Technology Forum

Waterborne Epoxy Protective

Coatings for Metal
Jim D. Ehnore, Derek S. Kincaid, Pratap C. Komar, and Jon E. Nielsen
Resolution Performance Products LLC*

Recent enhancements in waterborne resin system polymers as well
as the way they are formulated have produced paints with a set of
barrier properties that are superior to their standard solvent t~rne
analogs. New generation waterborne epoxy and curing agent dis-
persions, and the paints formulated from them, have been intro-
duced with changes from older generation watert~rnes. These
cMn g es include (1) totalIy nonionicaIl y dispersed paints in place of
the older ionicaIly dispersed types, (2) quictcer coalescing, mutually
soluble epoxy~amine vehicle resins rather than the former slow
coalescing, highly branched epoxy~amine systems, and (3) utiliza-
tion of stable, water compatible additives and filIers that comple-
ment the nonionic epoxy~amine resin vehicles. In this paper, the
success of these implonented technology changes is demonstrated
by comparing the performance properties of the new generation
with an industry standard epoxy/polyamide solventborne paint.
This paper presents no vel two-component waterborrze epoxy resin
and amine curing agent technology for ambient cure metal coat-
ings.

INTRODUCTION
This paper presents a rational view of
how solventborne, two-component (2K)
epoxy resin design and respective paint
formulating has changed to produce
higher performing waterborne protective
coatings for metal. This paper demon-
strafes how implementing change in ep
oxy chemistry and coatings has produced
more viable waterborne paints with bet
ter metal protection at lower levels of
volatile organic compounds (VOC).
The chemistry of 2K epoxy coatings
has afforded good value for metal pro-
tection since the 1950s. Inthe U.S. alone,
over 100 million pounds of 2K epoxy
paints are produced from epoxy/polya-
mide chemistry per year. 1For 30 years,
epoxy paint producers have tweaked,
remodeled, patched, and reformulated
the epoxy/polyamide paint chemistry
to adapt it to changingperformance and
environmental compliance expectations.
Most of the patches and fixes have ei-
ther compromised paint metal protec-
tion, fallen short on compliance, or lim-
ited the versatility of the resin system.
The environmental, health, and safety
costs of storing and handling high VQC,
low flash, non HAPS 2K epoxy paints
narrow profit margins beyond survival.
To use home building as an analogy, it
is time to dismantle the old epoxy/
Presented al lhe 79th Annual Meeling of lhe Federation
of ~qocieties for Coatings Technology, on November 4 7,
2001, in Atlanta, GA
*P Q Bo... 1380, Houston, TXZ7251
polyamide chemistry. We may then sal
vage the useful old technology pieces
and put them together with mostly new
materials to make new paints that meet
current performance and environmen-
tal expectations.
Tile first two parts of this paper high-
light the old epoxy paint chemistry that
needs change. First is a review of the 2K
solventborne epoxy/polyamide resin
chemistry. Next is a critique of two popu
lar solventbome epoxy paint recipes. In
these first two parts, the foundation con
cepts of resin design and paint formu
lat ing that are worth salv aging are iden-
tified. The third part of this paper
introduces the new resin chemistry
framework. In the fourth part, a new
resin framework is "trimmed out" with
new formulating enhancements. Finally,
in the Summary and Conclusion, the per
formance of a new generation of paints
compared to traditional epoxy paints is
presented along with the implemented
changes and their respective paint per-
formance improvements.
Tile goal of this paper is to promote
the implementation of changes in the
Industrial Maintenance (IM) 2K epoxy
coatings market sector by eliminating
the frustrations associated with tradi
tional epoxy paint formulations. This
paper also offers improved options for
Original Equipment Manufacturer
(OEM) paint makers, although the for-
mulations herein are ambient cure. For
example, bythe time this paper was pre-
sented, more than one QEM customer
has already implemented some of the
highlighted changes to extend the recoat
window of standard epoxies from two
weeks to over two years.
EVALUATION OF TRADITIONAL
2K EPOXY/POLYAMIDO
AMINE RESIN CHEMISTRY
In this section, the tradffional 2K bisphe-
nol A epoxy-tall oil dimer acid polya-
mide resin system is critically evaluated.
The bisphenol A epoxy in Figure 1 with
the polyamido amine pictured in Figure
2 show the foundation chemistry of 2K
solventborne epoxy paints. At a quick
glance at these two resin structures it is
apparent that the amine curing agent has
many more -NH amine reactive sites per
molecule than the bis A diglycidyl ether
has oxirane sites. The diepoxy is -1,000
molecular weight with -500 equivalent
weight when n 1. The most common
polyamido amine curative for low cost
and relatively low viscosity has an
equivalent weight of 156. This "1" type
epoxy chemistry is popular for low cost,
low solution viscosity, and fast lacquer
dry in 2K industrial paints. The
polyamido amine curing agent is very
hydrophobic, or oily, due to the tall oil
dimer content. It affords water resistance,
good metal substrate wetting, and excel
lent pigment and filler wetting. The
crosslinked type "1" epoxy/polyamide
provides flexibility and toughness with
decent impact resistance. These attributes
are the foundation of the traditional ep-
oxy resin chemistry.

Vol. 74, No. 931, August 2002 63

J.D. Elmore et al.

0 CH~ OH 0
ix< / , \ /',

d Figure 1 Bisphenol A epoxy resin.

