a sustainable approach to - patcham...

WOOD COATINGSA SUSTAINABLE APPROACH TO

MODERN COATING TECHNOLOGY

w w w . p a t c h a m l t d . c o m

A Sustainable Approach to Modern Coating Technology

Patcham FZC is a well-established manufacturer of specialty additives headquartered in the United Arab Emirates. Since its inception, Patcham has steadily grown into a leading supplier of specialty additives for the Paint & Coatings, Ink, PVC and Composite industries.

The company’s Pat-Add range of coating additives includes wetting & dispersing agents, defoamers, slip & leveling agents, rheology modifiers. Whilst keeping focus on environmental sustainability, the company produces products using green raw materials that are APEO free and have low or no VOC.

These products are multi functional and multi compatible, which simplifies the production process, reduces the chance of errors and minimizes inventory thus improving cost effectiveness.

Patcham has built a strong manufacturing and R&D infrastructure that enables the rapid transition from concept to products. The company has strategically located technical service laboratories, offices and representatives around the world to provide the most efficient customer service. In addition, a well-developed robust supply chain network enables it to deliver its products and services to customers around the globe with minimal lead-time.

Contents

1

3

5

8

9

13

14

Introduction

Wood coat sealer and primer

Waterborne sealer

Solventborne sealer

Wood coat clear

Waterborne clear

Solventborne glossy and matt clear

Pigment concentrates / stain for wood coating

Waterborne stain / pigment concentrate

Solventborne stain / pigment concentrate


Introduction

The main challenges involved in the development of wood coatings are poor substrate wetting, presence of air bubbles, insufficient leveling and pigment settling. The latter is attributed to primers and sealers with high pigmentations. To achieve flawless finishes, the coating should provide excellent substrate wetting and leveling, low foam, surface slip property, mar resistance, soft feel and surface smoothness.

Patcham offers a line of additives that help customers to address the above challenges and provide best possible solutions. Patcham products allow coating formulators to develop aesthetic as well as durable wood finishes.

Wood coating system

Wood substrate Sanding with emery paper and cleaning of substrate Application of wood stain Application of 2 to 3 coats of wood sealer Sanding with emery paper Apply 2 coats of wood coat glossy/matt clear.

Figure 1: Schematic representation of wood coating system

1w w w . p a t c h a m l t d . c o m 1w w w . p a t c h a m l t d . c o m

Due to the porous nature of wood it has to be properly sealed with sealer or primers. Primers pose challenges for sealing due to incorporation of air bubbles during the grinding stage. Patcham defoamers prevent the formation of micro/macro foam during manufacturing and application of wood coating sealers. Patcham has a line of defoamers for various types of wood sealer applications.

2w w w . p a t c h a m l t d . c o m

Woodcoat sealer and primer

Waterborne sealer

Patcham offers a package of additives for waterborne wood coat sealers which includes wetting and dispersing agent, defoamer, coalescing agent and rheology/sag control agent.

Purpose of sealer

To fill the grains in wood

To get uniform coverage

To get uniform color by reducing blotching

Figure 2: Role of sealer in wood coatings

Additive Features

Waterborne wood coat sealer

Pat-Add AF 34

Pat-Add DA 603

Pat-Add Rheol 99/100

Specially designed polysiloxane based defoamer to prevent micro and macro foams with excellent balance, foam control and compatibility

Wetting and dispersing agent for pigments and fillers; enables high filler loading, provides optimum viscosity and long term stability to the sealer.

PU associative thickener provides best rate of viscosity regain with sufficient flow and finish. Avoids viscosity loss on tinting and exhibits good anti-settling properties

0.01 - 0.4Grinding/Letdown

0.5 - 2.0Grinding stage


Table 1: Patcham additives for waterborne sealer

Dosage on total formulation (%)


Pat-Add AF 34 is an oil and VOC free defoamer used in waterborne wood, plastic and industrial coatings

Pat-Add DA 603 is a specially designed wetting and dispersing agent for all kinds of pigments, extenders, fillers and sanding aids. It also contributes to less foam genera-tion during wetting and provides stability to the dispersion

Pat-Add Rheol 99/100 is a PU associative rheology modifier with balanced rheology profile maintaining mid and high shear viscosity

Patcham additives have wide compatibility with waterborne 2K PU, PUD, acrylics and other waterborne resin systems.

