EngineeringGFPaintsandCoatingsInstructors:RyanDenny&AlexHade

TableofContents1. Briefhistoryofthepaintsandcoatingsindustry2. Compositionofmodernpaintsandcoatings3. RawMaterials4. Manufacturingprocess5. QualitycontrolandExperimentaltestingprocedures6. Applicationtechniques

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Introduction1. Tryandimaginesomethingthatdoesnothavea

coatingonit2. PerhapstheWorld’ssecondoldestprofession3. Constantlyevolvingwithnosingleinventor

a. Oil-based,solventborne,waterbornetechnologiesb. Advancesinrawmaterialtechnologyc. Greeninitiative(ZeroVOC)

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PaintsandCoatingsTimeline

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••30,000yearsagocavedwellersusedcrudepaintstoleaverepresentationsoftheirlives••1,000BCGumArabicfirstusedtodeveloppaintsandvarnishes

••600BC-400ADVariouscivilizationsbeginusingoilsasvarnishesandpigmentandbindercombos••1500sArtistsbeginaddingdryingoilstohastenevaporation;linseedoilbecomesthemostcommon

••1856HenryPerkindiscoversfirstrealsyntheticdye••1865D.P.Flinn obtainspatentforthefirstwater-basedpaint

••1867D.R.Averillpatents"ready-mixed"paints••1930sAlkydsforhousepaintsandindustrialuse

••Late1930sEpoxiesaredevelopedforindustrialuses••1940sNewsyntheticbindersaredeveloped(polyurethanesandacrylics)

••1970sPowdercoatingsaredeveloped••TodayhybridandUVtechnologiesarebeingdeveloped••Currentlyenvironmentalregulationsarepushingwater-basedlowVOC/zeroVOCpaintsandcoatings

Composition1. Vehicles

a. Solids- Resinb. Volatiles- Solvents

2. Pigmentsa. Color- hidingpigments(TiO2,Carbonblack,Redironoxide)b. Inert- fillerpigments(calciumcarbonate)c. Effectpigments(Metallic)

3. Additivesa. Dispersantsb. Driersc. FlowandRheologicalmodifiersd. Substratewetting/surfacetensionmodifiers 5

Composition

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MilkPaintComposition

ChalkPaintComposition

Pigments

Volatiles

ResinSolids

Additives

• Paintismanufacturedandrawmaterialsarepurchasedviaweightforaccuracy.

• Paintisusedandsoldbyvolume6

CompositionalVocabularyWeight/Gallon=weightperunitvolumePigmenttoBinderratio=pigmentweight/resinsolidsweightPigmentVolumeConcentration(PVC)=pigmentvolume/volumesolids(criticalPVCisapproximately60%)VOC=weightoforganicsolvent/gallon-water

*NotethatwaterdoesnotcountinthecalculationofVOC,soagallonof100%organicsolventhasthesameVOCasagallonof50%waterand50%organicsolvent

*Notesomeorganicsolventsareexempt,meaningtheydonotcontributeVOCtothecalculation.HenceyoucanhaveapaintorcoatingthatsayszeroVOCthatstillhasorganicsolventwithinit 7

Solvents• Aliphatic• Aromatic• Alcohols• Glycolethers• Ketones• Acetates• Water• Blendsofthesolventsabove

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Water1. Considereda“universal

solvent”2. Physicalcharacteristicsgovern

theapplicationofwaterbornecoatings

3. Evaporationrateistemperatureandhumiditydependent

a. Controls/Effectsthedryrateandopentimeofthecoating

b. Optimumconditionsare70Fand40%humidity

4. Airmovementwillalterdrytime 9

VOC’s1. Organicsolventsareregulatedbyhowmuchozone/smog

formationtheycausecomparedtoethaneasastandard2. Exemptsolventsdonotcontributetosmogformationorthe

formationisconsiderednegligiblea. Acetone,Methylacetate,andT-butylacetatearesomeexempt

solventsb. Noticethatanexemptsolventcanstillbetoxictohumanseven

thoughitisnotregulatedasaVOC

3. Apaintorcoatingcanandwillhaveotherorganicsolventswithinthemeventhoughtheyareconsideredzero/lowVOC

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IndustryStandards&Regulations

VOC:volatileorganiccompound;limitedtolessthan420g/LorlowerdependingonlocationLabeling:certainmaterialsrequirespecificwarningsSafetyDataSheet(SDS):mustmeetOSHAstandard,mayneedANSIcompliance

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ResinBinders1. Alkyds2. Polyesters3. Acrylics4. Latexes5. Melamine6. Urethanes7. Epoxies8. Hybrids

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AlkydsAlkydsaremodifiedwithoilandweusethemineachofouroil-basedproductsonthemarket.