Critical evaluation of this resin chem-
istry at the molecular level allows one to
quickly identify problems that limit the
formulated paint performance. The fore
most of these is a solubility problem. The
somewhat polar, hydroxyl bearing ep
oxy polyether is not soluble in concen-
trated solutions of the predominantly oily
polyamide. Although this solubility is-
sue is partially overcome b y the selec-
tion of o p t i m u m coupling solvents, the
p r o b l e m is inherent in the bis A e p o x y /
tall oil based p o l y a m i d e resin system.
This will be more obvious when we look
at the solventbome paint formulations
in the next section. When the p o l y a m i d o
amine is appropriately mixed with the
e p o x y component, the resin mbx re-
sembles, on a molecular level a peanut
butter sandwich (Figure 3). The planar,
rigid bis A epoxy aromatic ring back
bones form the bread slices. The low Tg,
amorphous aliphatic curing agent, like
smooth peanut butter, penetrates into the
layers of epoxy and, upon crosslinking,
COOH COOH
I I
CH CH
fl. la
CH + CH
I I
CI'-12 CH
I I'
CH CH
It ( OH2 )5
CH /
I Ci-h
( ~H2 )4
CH3
(?l-la)7 -- CO~H
CH
i@"1 X(~H -( CH2)7-- CO.---NH ( CH2'-CH2-NH)xH
CH ..,CH"CH2-CH =GH -- (CH2)4-CH3
CH
( CH~_)s Ci'-13
-4 Figure 2--Polyamido amine curing agent for epoxy.
the curing agent holds the epoxy layers
together.
If we look at these resins the w a y we
w o u l d look at the frame of a house, we
w o u l d definitely like to keep the hard
ness of the bis A epoxy and the flexible,
hydrophobic, pigment wetting character
of the tall oil p o l y a m i d o amine. The
toughness and chemical resistance of
these paints are attributed to the highly
crosslinked, "tightly w o v e n cloth" na
ture of the denselypacked aromatic rings
of bis A laced together with the more
flexible polyamide. For this resin system,
maximizing the performance of this resin
system means maximizing the
crosslinking b e t w e e n the e p o x y and
amine sites. Look closer at the contrast-
ing equivalent weight and the contrast-
ing rigid versus flexible backbones of
these polymers in Figure 3. With a little
imagination it is easy to understand that
too much bis A epoxy can lead to a brittle,
friable paint film, whereas too much cur
ing agent can lead to sticky, moisture-
(C H2)7 -- COOH
I pot (induct) for at least a h a l ~ h o u r be
CH
ICH ~(~H-(CH~t)7-- COOH
C H ..CH -CH2-CH=CH--(CH2)4 "CH3
CH
I
( CH~5 Cl'-h Dimer Acid
H2N ( CH2-CH2-NH)xH
Ethyleneamine
( CH2-CH2"NH )x H
Polyamide
P o p t i m u m metal protection. We will find
P
sensitive slow drying paints. The lower
cost p o l y a m i d o amine curing agents are
too frequently used in stoichiometric ex
cess. This common practice of using ex
cess equivalents of curing agent is a rna
jor p r o b l e m with these s t a n d a r d 2K
epoxy systems. This practice goes against
what is needed for m a x i m u m corrosion
protection. For o p t i m u m salt spray and
acid corrosion resistance, an excess of at
least 5 to 10% epoxy over the equivalents
of amine is required. 2 The use of excess
uncrosslinked amine causes water ab
sorbing N H : groups to remain in the
paint film. Primary amines form carbonic
acid and carbamic acid salts from the
moisture and carbon dioxide in air (Fig-
ure 3). 3 These amine salts cause surface
defects called "sweat out" that lead to
poor gloss in enamels and poor intercoat
adhesion when these films are topcoated.
These hydrated carbonic and carbamic
amine salts provide a path at the metal
paint interface for moisture to cause cor
rosion undercutting. To insure resin com-
patibility and to minimize the p r i m a r y
amine carbonic or carbamic salt forma-
tion, s o l v e n t b o r n e e p o x y / p o l y a m i d e
paints are usually allowed to react in the
fore they are applied. This is often re
ferred to as the induction time. At the
molecular l e v e l it is the time it takes for
the majority of the hygroscopic p r i m a r y
amines to react with the epoxy groups in
the paint bucket, instead of reacting with
the moisture and carbon dioxide in the
thin applied paint film. This induction
requirement often prohibits the use of
plural component spray equipment when
applying these 2K solventbome paints.
We have just identified the two major
weaknesses in the solventbome resin sys
tem framework. They are: (1) lack of ini-
tial mutual compatibility of the epoxy
resin with the amine resin and (2) excess
p r i m a r y amine from the curing agent,
which forms water sensitive defects in
the paint. On the salvage list, we would
like to keep the quick hardness develop
ment of the aromatic bis A epoxy and the
good wetting and flexibility of the curing
agent. With these resin chemistry pic-
tures in mind, we can move on to dis-
mantle the paint formulations in order
to salvage components and practices
from which to p u t together paints with

64 Journal of Coatings Technology

 Waterborne E p o x y P r o t e c t i v e C o a t i n g s for M e t a l

in the next section that current "formula

tion fixes" do not completely overcome
these two identified problems with the
0 ~, Carbamic salt
solventborne epoxy/polyamid es.