Woodcoat sealer and primer - Waterborne sealer

Formulation of WB acrylic sanding sealerWeight (%)

Water

HEC

pH Regulator

Pat-Add DA 603

Pat-Add AF 34

Propylene glycol

Biocide

Talc

Zinc stearate dispersion

(50% solution)

Letdown

Acrylic resin

Pat-Add Rheol 99

Coalescing agent

Total

Table 2: Formulation of waterborne acrylic sealer

9.10

0.40

0.30

0.50

0.10

6.50

0.30

5.00

16.00

60.000.30

1.50

100.00

Raw materials


Pat-Add AF 34 is an efficient defoamer for sealer application as shown in Figure 3 by roller application test. This is further supported by the density cup test which also shows that sealer with Pat-Add AF 34 has more density than reference, indicating less foam inclusion in the sealer.

Pat-Add DA 603 provides excellent wetting and dispersion of extenders and sanding aids that gives optimum viscosity and long term stability to the sealer. Pat-Add Rheol 99 further optimises viscosity, anti sagging property and therefore prevents settling of heavy pigments in the system. The flow behavior of the sealer is shown in Figure 5.

Woodcoat sealer and primer - Waterborne sealer

Figure 3: Foam test by roller application

Reference Pat-Add AF 34

1.05

1

0.95

0.9

0.85

0.8Blank

Den

sity

g/I

Density test of WB acrylic sealer

Pat-Add AF 34

0.88

1.03

Figure 4: Density test to study the defoaming efficiency of Pat-Add AF 34

Figure 5: Stability of waterborne acrylic sealer with Pat-Add additives

Before incubation After incubation @ 50 C0


The package of Patcham additives for solventborne wood coating provides effective wetting and dispersion of fillers, extenders and sanding aids; efficient defoaming properties during manufacturing and application; excellent leveling, substrate wetting of wood and excellent stability for the sealer.

The package has good compatibility with PU, Acrylic, Polyester melamine, acid catalyst and other solventborne resin systems.

Pat-Add AF 62 is an efficient deairing and defoaming agent for solventborne coatings and suitable for various types of applications like brushing, spraying, airless spraying, roller and curtain coating

Pat-Add DA 1801 is an effective wetting and dispersing agent for zinc stearate, extenders and fillers which effectively reduces the viscosity and enhances the stability of dispersion. It also provides wetting of wood substrates and releases the air trapped in the pores

Pat-Add LE 1020 aids flow, leveling, slip and mar resistance for wood coatings. It also supports the wetting of wood substrate and enhances the orientation of fillers and matting agents

Woodcoat sealer and primer - Solventborne sealer

Table 3: Patcham additives for solventborne sealer

Additive Features

Solventborne wood coat sealer

Pat-Add AF 62

Pat-Add DA 1801

Pat-Add LE 1020

Silicone free, polymeric defoamer for both clear and pigmented systems. Suitable for all kinds of SB resin systems

Effective wetting and dispersing agent for sanding aids, matting agents, extenders and pigments.

Polyether modified polysiloxane surface modifier improves substrate wetting and matting agent orientations






Raw materials Weight (%)

Woodcoat sealer and primer - Solventborne sealer

2K PU sealer for wood coating

Part A

Acrylic polyol (50%)

Pat-Add DA 1801

Zinc stearate

Butyl acetate

Pat-Add LE 1020

Pat-Add AF 62

Xylene

Butyl acetate

Total

Part BAliphatic polyisocyanate

Mixing ratio (w/w)

70.00

0.30

6.00

10.00

0.10

0.30

7.40

5.80

100.00

6.00

100:6

Table 4: Formulation of solventborne 2K PU sealer

Figure 6: Effectiveness of Pat-Add additive package in 2K PU sealer

Reference Pat-Add additives


The clear coats for wood should provide proper leveling, smooth surface, slip property, scratch, chemical and UV resistance. Patcham offers a package of additives to achieve exceptional properties for clear coats that includes wetting and dispersing agent (if dispersion of pigments are required), defoamers and leveling agents. These additives are compatible with PU, Epoxy, Polyester-melamine, TPA and acid catalyzed systems to provide superior performance.

