Breakthrough Waterborne Alkyd Technology for Interior Wood Stains

Michael KnightPCCR USA, INC.Technical Service ManagerOctober 9, 2014

AGENDA

BACKGROUND ALKYD DEVELOPMENT EMULSIFICATION PROCESS EMULSION STABILITY STAIN FORMULA OPTIMIZATION PENETRATION TEST LAPPING RESISTANCE TEST GRAIN RAISE RESISTANCE EXTERIOR STAIN CONCLUSION

2

3

BACKGROUND

SOLVENTBORNE CONVENTIONAL SOLIDS LONG OIL ALKYDS USED FOR WOOD STAINS

AS VOC REGULATIONS TIGHTENED, HIGH SOLIDS ALKYDS INTRODUCED SLOWER CURE DUE TO LOWER MW

THEN WATER REDUCIBLE LONG OIL ALKYDS INTRODUCED HYDROLYSIS ISSUE

ALKYD EMULSIONS SAME PENETRATION INTO WOOD NOT SEEN AS WITH

SOLVENTBORNE

4

BACKGROUND

ALKYD EMULSION DEVELOPED TO OVERCOME SHORTCOMINGS OF EARLY OFFERINGS

VERY GOOD HYDROLITIC STABILITY EXCELLENT PENETRATION INTO WOOD EXCELLENT LAPPING RESISTANCE EXCELLENT GRAIN RAISE RESISTANCE

ALKYD DEVELOPMENT

EMULSION OF TRADITIONAL LONG OIL ALKYD– POOR PENETRATION, LAPPING AND GRAIN RAISE

RESISTANCE

ALKYD BACKBONE WAS MODIFIED TO IMPROVE– LONGER OIL LENGTH– RESULTANT LOWER MW– FASTER DRYING OIL

STAIN PERFORMANCE WAS IMPROVED

5

EMULSIFICATION PROCESS

CRITICAL PARAMETERS– SURFACTANT TYPE– SURFACTANT LEVEL– SHEAR RATE– RESIN AND WATER TEMPERATURE– WATER ADDITION RATES

OBSERVATIONS– VERY FORGIVING PROCESS– HIGH TO LOW SHEAR– ADDITION OF SURFACTANT CRITICAL

6

EMULSION STABILITY – 140 F HOT BOX

LAB HIGH SHEAR– BEWOID BLADES– ~500 NM – 10 WEEKS HOT BOX STABLE

PILOT HIGH SHEAR– ROTOR STATOR– ~300 NM – 10+ WEEKS HOT BOX STABLE

LAB LOW SHEAR– NORMAL PADDLE BLADES– ~600 NM – 8 WEEKS HOT BOX STABLE

PILOT LOW SHEAR– SAME STABILITY

7

BEWOID BLADE

8

STAIN FORMULA OPTIMIZATION

OPTIMIZATION FOR OPEN TIME AND LAPPING– PROPYLENE GLYCOL AS SOLVENT– CAN BE FORMULATED TO AS LOW AS 50 G/L VOC

OPTIMIZATION FOR COLOR ACCEPTANCE– ADM 750 DISPERSANT

OPTIMIZATION FOR GRAIN PENETRATION– WHITE STREAKS IN STAINED WOOD

• ENVIROGEM® 2010 SURFACTANT

OPTIMIZATION FOR DRY TIME/URETHANE CLEARCOAT ACCEPTANCE– 3% BORCHI® OXYCOAT 1101/0.3% CA (HYDRO-CEM®)– 2% BORCHI® OXYCOAT 1101.0.2% ZR/0.2% CA (HYDRO-

CEM®)

9

50 g/L VOC TINTABLE STAIN FORMULATION

10

PENETRATION TEST

NO QUANTITATIVE TEST METHOD DESIGNED OUR OWN QUALITATIVE TEST COUPLE DROPS OF STAIN PLACED ON BOARD COVER 15 MINUTES WITH WATCH GLASS AND

OBSERVE– EXTERIOR ACRYLIC STAIN – SITS ON SURFACE– INTERIOR ACRYLIC STAIN – MORE CONTACT WITH

WOOD– ALKYD EMULSION – SPREADS ON WOOD AND

PENETRATES

11

PENETRATION TEST

12

LAPPING RESISTANCE TEST

COMMON APPLICATION PROBLEM– STOPPING MID-FLOOR OR MID-BOARD

WIPE STAIN ONTO 9 INCHES OF 12-INCH OAK FLOOR BOARD

AFTER TWO MINUTES, WIPE OFF EXCESS WAIT 20 MINUTES APPLY STAIN TO OTHER END OF BOARD

WITH 3-INCH OVERLAP AFTER TWO MINUTES, WIPE OFF EXCESS OBSERVE

13

LAPPING – 20 MINUTES BETWEEN COATS

14

GRAIN RAISE RESISTANCE

WOOD IS POROUS SUBSTRATE WATER SWELLS THE WOOD GRAIN ROUGH TO TOUCH SOLVENTBORNE STAINS DO NOT HAVE GRAIN

RAISE ISSUES TYPICALLY, WATERBORNE STAINS DO ALKYD EMULSION STAIN HAS EXCELLENT

GRAIN RAISE RESISTANCE

15

EXTERIOR STAIN

FORMULA TRANSFORMATION FOR WATER BEADING

– SILICONE AND PARRAFIN WAX EMULSIONS ADDED

FOR UV DURABILITY– TINUVIN® 1130 AND TINUVIN® 292 ADDED

FOR FUNGUS CONTROL– A FUNGICIDE WAS ADDED

GLOSS WAS FLATTENED WITH SILICA COMPARED TO 6 COMMERCIAL DECK STAINS ONE YEAR OUTDOOR EXPOSURE TO DATE

16

EXTERIOR STAIN – ONE YEAR OUTDOOR EXPOSURE – CARPENTERSVILLE, IL

GLOSS RETENTION 20

DEGREE

GLOSS RETENTION 60

DEGREE

DELTA E

ALKYD EMULSION

100% 65% 3.8

STAIN #1 100% 44.4% 3.0

STAIN #2 50% 34.2% 4.05

STAIN #3 50% 44.9% 3.6

STAIN #4 100% 22.5% 2.5

STAIN #5 100% 92.3% 4.0

STAIN #6 50% 83.4% 2.3

17

18

SUMMARY

“HOLY GRAIL” FOR REFINISHING WOOD FLOORS

EXCELLENT STAIN PENETRATION EXCELLENT LAPPING RESISTANCE EXCELLENT GRAIN RAISE RESISTANCE VOC AS LOW AS 50 G/L, LOWER POSSIBLE FEASIBLE AS EXTERIOR DECK STAIN

ANY QUESTIONS……