HO., ~'~CHg H 0 O ~ (\ ~--~ ~"o

DISMANTLING TRADITIONAL
2K EPOXY/POLYAMIDO
AMINE PAINT FORMULATIONS

Solventborne White Primer

Formulation i is a s o m e w h a t d a t e d , b u t > -, -, , r J ~ 4 s. C ~ 0 .. H "h t K-.,'~HO 0 ~z'rh.~"~-CH3
still popular, 2K solventborne epoxy
white primer in which excess amine is
used to achieve a simple mix ratio. Ar- H 3 c ' ~ 2 - ~ o , , ~ r 1 6 3 0;~.~.. NH-~N~ k, n~NH sOIl 3 I~
H 2 HHO
rows in the left colun~s point out formu-
lating tools that are at issue for shorh G H~C I ~ ~ H 0 v~_,~C H .
up paint performance. The first arrow
marks the zinc molybdate plus zinc ox
ide anticorrosive. This anticorrosive is a
scavenger for aqueous corrosives that
would attack the iron substrate. 4The sec N
H~C
ond arrow marks barium sulfate which
serves as a physical, water insoluble, pro-
tective barrier when it settles in dense
q Figure 3 Sandwich nalure of crosslinked 2 K e p o x y polyamide. 3 J
platelets to the bottom of the paint film.
The high density b a r i u m sulfate works
well as a barrier in the cured film, but it is
influence of common paint solvents on The n u m b e r of organic low flash point
very difficult to keep suspended in the
the cure speed of aromatic epoxies with HAP solvents in this paint pose unbear-
paint can on the shelf. The zinc molyb
ethylene amine curing agents is shown able inventory as well as e n v i r o n m e n
date and the b a r i u m sulfate are tools to
in Table 1. It is interesting to note that tal, health, and safety risks. Certainly,
shore up moisture barrier properties. The
w a t e r is the most catalytic s o l v e n t these solvent choices with their total
third arrow marks the clay thixotrope
whereas benzene, acetone, and methyl VOCs, 4.51 lb/gal, are no longer toler
which delays the barium sulfate from set-
ethyl ketone retard the cure reaction. ated in our industry.
tlhG. The clay also helps control sag. Usu-
ally, the clay has to be preswelled with
an alcohol before use. This is a chore that
requires an extra paint making step. Formulation 1 - 2 K Epoxy W h i t e Corrosion Resistant Primer s
The fourth arrow points out the un-
balanced epoxy:amine equivalent s ratio. EponTM Resin 1001-Y-75/ER-CURETM 3115-E-73
This primer is formulated too high in
Material Pounds Gallons
amine equivalents per epoxy. This ratio
is high enough in amine to critically cons- Zinc M o l y b d a t e , Zinc O x i d e A n l i c o r r o s i v e ................................ 100.0 2.38
promise the paint's acid resistance. This Rulile Iilanium Dioxide ..................................................................... 200.0 6.05
is caused by the leftover, partially water Barium Sulfate ............................................................................ 75.0 2.04
soluble, curing agent w h e n the paint is O r g a n o p h i l i c Clay IhixolTope (preswelled by alcohol) ............ 5.0 0.33
exposed to aqueous acid. When the amine
(0.31 equivs) Epon TM Resin 1001 -Y-75 ........................................ 208.0 22.50
Xylol ............................................................................................. 14.4 2.00
curing agent is salted with aqueous acid 2-Propoxyethanol ............................................................................ 46.6 6.00
it will absorb water and swell the paint. Diacetone Alcohol .......................................................................... 39.2 5.00
The swollen paint then becomes perme- C y c l o h e x a n o n e ............................................................................... 29.2 3.70
able to salts and corrosives that pass 1 v o l u m e Part A Total ................................................................ 717,4 50.00
through the resin matrix to attack the
substrate. The fifth arrow points out the Talc, Magnesium Silicate ................................................................. 175.0 7.38
root cause as to why epoxy:amine ratio Organ ophilic Clay Thixokope .......................................................... 8.0 0.53
is out of balance; the forced 1:1 compo (0.53 equivs)Epi Cure TM 3115 E 73 Curing A g e n t ................... 115.0 14.97
Ethyl Benzene ............................................................................ 25.3 3.50
nent mix volume ratio. -~ 2 Propoxyethanol ...................................................................... 54.4 7.00
The sixth arrow shows solvents that n-BuM Alcohol ........................................................................... 71.0 10.50
are used to control solubility and reac- -~ Isopropyl Alcohol ....................................................................... 40.2 6.12
tivity of the epoxy and amine. Protic sol- 1 volume Part BTotal .....................................................................488.9 50.00
vents, like ethylene glycol ethers and
Total A + B .....................................................................................1,206.3 I D0.00
alcohols, are used for viscosity control
and to accelerate the epoxy amine reac Typical Coaling Propedies
tion; i.e., shorten the time for the paint to
dry and h a r d e n by speedh G up the nViscosily Parts A + B 68 KU
crosslh&hG. The solvents ethyl benzene, -~Pounds/Gallon P a r t A ............................................................. 14.35
~ P o u n d s / G a l l o n Parts A + B ...................................................... 12.06
xylene, and cyclohexanone slow d o w n Tolal W e i g h l Solids, % .................................................................. 66.7
the epoxy-amine reaction. The relative

Vol. 74, N o . 9 3 1 , August 2 0 0 2 65

J.D. Elmore et al.