Waterborne additive package for wood coat clear

The package of Pat-Add additives for waterborne wood coating include leveling agents, defoamer and rheology modifier.

Pat-Add LE’s additives provide excellent flow, leveling, perfect DOI, gloss and substrate wetting

Pat-Add AF 32 eliminates foams during processing and application

Pat-Add Rheol 99/100 improves flow and anti sag properties of the paint systems

Additive Features

Wood coat clear - Waterborne clear

Table 5: Patcham additives for waterborne wood coating

Waterborne wood coat clear

Pat-Add LE 1030

Pat-Add LE 1040

Pat-Add Rheol 99/100

Pat-Add AF 31

Pat-Add AF 32

Polyether modified polysiloxane enhances flow and leveling, substrate wetting and supports air release from the system

Provides flow, leveling, slip and mar resistance. Contributes to orientation of matting agents and metallic pigments

PU associative thickener. Provides balanced flow and sag properties. Avoids viscosity loss on tinting and exhibits good anti-settling properties

Oil free, easily dispersible defoamer for clear and low pigmented WB resin systems with no adverse effects

Specially designed polysiloxane, oil and VOC free defoamer for versatile applications compatibile with all WB resin systems

0.05 - 0.4Letdown stage







The clear coats for wood should provide proper leveling, smooth surface, slip property, scratch, chemical and UV resistance. Patcham offers a package of additives to achieve exceptional properties for clear coats that includes wetting and dispersing agent (if dispersion of pigments are required), defoamers and leveling agents. These additives are compatible with PU, Epoxy, Polyester-melamine, TPA and acid catalyzed systems to provide superior performance.

Waterborne additive package for wood coat clear

The package of Pat-Add additives for waterborne wood coating include leveling agents, defoamer and rheology modifier.

Wood coat clear - Waterborne clear

Waterborne 1K PU clear

Polyurethane dispersion

Polyacrylate dispersion

Dipropylene glycol methyl ether (DPM)

Butyl diglycol (BDG)

Pat-Add Rheol 99

Pat-Add LE 1030

Pat-Add AF 31

Water

Total

Waterborne 2K PU clear

26.00

66.00

2.50

2.50

0.50

0.30

0.10

2.10

100.00

Figure 8: Illustrating the DOI and gloss of 2K WB PU clear

Table 6: Formulation of waterborne 1K PU clear

Table 7: Formulation of waterborne 2K PU clearcoatFigure 7: Wetting of substrate

with Pat-Add LE 1030

Part A

Hydroxy polyacrylic dispersion

Pat-Add AF 32

Pat-Add LE 1030

Pat-Add Rheol 99

Water

Part B

Aliphatic polyisocyanate

MPA

Total

60.00

0.06

0.10

0.25

21.54

12.50

5.55

100.00

Weight (%)Raw materials

Weight (%)Raw materials


Pat-Add DA 1801 is used for the dispersion of pigments and matting agents to have a uniform film. It promotes the orientation of matting agents and stabilizes the pigments

Pat-Add AF 62 defoamer provides optimal balance between defoaming efficiency and compatibility with the coating

Pat-Add Leveling agents are multifuctional additives and they contribute as follows:

Additive Features

Solventborne wood coat glossy and matt clear

Pat-Add DA 1801

Pat-Add AF 62

Pat-Add LE 1020

Pat-Add LE 1477

Pat-Add FL 7

Pat-Add SL 1120

Wetting and dispersing agent for matting agents and other pigments. Provides stabilization to the pigments

Silicone free defoamer for both glossy and matt systems. Suitable for all kinds of SB resin systems

Polyether modified polysiloxane surface modifier improves substrate wetting and matting agent orientations

Fluoro based leveling agent for efficient surface tension reduction with no adverse effects. Suitable for water repellent coatings

Polyacrylate surface modifier for excellent flow and leveling and no influence on recoatability and intercoat adhesion. Suitable for all SB systems.

