pigments. The advantages of Dynasylan® SIVO 140 are as follows:
• improved heat resistance compared to organic binders
• almost zero VOC • low temperature curing • low or higher fi lm thicknesses are possible • Dynasylan® SIVO 140 is more environmentally friendly than traditional zinc silicate coatings based on silicic acid esters
For commercial applications a detailed formulation development and stability testing is required.
Contact Dynasylan® [email protected]
Contact Dynasylan® [email protected]
Contact Dynasylan® [email protected]
10
Smart Formulating Journal | Issue 10 | March 2013
DYNAPOL® Terra – Sustainable Binder Systems for Pre-Coated Metal
The majority of the paint binders which are used for these kinds of paints are based on saturated, hydroxyfunction-al polyester polyols, manufactured from crude naphtha based raw materials.
For quite some time the paint and coatings industries has been looking for adequate replacements for these pet-rochemical based building blocks. However it’s a fact that resource effi ciency is one of the future driving forces and growth generators and Evonik is working hard to provide customized solutions for its customers.
To cope with our growing responsibility for envi-ronmentally friendly and sustainable products, Evonik Coatings & Additives Market Segment Pre-Coated Metal is currently launching the new polyester polyol product line DYNAPOL® Terra, partially or completely based on renewable, bio-based raw materials. DYNAPOL® Terra polyester resins were designed as paint binders for Coil Coating primers, top coats and backing coats.
To identify bio-based building blocks, which are suit-able for the polyester syntheses at all, was just one of the major challenges. It is not like just replacing a petrochemi-cal based monomer by a bio-based raw material, general practicability, quick feasibility and last but not least the availability on a large industrial scale had to be evalu-ated. By taking all this into account and a� er extensive R&D work some fi rst “green” DYNAPOL® polyester resins were introduced to customers with very positive feedback and the result that evaluations for modern, bio-based coil coating paints were successfully started.
Coil Coating enamels based on DYNAPOL® Terra paint binders are showing excellent cure response and provide a perfectly balanced hardness / fl exibility ratio as well as excellent fl ow properties and process stability. Stoved paint fi lms are adequate to those based on conventional polyester binder systems, e. g. from our DYNAPOL® LH product line. Beside the solvent borne DYNAPOL® Terra
Since decades pre-coated metal sheet or strip is the material of choice for exterior and interior architectural applications. Coil Coated steel and aluminium substrates are widely used for roofi ng and wall claddings, for ceiling panels, appliance coatings, air condition devices and many other applications. Can coated metal substrates like for example TFS (Tin Free Coil Coated steel and aluminium substrates are widely used for roofi ng and wall claddings, for ceiling panels, appliance coatings, air condition devices and many other applications. Can coated metal substrates like for example TFS (Tin Free Coil Coated steel and aluminium substrates are widely used for roofi ng and wall claddings, for ceiling panels, appliance
Steel) are widely used for rigid packaging applications like 2- and 3-piece food and beer & beverage containers.coatings, air condition devices and many other applications. Can coated metal substrates like for example TFS (Tin Free Steel) are widely used for rigid packaging applications like 2- and 3-piece food and beer & beverage containers.coatings, air condition devices and many other applications. Can coated metal substrates like for example TFS (Tin Free
grades, a liquid and 100 % solid body bio-based saturated polyester polyol that can be perfectly used e. g. as a fl exi-bilizer resin is just one of the particular highlights of the new product line. Further developments to expand our product portfolio for sustainable binder resins, not only for Coil Coatings but also for Packaging Coating applica-tions, are ongoing.
With our new polyesters DYNAPOL Terra, Evonik takes resource effi ciency seriously and supports our cus-tomers in this new area of growth.
ContactThomas Mohr
11
Smart Formulating Journal | Issue 10 | March 2013
Evonik Heat Sealing provides solutions to meet the trend of PVC-free packaging Evonik Heat Seal Binders are designed to provide secure sealing and a clean & smooth peel.
In yoghurt packaging cups sealed with DEGALAN® Heat Seal based lidding open without chattering. No plastic strings or delaminating will appear during the removal of the lid. Since 2007 PVC-free DEGALAN® binders have become state of the art in dairy packaging applications. In solvent based lacquer formulations DEGALAN® PM 666 is meanwhile market standard with regard to primerless heat seal lacquers. DEGALAN® PM 666 is established as an universal binder in PVC free heat seal lacquers for sealing aluminium foil versus polypropylene (PP), poly-styrene (PS), polyethylene terephthalate (PET) or vinyl (PVC).