customers for 50 years with decent, yet with good applied filmproperties. As in
Table 1 - S o l v e n t Effects Cure of
Epoxy.Amines 6, 7 compromised, performance as a metal the primer, corrosion protection is com-
primer. In the next section, a solventborne p r o m i s e d to obtain these pot life and
Solvenl Elfecl on Cure Rate direct4o metal (DTM) enamel evaluation mix ratio priorities.
illustrates these same common practice The first arrow in this enamel recipe
A c e t o n e ................................ s l o w s - x 0.5 formulating deficiencies in standard 2K marks the calcium carbonate that is used
M e t h y l ethyl k e t o n e ............. slows ~x 0.5 solventborne epoxy paint s. to lower paint cost. Again, as in the
Benzene ................................. s l o w s - x 0.5
N e a t Resins--No Solvent .... c o n k o l x 1.0
primer, barium sulfate is used to enhance
N i l r o m e i h a n e .................... s p e e d s ~ x 1.5 Solventborne Gray Enamel barrier properties. As ment ioned earlier,
I s o p r o p a n o l ...................... s p e e d s ~ x 2.6 the dense b a r i u m sulfate requires clay to
Formulation 2 is a general p u r p o s e provide thixotropy to delay the dispersed
M e l h a n o l ........................... s p e e d s ~ x 3.0
DTM industrial maintenance enamel. To pigments and fillers from settlh G. The
W a t e r ................................. s p e e d s ~ x 5.0
validate that the shortcomings seen in sixth arrow marks a butylat ed urea resin
the p r i m e r are common practice, we will that is used to enhance resin compatibil-
The next arrow, in the paint proper- critique the formulation of this enamel ity, flow, leveling, and gloss. Unless this
ties section, points out the high weight recipe. In this paint, the 3:1 combining paint is baked, the urea resin, Beetle |
per gallon of the "A" component. High ratio is a highlighted feature. Mainte 216 8, does not crosslink or enhance car
weight per gallon limits shelf settling sta- nance departments and do it yourself rosion protection.
bility. By n o w it is obvious that most of consumers prefer a 3:1 or 4:1 mix ratio.
these arrows point to extra effort and These ratios allow convenient small Methyl isobutyl ketone (MIBK) is used
cost to shore up paint performance. Some packaging from one-quart to five-gallon in the curing agent component to make
of these formulation fixes led to other piggybacks of the two components. For- it compatible with the epoxy. MIBK slows
rrzulation 2 demonstrates the t y p e of pig- down the reaction between the epoxy
patches. For example, the high density
b a r i u m sulfate requires a thixotrope for ments, fillers, solvents, solvent levels, and amine. This extra solvent extends
shelf stability. The thbxotrope in turn adds and flow modifiers used to obtain coa- the paint pot life but leads to a high VOC:
at least two extra manufacturing steps to lescence and high gloss with a DTM 3.7 lb/gal. This high organic solvent level
achieve the 1:1 objective. In addition to enamel. P a i n t e r s often select e p o x y helps the compatibility of the resin and
the clay alcohol swelling step, there is an enamels over other 2K paints because curing agent but still does not completely
additional step to disperse the talc in the they have a long enough p o t life be fix the lack of resin mutual solubility.
"B" component. Without the excess soft tween mixing and gelling to do a w o r k Due to the high V9 this enamel re-
p o l y a m i d o amine, talc loading d e m a n d shift of painting. This long pot life elimi- quires 14 days for solvent evaporation
for sandability could have been fitted into nates the need for plural component and crosslinking before it is resistant to
the "A" part. s p r a y equipment. After the 2K enamel aqueous chemicals. This two w e e k cure
D e s p i t e all the f a u l t s w i t h t h i s is mixed and allowed to induct, it pro- requirement is necessary for the high
solventborne primer, it has pleased many vides at least a full 8 10 hr of p a i n t i n g level of slow solvents to migrate from
the film, even though the curing agent
c o n t a i n s a v e r y h i g h l e v e l of fast
crosslinking p r i m a r y amines.
Formulation 2 - 2 K Epoxy Gray Enamel Formulation s
Within a few weeks of full cure this
r:ponTM Resin1001-CX-75/Epi-CureTM 311.5Cu~q Ager~ enamel will begin to drop in gloss due to
the migration of the carbonic salted
Epoxy Cornponenl Pounds Gallons amines to the paint surface. For this rea
Rulile Titanium D i o x i d e ......................................................................... 175 5.01 son, the recoat w i n d o w of this paint m a y
--> C a l c i u m C a r b o n a t e .....................................................................65 2.95 be limited to less than six weeks. This
Barium Sulfate ...............................................................................29 0.55 short recoat w i n d o w is intolerable for
--> C a r b o n Black .................................................................................4 0.27 small auto or equipment parts that re-
O r g a n o p h i l i c C l a y / 9 5 % e t h a n o l in w a t e r 65/35 b y w t ................ 8 0.76 quire recoating to color match brand
--> (0.45equivs) EP 9 TM Resin 1001 C X 75 ..................................... 301 33.44 specified colors after being inventoried
Bettle 216-8| ( C y t e c ) .................................................................... 12 1.43
in the s u p p l y train for up to two years.
--> M e t h y l isobulyl k e t o n e .................................................................64 9.68
P r o p y l e n e g l y c o l m e t h y l e t h e r .................................................... 76 9.89
Enough amine carbonate salt accumulates
--> X y l e n e ............................................................................................79 11.02 on the surface of the coating after a couple
3 vols. Pigmented Epoxy Component ...................................... 804 75.00 months to cause intercoat adhesion prob
lems between this epoxy enamel and a
Curing Agent Componenl color match second coat. These recipe
"convenience" fixes must be significantly
( 0.78 eqdvs) Epi C u r e 3 1 1 5 X 70 Curing A g e n t ....................... 174 22.31
M e t h y l isobuiyl k e t o n e ................................................................. 18 2.69 changed for the enamels if corrosion pro-
--> 1 vol. Curing Agent Component ........................................ 192 25.00 tection is the first priority.
Total Formulation ....................................................................... 996 100.00 In this e n a m e l as in the primer, bar-
rier properties are shored up with addi-
PqJnt Physical Conslants tives to compensate for the amine/epoxy
E p o x y / C u r i n g A g e n t ratio (solids) ............................................................... 100/54
imbalance. The enamel has -50% excess of
N o n v o l a t i l e c o n t e n t , % b y w e i g h t .....................................................................62.6 NH p e r oxirane. This excess amine short
Pigm e n t / b i n d e r , w e i g h t ralio ......................................................................0.76/1.0 ens the paint pot life and weakens bar
--> I n d u c l i o n l i m e ( r e q u i r e d b e f o r e a p p l i c a l i o n for c o m p a l i b i l i l y ) ................ 1.0 rier properties. The compatibility of the
Pot life, o n e q u a r t m i x e d v o l u m e , hours .....................................................8 epoxy with the oily p o l y a m i d e is, here
--> V O C , calculated, p o u n d s / g a l l o n ...............................................................3.72 again, improved but not fixed by selected
Ambient Cure Schedule: Dry t o H a n d l e ....................................................6 hours coupling solvents. The extra ketone ex-
For Solvent Resistance ...................................... 7 d a y s tends the useful paint gloss pot life but it
For a q u e o u s c h e m i c a l r e s i s t a n c e ................... 14 d a y s
also slows the protective p r o p e r t y devel-
--> R e c o a t W i n d o w ............................................................................................2 6 w e e k s
opment of the applied paint. For DTM

66 Journal of C o a t i n g s T e c h n o l o g y
 Waterborne Epoxy Protective Coatings for Metal

corrosion protection as well as for VOC

compliance, not only must the resin and HaC
curing agent be modified but paint for
mulation modifications are also required.