Provides slip, mar resistance and contributes to perfect leveling






0.05 - 1.0 Letdown stage

Wood coat clear - Solventborne glossy and matt clear

Excellent leveling and substrate wetting

Slip and mar resistance properties

Offer better orientation of matting agents

Provides soft feel effect

Contributes to air releasing properties

Lower the coefficient of friction

Gives exceptional DOI

No adverse effect on dry film

Table 8: Patcham additive for solventborne wood clear


2K PU wood coat glossy clear


The formulation based on Patcham additives in 2K PU clear are shown below in Tables 9 and 10.

Water beading test for 2K PU clear clearly shows that Pat-Add LE 1477 surface modifier based clear coat repels water droplet better than the reference. This is evident by looking at the shape of the droplet on the surface. Lower coefficient of friction value shows that Pat-Add LE 1477 has better slip properties than the reference.


2K PU wood coat matt clear

Part A


CAB solution (20%)

Pat-Add DA 1801

Pat-Add LE 1477 / LE 1020

Pat-Add AF 62

PU solvent

Matting agent

PU solvent

Ethyl 3-ethoxypropionate solvent

Total

Part B


75.00

1.00

0.20

0.20

0.50

7.00

4.00

5.35

6.95

100.00

18.00

Weight (%)

Table 10: Formulation of 2K PU matt clearTable 9: Formulation of 2K PU glossy clear

Figure 9: Water beading test on wood coat 2K PU clear

Raw materialsWeight (%)Raw materials

Part A


CAB solution (20%)


Pat-Add AF 62

PU solvent

Ethyl 3-ethoxypropionate solvent

Total

Part B


75.00

1.00

0.20

0.50

16.35

6.95

100.00

18.00


Guideline formulation of acid catalyzed wood clear with Pat-Add additives are shown inTables 11 and 12.

0.39

0.38

0.37

0.36

0.35

0.34

0.33

0.32

0.31

0.3

Pat-Add LE

CO

F

Coefficient of friction

Reference

0.33

0.38

Weight (%) Weight (%)


Figure 10: Coefficient of friction for 2K PU clear

Table 11: Formulation of acid catalyzed wood coat glossy clear

Table 12: Formulation of acid catalyzed wood coat matt clear

Acid catalyzed wood coat glossy clear Acid catalyzed wood coat matt clear

Part AShort oil alkyd

Urea formaldehydeMelamine formaldehyde

Xylene


Pat-Add AF 62Toluene

n-butyl alcohol

Solvesso 100

Total

Part B

PTSA (40% solution in butanol)

33.00

26.00

2.20

14.70

0.20

0.20

8.00

5.50

10.20

100.00

4.00

Part A

Short oil alkyd

Urea formaldehyde

Melamine formaldehyde

Xylene

Pat-Add DA 1801


Pat-Add AF 62

Matting agent

Solvesso 100

n-butyl alcohol

Toluene

Xylene

Total

Part B

PTSA (40% solution in butanol)

33.00

26.00

2.20

8.70

0.20

0.20

0.20

4.00

10.20

5.00

8.00

2.30

100.00

4.00

Raw materials Raw materials


The air releasing property of Pat-Add LE 1020 and LE 1477 are illustrated in Figure 11. Pat-Add LE 1477 shows stronger efficiency in air releasing properties than the reference.

Pat-Add LE 1020 also supports the orientation of matting agents in the wood coating systems and the panels are shown below.

8

7

6

5

4

3

2

1

0

Pat-Add LE 1020

Pat-Add LE 1477

Tim

e (m

in)

Defoaming time

Reference

5

7

3


Figure 11: Defoaming property of leveling agents in acid catalyzed glossy clear

Figure 12: Representing orientation of matting agents in acid catalyzed system


Stain creates a rich, deep color that highlights the natural wood grain and enhances the aesthetics of a wood coating. Highly loaded pigment concentrates and stains can be used to provide desired color for wood coating.