OilTypes

Drying Semi-Drying Non-Drying

Linseed Soya Coconut

Tung Safflower Castor

DehydratedCastorOil

TallOilAcids

FishOil

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Alkyds• Highlyversatilechemistry• Householdpaint• Industrialapplications

• Dryviaoxidation• Canbemodifiedwithotherresinsandchemicals• Styrene• Phenolic• BenzoicAcid• VinylToluene• Rosin• Acrylic• Silicone 14

Acrylics• Dryviasolventevaporation(lacquer)orcrosslinkingmechanism(urethaneormelamine)

• HighestUVresistanceofallorganiccoatings• Contributevaryingdegreeofcoatinghardnesstothesystem• Canbeblendedwithotherresinsystemstoimpartdifferentproperties• Polyurethanesincreasechemicalresistancewhenblendedwithacrylics

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Polyurethanes• AlsoreferredtoasurethanesorPUD’s• Ambientcurecoatings• Impartexcellentchemicalresistanceanddurability• Cancrosslinkwithacatalyst(2Ksystem)forincreasedperformance,butreducingpotlife

• Canbeblendedwithacrylicstogetbothsurfacehardnessandchemicalresistance

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FilmFormationMinimumFilmFormingTemperature(MFFT)=theminimumtemperatureneededtoformacontinuousfilm

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ColorPigments1. TiO2(Titaniumdioxide)istheonlyhidingpigmentthat

scatters/reflectslight2. Allothercoloredpigmentsabsorblightatspecific

wavelengths3. Blackpigmentsabsorballwavelengthsoflight

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Opacity1. Opacityisdefinedbyhowmuchthepaintabsorbs,reflects

orscatterslighttohidetheunderlyingsubstrate2. Measuredasapercentonaspectrophotometerovera

sealedwhite,sealedblack,andunsealedwhitesurface

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ExtenderPigments1. Calciumcarbonate/claysactasfillersatalowcosttospace

outTiO2moleculesforimprovedlightrefraction2. Talc/Magnesiumsilicateactsasflatteningagents3. Amorphoussilicaactsasahigh-efficiencyflattener4. Crystallinesilicaimprovesadhesion,fills,andflattens5. Fumedsilicaimpartsrheologicalcontrolandflattens

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Additives1. Dispersants:surfactantsthathelpthesystemacceptdry

pigmentwithinthegrindphase2. Flow&Leveling:surfacemodifierssuchasfluorosurfactants

andsilanes thatimprovethewettabilityoftheproductovertheapplicationsurface

3. Rheologymodifier:actstothickenthepaintorcoating4. Defoamers/Deaerators:knockdownfoamformationduring

themanufacturingandapplicationprocess5. Slipaids:surfacemodifiersthatalterhowslipperyasurface

feels6. Biocides:killersofbacteria,mildew,andfungusbothincan

andinfilmforincreasedstability 21

ManufacturingProcessGrindPhaseHighspeeddisperseanydrypigmentorflatteningagentintoeitherwaterortheresinsystemwithadispersantmakingsureyouhaveagoodvortexPremixInaseparatevesselmixtogetherwaterandanysolventneededforcoalescenceofthecoatingsoyoudonotshocktheresinsystemwhenaddedLet-downReducethespeedofyourdispersionandaddyourpremixandanyslip-aids,rheologicalmodifiers,biocides,andsurfacemodifieradditivestoimproveyourcoatingsperformance 22

ManufacturingProcessTechnology:HighspeeddispersionusingaCowlesblade• Agoodvortexpullsthecontentsofthevesseltothebladesedge

• Overchargingorundercharginganyonematerialcanresultinapoordispersion

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PerformanceCharacteristics1. ChemicalResistance2. WaterResistance3. Heat/HumidityResistance4. YellowingResistance/TanninBleedResistance5. Weathering6. Adhesion7. Incanstability

a. OvenStabilityb. Freeze/ThawStability

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ChemicalResistanceMethod1. Spraybirchpanelswiththreecoatsofproduct(3drymils)2. Dryeachpanelundera120Fheatlampbetweeneachcoat

andallowthepanelstocureforfivedays3. Applythe21differenthouseholdproductstoeachpanel

beingtested4. Placewatchglassesontopofeachchemicalandallowtosit

foronehourbeforescoring5. Scorethecoating’sresistancetoeachchemicalwithascore

from1-5(1-completedegradation,5-noeffect)6. Addupthescoresandcomparetheexperimental

competitiveproductstothestandard (105max)