NEW GENERATION 2K
WATERBORNE EPOXY: IMPLE- C~H~>__,,.a
H3 r--"O - - / - - b
MENTING RESIN CHANGES O o - - ~ ~ '-'-j O_ / - - o H~ C
~HO3~
Understanding the changes needed in
the solventborne epoxy paints, includ
ing which resin and paint attributes can
be salvaged, makes it easier to confidently
design a new paint system for corrosion
protection. This n e w generation resin
system is built on the standard bisphe-
nol A cost/performance foundation with
out having to use excess equivalents of
amine curing agent to obtain convenient q Figure4 New generalion "1" lype epoxy resinmodel.
t-
component mix ratios. The new resin sys
tern is designed to take advantage of wa
ter as a cheap, catalytic solvent that al-
lows higher molecular weight epoxy
polymers to be delivered at low viscosi-
ties. Delivering these resins as aqueous
dispersions also offers an additional di
mension to extend the paint pot life. As a
bonus benefit, w h e n water is used as the ~C~o v"~J"~"> PolyetherHydrophiles
solvent, paints can be more readily for
mulated at reasonable viscosities that
meet the VOC and non-HAPS customer
expectations.

New Generation Epoxy

Resin Dispersion
Figure 4 is a model of the new genera
tion "1" type epoxy resin. It has three
distinctive polymer segments: (1) the
standard his A aromatic segment that
forms planar, close-packed hard films;
(2) the aliphatic, hydrocarbon R groups
that wet pigments and wet nonpolar sub-
strafes; and (3) the appropriatel~sized
q Figure5 Associalionof resinmicellesin water.
I-
polyethylene oxide (PEO) hydrophile.
This all important PEO segment is the
middle of the polymer. It delivers water
dispersibility, film flexibility, additive/
filler compatibility, and paint stability.
This PEO segment also controls sag re-
sistance of the paint.
The orientation of the three resin seg- R
ments in the paint are as important as
the layout of the p l u m b i n g and electrical ('"F:h-Poly Aromatic-4.R PolyAromatiC'"
work in a new house. Simply stated, the
PEO is similar to the plumbing; it con
trois the movement of water in the paint
film. The hydrophobic segments insulate
the paint film from the flow of ions much
the way insulation on electrical wire func-
tions. The n u m b e r of epoxy end groups
determines the crosslink density. Figure
5 models the resin's tendency to self as
semble into particles in water. The epoxy
groups on the hydrophobic segments
concentrate toward the micelle hydro-
phobic center, whereas the more water q Figure6--New generation amine curallve for 2Kepoxy model.
I-
Vol. 74, No. 931, August 2002 67
J . D . E l m o r e et al.

located in the epoxy resin backbone in

such a manner that they are rendered
encapsulated b y the hydrophobic p o l y
HaC ~-" Ho mer segments in the cured film. l~

,9 ~-~ ~ I ,,~q,~ .~i 'J NH

b ~ ~ ;'r~~H~_R,.Polyarom=,tir.,, "-Rr162
9 Ego
------- , , .J ~""NH--FI New Generation Curing
A g e n t Resin
R Looking at the curing agent model in
Figure 6, it is now easier to see similarity
between the n e w generation type "1"
epoxy and the matched curing agent. The
mutual solubility of resin and curing
agent polymers is illustrated in Figure 7.
This mutual solubility is built into the
matched epoxy resin and curing agent.
This "like dissolves like" compatibility
eliminates the induction time. It greatly
minimizes the need for cosolvents and it

-4 Figure 7 - - M u t u a l l y soluble n e w g e n e r a t i o n e p o x y / c u r a l l v e resin model.

P promotes the fast particle coalescence re-
quired for high gloss early in the pot life.
The polyaromatic segments of the cur-
ing agent are designed for solubility in
soluble portions of the p o l y m e r migrate semble to form the resin particles? The the bis A segments of the epoxy resin.
toward the water phase. As the PE 9 seg- resulting micelle formation is facilitated The PEO segments and the aliphatic seg
ments are pulled into the water phase b y cosolvents, reactive diluents, and the ments of the curing agent are also de
the epoxy reactive sites attached to the highly specialized design of the PEO seg- signed to enhance compatibility and coa
h y d r o p h o b i c p o l y m e r s e g m e n t s as- ments. The PEO segments are optimally lescence with the new generation epoxy
resin.
By design, both epoxy and curing
agent are multifm~ctional polymers with
Formulation 3 - N e w Generation Waterborne Gray Enamel hard aromatic sections. Both have flex-
ible sections and built in nonionic dis
New Generation Epoxy D PW-6520 / Curing Agent DPC-6870
G r a y Enamel Formulalion 1:1 Mix RalJo
persants, but neither resin is ionic or w a
ter soluble. In order to insure quicker
Malerial Pounds Gallons curing agent homogeneity in the mixed
Part A: Pigmenled Curing Agent DPC-6870 Component epox~amine paint, the equivalent weight
of the curing agent is made higher than
EPI-CURETM Curing Agent 3115 (Resolution PP) ............................... 10.35 the p o l y a m i d o amine standard curing
--> DPM, d i p r o p y l e n e glycol m o n o m e l h y l e l h e r .................................. 30.68 agent discussed in the first section. This
R h o d a m e e n | OA910 (Rhodia) ......................................................... 2.58 also allows the relative volume of curing
--> Opliflo| IX1492 (Sud C h e m i e ) ......................................................... 19.40
agent in the paint to be increased over
Deionized Water ..................................................................................... 41.40
that which is in the standard solvent
Ernulsity a t high s p e e d with Co wles borne epoxy system. This larger volume
C a r b o n Superlet LB1011 (Elemenlls) ..................................................... 4.00 of curing agent accommodates 1:1 and
Kronos~ 2310 (l<ronos) ............................................................................ 215.71 3:1 simple paint combining v o l u m e s
BYK| 22 (BYK-Chemie) ..................................................................... 2.15 without having to use excess curing
--~ R a y b o | 60 ( R a y b o C h e m i c a l C o . ) .................................................. 1.00
agent. The equivalent weight of the n e w
Grind to 8 Hegrrlan generation epoxy is 525 and the com-
Deionized Water ..................................................................................... 113.73 panion curing agent is 225.
A d d C u d n g Agent DPC-6870 (Resolulion PP) G t l o w s p e e d ................ 156.(~3 As shown in Figure 6, the curing agent
I Volume PartA: 95 KU @ 11.9 LB/gal ............................................ 597.00 50
is designed with predominately second-
Part B: UnpigrnentedEpoxy DispersionDPW-6520 Component ary amine functionality with very little
p r i m a r y amine. This minimizes the det-
Dispersion DPW-6520 (Resolulion PP) .................................................... 347.73 rimental carbonic and carbamic salts that
Cardura'" E-lO(ResoluJion PP) ....................................................... 5.23 form with p r i m a r y amines. The curing
--~ SilquesleA 2287 ( C r o m p t o n , OSi) .................................................... 10.46
agent resin is made at a lower Ts than the
BYK 22 (BYK-Ch emie) ............................................................................. 0.63
--~ PnB, p r o p y l e n e glycol m o n o b u l y l e l h e r ......................................... 26.15
epoxy resin in order to facilitate film for
D i a c e t o n e Alcohol ........................................................................... 26.15 marion at lower temperatures without
D e i o n i z e d W a t e r to adjust viscosily to 75 I<U ......................................... 26.15 having to use volatile organic cosolvents.
I Volume PartB: 70KU@8.85 LB/gal .............................................. 442.50 50 This lower m i n i m u m film formflG tem-
perature (MFFT) of the dispersed resins
Total Parts A a n d B ...............................................................................
1039.50 I00
allows paints to be formulated at very
Typical Formulationand Coaling Propedies low VOCs. The molecular weights of the
epoxy and curing agent are higher than
Resin/Curing A g e n t RaJJo (solids basis) ................................................. 69/31 the old standard products to facilitate
--> Volalile O r g a n i c C o m p o u n d s ( V O C ) P o u n d s / G a l l o n .................... 1.9 faster lacquer dry. By p r o v i d i n g the res
Induction Time, minutes: None ~ R e c o a t W i n d o w : 4 hours - 2 years ins in a dispersed form, the higher vis-
cosity penalty for the higher molecular