Waterborne stain and pigment concentrates for wood coating

Pat-Add DA 603 is a robust dispersing and wetting additive for various types of pigments. The additive enables high pigment loading and stabilizes the pigment dispersion whilst being compatible with all types of WB resins.

System Additive Features Dosage (%)

Pigment concentrates/stain for wood coating

Versatile wetting and dispersing agent suitable for pigment concentrates of organic, inorganic, black pigments and compatible with all WB resins.WB Pigment

concentrates/stain for wood coating

Pat-Add DA 603

Pat-Add AF 34

White pigment : 1-5 Carbon black : 30 - 200Inorganic pigments : 10-20 Organic pigments : 30-70On SOP (Grinding stage)

Specially designed polysiloxane based defoamer prevents micro and macro foams with the excellent balance foam control and compatibility with WB resins

Table 13: Patcham additive for waterborne colorants

Rubine red PR 254 DPP orange PO 73 Yellow PY 110

Figure 13: Flow behavior of waterborne colorant for wood coating

Figure 14: DOI and gloss of wood panel coated with 2K PU clear with Pat-Add DA 603 based colorant

Waterborne wood stain

Raw materials Weight (%)

Styrene acrylic emulsion

Water

pH regulator

Pat-Add DA 603

Transparent red iron oxide

Fumed silica

Pat-Add AF 34

Total

Table 14: Formulation of waterborne wood stain

60.00

33.25

1.00

0.40

5.00

0.30

0.05

100.00

0.05 - 0.4Grinding/LetdownOn total formulation


Additive Features Dosage on SOP (%)

White pigment : 1-5 Carbon black : 30 - 120Inorganic pigments : 10-20Organic pigments : 30-70Grinding stage

Pigment concentrates/stain for wood coating

Solventborne wood stain and pigment concentrates

SB pigment concentrates/stain for wood coating

Pat-Add DA 932

High Molar Volume technology polymeric dispersing agent for all kind of carbon blacks, organic and inorganic pigments. Enables high loading of pigment concentrates and supports stabilization of pigments

Table 15: Patcham additive for solventborne colorants

Table 16: Formulation of solventborne resin free pigment concentrate

Figure 15: Flow behavior of resin free pigment concentrates

Figure 16: Wood panel coated with stain and 2K PU clear shows excellent gloss and DOI

Solventborne resin free pigment concentratesRaw materials

TiO PY 74 PR 170 PR 101 PB 15:3 2

Mill base

Pat-Add DA 932

Pigment

Xylene : MPA (1:1)

Letdown

Xylene : MPA (1:1)

Total

22.00

60.00

16.00

2.00

100.00

9.00

26.00

50.00

15.00

100.00

21.27

20.00

20.00

38.73

100.00

15.00

40.00

25.00

20.00

100.00

36.50

20.00

20.00

23.50

100.00

38.20

18.00

41.00

2.80

100.00

SB resin free pigment concentratesfor wood coating

Carbon black


Notes

www.patchamltd.com

PATCHAM (FZC)

P.O. Box: 7753,Saif Zone, Sharjah, UAETel: +971-6-5570035Fax: +971-6-5570038Email: [email protected]

PATCHAM INDIA

B-52, Pravasi Industrial EstateVishweshwar Nagar, Off Aarey RoadGoregoan (E), Mumbai - 400 063 (India)Tel: +91-22-29272471Email: [email protected]

PATCHAM EUROPE BV

Klavermaten 65-1 7472 DD GoorNetherlandsEmail: [email protected]

PATCHAM USA LLC

700 Plaza Drive - Suite 216Secaucus, New Jersey 07094Tel: (201) 293-4282Fax: (201) 820-0818Email: [email protected]

The information given in this booklet is intended for technical guidance without obligation. Ver. 1.0

a sustainable approach to - patcham...

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