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Breakthrough Waterborne Alkyd Technology for Interior Wood Stains Michael Knight PCCR USA, INC. Technical Service Manager October 9, 2014.

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Presentation on theme: "Breakthrough Waterborne Alkyd Technology for Interior Wood Stains Michael Knight PCCR USA, INC. Technical Service Manager October 9, 2014."— Presentation transcript:

1 Breakthrough Waterborne Alkyd Technology for Interior Wood Stains Michael Knight PCCR USA, INC. Technical Service Manager October 9, 2014

2 AGENDA  BACKGROUND  ALKYD DEVELOPMENT  EMULSIFICATION PROCESS  EMULSION STABILITY  STAIN FORMULA OPTIMIZATION  PENETRATION TEST  LAPPING RESISTANCE TEST  GRAIN RAISE RESISTANCE  EXTERIOR STAIN  CONCLUSION 2

3 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 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

5 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

6 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

7 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

8 BEWOID BLADE 8

9 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 % ZR/0.2% CA (HYDRO- CEM®) 9

10 50 g/L VOC TINTABLE STAIN FORMULATION 10

11 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

12 PENETRATION TEST 12

13 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

14 LAPPING – 20 MINUTES BETWEEN COATS 14

15 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

16 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

17 EXTERIOR STAIN – ONE YEAR OUTDOOR EXPOSURE – CARPENTERSVILLE, IL GLOSS RETENTION 20 DEGREE GLOSS RETENTION 60 DEGREE DELTA E ALKYD EMULSION100%65%3.8 STAIN #1100%44.4%3.0 STAIN #250%34.2%4.05 STAIN #350%44.9%3.6 STAIN #4100%22.5%2.5 STAIN #5100%92.3%4.0 STAIN #650%83.4%2.3 17

18 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……


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