68 Journal of Coatings Technology


weight is avoided. Likewise, there is no
viscosity penalty for havh G additional
branching in the resin backbones. Both
the branching and the higher molecular
weight of the epoxy resin and curing
agent speed up the cure rate of the new
generation paints to insure quicker back-
to-service times for the painted substrate.
NEW GENERATION EPOXY
PAINT: IMPLEMENTING PAINT
FORMULATION CHANGES
New performance enhancing paint ad
ditives were selected as a means of imple
menting need ed changes to the standard
2K epoxy paints. However, the first ar-
row in Formulation 3 is not a n e w addi-
tive. It is the old p o l y a m i d e salvaged to
pacify the pigments' oil absorbency. In
combination with Rhodameen OA910, it
is superior for wetting and dispersing
pigment, especially carbon black. The
O p t i f l o TX1492 is a n o n i o n i c w a t e r
soluble hydrophobic modified synthetic
thixotrope that serves to stabilize the dis-
p e r s e d p i g m e n t s . This p a r t i c u l a r
thixotrope enhances the shelf stability of
the pigmented curb G agent component
without compromising the gloss or wa
ter sensitivity of the cured paint. This
thixotrope works well for pigmenting ei
ther the amine dispersion or the epoxy
dispersion.
D i p r o p y l e n e glycol m o n o m e t h y l
ether (DPM) serves not only as a good
resin and water coupling solvent, but also
as an antifreeze for the waterborne pig-
mented curing agent component. DPM
is the preferred gloss promoting coales-
cent for this 2K system. The DPM level
used in this formulation does not hurt
the paint d r y time.
The BYK 22, BYK 24, BYK 28, and
BYK 307 silicones in the pigment grind
promote both foam release in the wet
paint and surface abrasion resistance in
the cured paint. Of these silicone based
additives, BYK 22 is the most effective
for defoaming, whereas BYK 307 is the
most effective for mar resistance. The
Raybo 60 is a flash rust fffffibitor. The
use of s o d i u m and p o t a s s i u m nitrite-
based flash rust inhibitors should be
minimized to insure the water immer
sion resistance of the paint.
In this n e w generation gray enamel,
the 1:1 volume ratio is highlighted along
with the stoichiometry of 1:1 epoxy per
amine hydrogen. The Cardura E 10 is a
hydrophobic, branched alkyl glycidyl
ester (Figure 7). It reacts moderately fast
with amines. It is used to promote gloss
and leveling in this enamel formulation.
It reacts slower with secondary amines
than an aromatic bis A epoxy. By the
nature of its reactivity and solubility it
concentrates at the air film interface to
W a t e r b o r n e E p o x y Protective C o a t i n g s for Metal
0
Ha
~
Cresyl Gtycidyl Ether C10 Glycidyl Ester
G8 Alkyl Glycidyl Ether
/
I Figure 8 Monoepoxide diluents as coalescing aids for waterborne epoxies, b
Table 2 - M o n o e p o x i d e Diluent Effects Bis A Epoxy Cured Properties*
ComposilJon PSI Tensile % Tensile 28 Day % H20
Replacing Bis A DGE HDT ~ Slrength Elongalion Absorption
Bis A DGEIh/TETA .................... 103 10,000 3.7 0.67
20% CGEth .............................. 69 11,300 6.3 0.57
20% p 113PGEIh ....................... 74 11,700 6.5 0.72
20% Cs-C10 GEth ..................... 56 6,500 8.9 0.91
20% C10 Branched GEM .......... 64 9,300 6.0 0.82
*Cureone day @RTplustwo hoursat 100~ SC:3037-01HeloxyModifierSelectionGuide
consume amines that could cause sweat The Silquest A 2287, as an alkoxy glycidyl
out or early loss of cured paint gloss. ether, is relatively stable in water. H o w
Aromatic epoxides such as the cresyl ever, the methyl diethoxy silane end of
glycidyl ether (Figure 8) react faster with the molecule will hydrolyze at a high
less compromise of paint film hardness. pH. 12 The Cardura E-10 provides a hy-
The preference for monoepoxide as a re- drophobic carrier to protect the silane
active modifier in this new generation from hydrolysis until the aqueous epoxy
paint system is driven b y the need for component is mixed with the amine dis
gloss and water immersion resistance. persion. 13 In an applied coating, the si
Cardura E-10 offers better film hardness, lanes migrate to the coating metal inter
gloss, and water immersion resistance face as well as to the paint air surface. 1~
than long chain alkyl glycidyl ethers. As The alkoxy silanes are excellent adhe-
shown in Table 2, the long chain alkoxy sion promoters at the metal-pabst h~ter-
monoglycidyl ethers tend to plasticize face. The epoxy end of the silane mol-
films, thus increasing the moisture ab- ecule promotes adhesion to metal b y
sorpt ion of the cured paint. The Cardura tying up the carbonic salt forming pri
E-10 serves an additional purpose in this m a r y amines. It also reacts with h y