With the introduction of DEGALAN® VP 4240 D in the beginning of 2013 Evonik has now broadened its portfolio for water based heat seal binders. The new product DEGALAN® VP 4240 D is an aqueous disper-sion of a methacrylate based heat seal binder with a solid content of 50 %. The dynamic viscosity is around 350 mPas and its pH is adjusted to 2.6. DEGALAN® VP 4240 D is a polymer designed for manufacturing PVC-free, aqueous heat seal lacquers with direct adhesion
TEGOMER® – Reactive Silicone Building Blocks for ResinsTEGOMER® products are linear reactive polydimethylsiloxanes with various terminal functional groups. These groups have been developed specifi cally for the modifi cation of binders such as polyurethanes, acrylic resins, polyesters, and epoxides.
The use of TEGOMER® products as reactive co-binders or coating additives allows the unique properties of siloxanes, such as fl exibility, water and dirt repellency, weather resistance, and slip to be included in the prop-erty profi le of organic binders, thus allowing further optimization of coating properties.
• TEGOMER® C-Si 2342 (carboxy functional siloxane)Used for modifi cation of alkyd resins and polyesters
• TEGOMER® E-Si 2330 (epoxy functional siloxane)Used for modifi cation of alkyd resins and polyesters
• TEGOMER® H-Si 2311 (hydroxy functional siloxane)Used for modifi cation of alkyd resins and polyesters
• TEGOMER® V-Si 2250 (acrylate functional siloxane)Used for modifi cation of radical UV systems
ContactMarion Siemens
DEGALAN® VP 4240 D – Sealing Strength vs. Sealing Temperature
Initial
200°C
7
180°C 160°CSealing Temperature
N/1
5m
m
140°C 120°C 100°C
10
8
6
4
2
0
48h Water Aluminium vs. PS• Single step coating• Dry film coating weight 7 gsm• Drying: 15 s/180°C• Sealing: 1.0 s, 6 bar DEGALAN® VP 4240 D provides sealability even at low temperature.
Cover lid
Cup
Sealing substrate
Label print
Aluminium
Direct adhesive heat seallacquer based onDEGALAN® VP 4240 D
to aluminum foil. It seals perfectly versus poly styrene (PS) cup material.
DEGALAN® VP 4240 D will give best heat seal perfor-mance at a typical dry coating weight of 7 g / m² obtaining a typical sealing strength between 6–8 N / 15 mm.
Like all DEGALAN® heat seal binders, DEGALAN® VP 4240 D fulfi lls the requirements according to FDA 21 CFR § 175.300.
Samples of DEGALAN® VP 4240 D are now available. Please contact our Technical Service (Tel. +49 6151 18 4960 or +49 6151 18 84 4549).
Today research at Evonik Heat Sealing is dedicat-ed to create the next generation of heat sealable bead polymers. Within the next years, the successor of DEGALAN® P 24 will be designed to give direct adhesion on aluminum foil as well.
ContactDr Bruno Keller
Smart Formulating Journal | Issue 10 | March 2013
12
Smart Formulating Trade Fair Appearances 2013
Latin America Coatings Show
Asia Pacifi c Coatings Show
ChinaCoat
TEGO® VariPlus – for a Brilliant AppearanceKetone-aldehyde resins from the TEGO® VariPlus line off er the right co-binder for nearly any every application. Printing inks and industrial coatings, for example, can be drastically improved with TEGO® VariPlus products. TEGO® VariPlus SK (pellitized, 100 % solid resin) increas-es pendulum hardness and improves gloss in industrial coatings. In printing inks, it optimizes antiblocking prop-erties and tinting strength. It also improves adhesion to a wide range of plastic substrates.
TEGO® VariPlus 1201 TF (49 % in ethyl acetate) off ers the fastest drying and the highest abrasion resistance in printing inks. It also signifi cantly improves jetness.
TEGO® VariPlus AP (pellitized, 100 % solid resin) improves the grinding of fi llers and enhances the “warming” eff ect of solvent-borne wood coatings.
TEGO® VariPlus DS 50 (33 % in water) drastically reduc-es the tendency to fl ash rust in one-component direct-to-metal coatings and improves early water resistance.
ContactHeiko Alzer
DatesEvonik Trade Fair Appearances 2013
June 10 ‒ 12, 2013Latin American Coatings Show | Mexico, Mexico City
September 12 ‒ 13, 2013Asia Pacifi c Coatings Show | Thailand, Bangkok
September 16 ‒ 18, 2013Abrafati | Brazil, Sao Paulo
November 20 ‒ 22, 2013ChinaCoat | China, Shanghai
ImprintEditorEvonik Industries AGRellinghauser Straße 1 – 1145128 Essen, Germany
Contact: [email protected]
Layout / DesignLiebchen+Liebchen Kommunikation GmbH www.LplusL.de Frankfurt am Main, Germany
PrintMargreff – Druck GmbH, EssenPrinted in Germany
Visit us at European Coatings
SHOW (ECS) 2013 SHOW (ECS) 2013
Hall 7 A, Booth 323 Hall 7 A, Booth 323