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HouseholdProducts• Water• Ketchup• Mustard• Coffee• Iodine• HydrogenPeroxide• Windex• 409Cleaner• Ammonia• IPA• SuntanLotion

• DEET• Ethanol• RedWine• DenaturedAlcohol• Naptha• Bleach(6%)• AmmoniumHydroxide(37%)

• OliveOil• SulfuricAcid(10%)• SulfuricAcid(37%) 26

TestingPanels

OldExterior450Satin NewExterior450Satin

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WaterResistance1. Applyagenerousamountof

waterovertheblackportionofthechemicalresistancepanel

2. Placealargewatchglassoverthewaterspotandallowtositforonehourbeforescoring

3. Givethespottestascorefrom1-5similarlytothechemicaltesting

4. Lookforblushingandpermanentwaterspots

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YellowingResistance1. Applyeachtopcoatoveraleneta chartwithsnowwhitemilk

paint2. Allowthetopcoattodryatambientconditions(70-75F,40-

50%humidity)3. Takeaninitialcolorreadingusingaspectrophotometerto

showthechangeincolorationfromthepainttothetopcoat4. Heatstresseachleneta chartina125Fovenandtake

additionalcolorreadingsevery24hours5. Analyzethedifferencesincolorationfromboththesnow

whitemilkpaintstandardandtheinitialtopcoatreading

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Adhesion1. Applya1mm.and2mm.crosshatchtothechemical

resistancepanelsafter24hrs ofambientcure2. Placecoatingindustrystandardtapetothecenterofthe

crosshatch3. Applypressureandremovethetapetoassessany

delaminationofthecoatingfromthewoodsubstrate

5- PerfectScore 1- Completeadhesionloss

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QualityControl1. Viscosity2. Gloss3. Color4. Opacity

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Viscosity1. Viscosityisavaryingstateofthicknessorconsistency

relativetotemperature2. CommonlymeasuredinmPas,cPs,orKreb units3. Temperaturemustbecontrolledwhenmeasuringviscosity

(75Fistheindustrystandard)4. Therearemanydifferentwaytomeasureviscosity,butwe

useaFordcup#4forallofourtopcoatsandaBrookfieldandKrebsviscometersforourpaintsandstains

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Gloss1. Glossismeasuredonanangletothepaintsurface2. Determinestheamountoflightreflectedbythesurfaceand

ismeasuredinglossunitsnotpercent3. Gloss:85+Semi-gloss:50-60Satin:25-35Flat:lessthan154. FlatoutFlat:lessthan5

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Color1. Viewcolorchangesbasedonvisualobservationofthein

processproductdrawndownonaleneta chartagainstastandard

2. Useaspectrophotometertomeasurethedifferenceincolorfromtheinprocessproducttoastandard

3. Colorvalueslessthanoneareundetectabletothehumaneye

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ApplicationTechniques• Brush• Roller• AirAtomizedSpray• AirlessSpray• ElectrostaticSpray• CentrifugalAtomization• AirAssistedAirlessSpray• Dip• DirectorReverseRollcoat(coilcoatings)• CurtainCoating• FlowCoating• FluidizedBed(Powder) 35

SubstrateandPreparation• Wood:sandand/orprime• Sheetrock:sandand/orprime• Steel:ironorzincphosphatizing,prime• Aluminum:passivateandseal• Plastics:solventselection,productscreening,flametreatment• Magnesium:passivateandseal• Galvanizedsteel:problematicforconsumer,zincphosphate• Glass:acidetchoruseofadhesionpromoters• Commontheme:Preparationiskeyforperformance

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Wood• Tannins(TannicAcid):Solubleinwater;causeofmajoryellowinganddiscolorationofwater-basedpaintsandcoatings

• MineralStreaks:Concentratedareasoftannin• VeneerGlue:Somegluesaresolubleinwaterandmigratetothesurfacecausingyellowinganddiscoloration

• Solution:GFSTAINBLOCKINGPRIMER• Oilinessofthewood:Bewaryofsubstratedifferences• Off-labeluse:DONOTRECOMMEND,butsomepeoplehavehadsuccess

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StainBlockingPrimer

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Thankyou!

39CourtesyofGeneralFinishes2016Flippin'FurnitureExpo