formulation. It is an excellent carrier for droxyls on the metal surface via the
dispersh G epoxy silanes (Figure 9) into alkoxy silane.
the aqueous epoxy dispersion. Couplh G of the metal surface hy-
The silanes are good pigment wetters. droxyls via the alkoxy silane condensa-
CH
o o
~c
glycidoxypropylrnethyldiethoxysilane epoxycyclohexylethyltfiethoxysilane
-I Figure 9--Epoxy silane additives for waterborne epoxies.
I-
Vol. 74, No. 931, August 2002 69
JID. Elmore et al.
ether (PnB), are selected for the e p o x y
dispersion to not only enhance the coa-
lescence of the applied paint b u t also to
extend the shelf stability of the e p o x y
groups in the presence of water 9 This
"% combination of ketone with a less water
soluble, more hydrophobic solvent like
PnB pushes water o u t of the epoxy par-
ticle. This is due to more hydrophobic
solvents partitioning favorably to the
resin phase of the dispersion. 17Less wa-
~l ~" ~ l~ l ~ l~l ~l ~
~9" ._,, ter a n d less protic solvent in the e p o x y
. c~ .o "c" .:,;P ?~P resin particle lowers the epoxy reactivity
~'- <3" " and thus improves the shelf life of the
epoxy groups. Likewise, secondary hy-
droxyl cosolvents, compared to primary
/ hydroxyl cosolvents, extend the shelf life
-t Figure 10--Epox7 p a i n t stability i m p r o v e d w i t h l ~ polar I~
cosolvents, / of the epoxy groups in the paint. This
organic cosolvent effect on the epoxy dis-
persion stability is shown in Figure 10.
The e p o x y dispersion stability in Figure
10 is reported with cosolvent modifica-
tions of 10 pph. Solvent blends are at a
50/50 ratio where added 9
Usually, the solvents that are good
for epoxy group stability are also good
for the paint component viscosity stabil-
ity. Figure 11, at 4 p p h modification,
shows stability comparisons of the new
generation e p o x y dispersions modified
with 50/50 blends of cosolvents which
1
are p o s t added 9 Methyl normal amyl ke-
tone (MnAK) is excellent for e p o x y and
viscosity stability. However, since it ob-
viouslypartitions ~ the dispersion resin
phase it imparts a high initial viscosity to
the paint. Therefore, its use is limited to
low-solids, thin-film paints. The solvent,
-I Figure 11 - - C o s o l v e n t selection for viscosity stability,
P dipropylene glycol normal butyl ether
(DPnB) is excellent for coalescing thedis-
persed new generation resins. It m a y be
used to enhance gloss. However, it also
Table 3 - W h i l e Primer Cure Rate and Film Hardness significantly retards the film property
Development Comparison* d e v e b p m e n t in the applied paint because
it is very slow to evaporate 9 The overall
Solventborne Plirner WateHoorneWhite preferred cosolvents for viscosity, paint
Cure Propedies Formulation I PrimerI~
slability, p a i n t film hardness develop-
Wet film mils .......................... 2,6 2.7 ment, and acceptable paint flash points
S e t t o t o u o h ........................... 0,50,2,5 are PnB and diacetone alcohol 9
C o l l o n free7,5 ....................... 2,0
Through drylO,5 .................... 3,,5
1 d a y pencil hardness .......... <6B F
1 w e e k pen, hardness .......... 2B F SUMMARY AND CONCLUSION
Cross h a t c h adhesion a ......... 5A 5A
MEK d o u b l e r u b s ~ ................. >200 132 Comparison of N e w Generation
M IBK spot test a ...................... 60 10
to Solventl0orne 2K Epoxy
*7 Day 25~ cure al" 56% relative humidib/on cold rolled steel,
The implemented changes combined in
the new generation 2K e p o x y resins and
paints are summarized as follows: (1)
tion with epoxy hydroxyls is a third mode sion is added.16 The coalescence a n d cure the amine and the e p o x y resins were
of promoting adhesion to the metal sub- speed of the p a i n t resin matrix is greatly changed t~ maximize their mutual solu-
s~rate, is Because t h e p H o f the amine cur- improved by the selection of the appro- bility and coalescence before they
ing a g e n t d i s p e r s i o n is significantly priate reactive diluents. With the appro- crosslink; (2) the carbonic a n d carbamic
higher than the epoxy dispersion, amino priate combination of epoxy and silane acid salts in the cured paint were mini-
silanes in the curing agent component diluents the ambient cure cycle for water mized by formulating paints at near 1:1
have shorter shelf lives than e p o x y si- immersion resistance is short~ned from stoichiometfic ratios from predominantly
lanes in the e p o x y side9 Thus, the con- 14 b 10 days for the new generation paints. secondary amine functional curing
densation of silanes in the epoxy side is The cosolvents, diacetone alcohol and agents;and (3) thenew generation paints
activated when the curing agent disper- p r o p y l e n e glycol mono n o r m a l butyl were formulated using reactive diluents,

70 Journal of Coati ngs T e c h n o l o g y

 Waterborne E p o x y P r o t e c t i v e C o a t i n g s f o r Metal

fog resistance of the new generation is

Table 4 - P r i m e r Comparisons: Salt Fog Resistance
noticeably better (Table 5).
@ 888 Hours on Grit Blasted Steel*
As shown in Table 6, the new genera
Solvenlborne Primer WalerborneWhile tion white primer has significantlybetter
Sall Fog Resistance* Formulalion I Primer18 acetic and hydrochloric acid resistance
Undercut scribe m m ............... 3 None with good aqueous base resistance com-
Rusl a l scribe mm ................... 2 0.5 pared to the solventborne standard ep-
Blisters a t scribe ....................... F #6 None oxy primer.
Field blisters ............................. F #6 None
X-Cut adhesion ....................... 5A 5A
*7 Day 25~ cure at 55%relative humidily, 25 milsdry films Implemented Changes Add Value
in Vehicle Resins a n d Paints
The changes implemented in the new
generation system are tabulated beside
TableS- Enamel Property Comparisons" their respective improvements in the
performaz~ce of the metal coating in Table
While Enamel Properly Solventborne20 Waterborne21 7. This table shows how these resin and
Through dry; hr ................................... 8.5 6.0 formulation changes are translated into
Pencil hardness ( 1d a y / 1week) ............ 4B / H 5B / F a d d e d value in the n e w generation
Gloss % (60~ / 20~ / 87 ....................... 102/90 paints.
I m p a c t resistance ( D/R inch LB)~ .......... 160 / 160 160 / 160 The most significant value enhance-
M E K d o u b l e rubs ~ ................................... 337 308 ments of these waterborne new genera-
25~ w a t e r immersion; days ................... >250 >250
tion paints add up to shorter cycles for
Blisterrating, fi eld ~ ................................... 10 (none,) 10 (none)
Salt spray resistance; hr ........................... 1152 1152
the paint. In the real world, a shorter
Blisterrating, field ~ ................................... 6F 6M 10(none) cure cycle means that a primer can be
sanded and coated in four hours instead
"14 Day 25~ cure at 55%relative humidity, 2.5 milswet film on cold rolledsteel. of 24 hours. A shorter cure cycle also
means a freshly painted metal loading
dock ramp will be out of service for only
two or three days instead of one week.
Table 6 - P r i m e r Comparisons: Acid/Base Spot Resistance The shorter cure cycle for 9 fin-
ASTM D1308 (14 Day Cure; 3.0-3.5 mils dryon Cold Roll Steel) ishes means that a part or component
can be packaged and shipped directly off
Solvenlborne Walerborne the end of the coating line instead of hav-
Acid or Base [ermulalien I White PrimerI~ ing to be racked for 24 hours for paint
5% a c e l l c Adhesion 100% loss Slight Swelling
drying before packaging. Packagingparts
10% HCI Adhesion 100% loss Dulls appearance directly from the end of the coating line
1096 H2S04 No effect Dulls a p p e a r a n c e not only eliminates warehousing and in
10% NaOH Slight swelling No e f f e c l ventory, it also means quicker returns
10% NH40H No effect No effect on the paint raw material inventory costs.
The ability to apply the new genera
tion coatings without an induction time
cosolvents, and a nonionic thixotrope for ondary amine content in the curing agent saves labor costs and material costs. The
o p t i m u m p a i n t stability, coalescence, and which crosslinks much slower than pri- elimination of induction time also allows
cure. mary amines. However, as shown in the use of plural component spray equip-
The az~ticipated paint performaz~ce en- Table 5, the ketone resistance of the new ment to apply the new generation paints.
hancements and trade offs are shown in generation enamel after 14 days is c o r n In addition to the added value from
Tables 3 6. Table 3 shows that the new parable to the standard solventbome shorter cure cycles, the improvements in
generation primer dries harder, quicker, enamel. The superior salt fog resistance water, acid, base, and salt spray resis
and develops salt spray resistance ear of the n e w generation primer at seven fauces add value to the protected metal
lier than the s t a n d a r d s o l v e n t b o r n e days cure is shown in Table 4. The water structure, part, or substrate.
primer. The slower development of ke- immersion resistance of the new genera- These performance enhancements of
tone resistance of the 2K waterborne tion enamel at 14-day cure is comparable cure speed and corrosion resistance,
primer is due to the predominant sec- to the solventborne standard but the salt along with the environmental compli

T a b l e 7 - V a l u e Added Improved Performance Resulting from Implemented Changes

Irnplernenled Changes Value Added Improved Perlorrnance

Increased e p o x y a n d a m i n e c o m p a l i b i l i i y G o o d gloss; no induclion 11me

Raised curin g a g e n l AHEW l o w e r e d primary N H
Increased resin Mw a n d b r a n c h i n g
Dispersed WB resins instead of o r g a n i c solulions
A p p r o p r i a t e cosolvents in paint
M a l c h the e p o x y a n d a m i n e equivalenls in p a i n l
H y d r o p h o b i c e p o x y a n d silane diluents in p a i n t
Superior corrosion protection / mix ralio 1:1, 3:1
Fasler l a c q u e r dry; faster through cure
Fast cure a n d low V O C c o m p l i a n t
Pkg. stabilih/with non-HAPS V O C c o m p l i a n c e
Superior corrosion p r o t e c l i o n with simple ralios
Shorlened cure for wafer immersion resistance

Vol. 7 4 , N o . 9 3 1 , August 2 0 0 2 71
J,D, Elmore et al,
ance and " u s e r friendliness" of this n e w
g e n e r a t i o n of w a t e r b o r n e t e c h n o l o g y
should allow coatings makers and appli-
cators to c o m m a n d a h i g h e r p r e m i u m
for these w a t e r b o r n e e p o x y paints.
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