The Waterborne Symposium 2025

Abstract

Lightweight, mechanically robust materials capable of high thermal transport and minimal electrical interference are critical for the protection of sensitive high power electrical systems. Polymer composites are an excellent materials solution for protection of such electrical components however their development is met with multiple challenges. For example, polymer-particle interactions, processability, thermal properties, innate particle properties, viscosity, dielectric properties and composite morphology are only a few considerations for material screening. Boron nitride (BN), a thermally conductive low-density ceramic, is a reasonable additive to develop polymer composite solutions due to its inability to conduct electrons and minimal impact on component weight. On the other hand, the polymer carrier material for such ceramic particles is equally important in the development of novel functional materials. The design versatility of benzoxazine (BOX) monomers and polymer precursors offer endless opportunities to tune matrix properties and particle-polymer interactions as well as processing methods. Herein we will discuss key considerations for optimal composite performance, current challenges and limitations toward the development of new materials to fulfill an industry need through the lens of BOX/BN polymer matrix composites.

Abstract

"Waterborne polyurethane dispersions (PUDs) are renowned for their exceptional film-forming ability, toughness, and flexibility. However, they are often challenged by poor water resistance and higher production costs. Polyurethane/acrylic hybrid resins offer a balanced, cost-effective solution, combining the strengths of both PUDs and acrylics. These hybrid systems provide enhanced mechanical properties alongside superior water and chemical resistance, making them an ideal choice for high-performance coatings.

This presentation highlights the development of an innovative polyurethane/acrylic hybrid waterborne resin designed to meet both environmental and high-performance requirements. Synthesized in the absence of added solvents, this resin allows for coatings to be formulated at low VOC levels while still offering a balance of hardness, flexibility, and favorable coalescence properties, making it an ideal binder for applications with stringent environmental constraints. Free from amines, the resin also addresses concerns over amine-related issues such as migration and yellowing, while enhancing overall formulation stability. The resin also exhibits good solvent resistance and excellent adhesion to a wide variety of substrates, including metals, plastics, and woods, making it suitable for diverse industrial applications."

Abstract

The paint and coating market for kitchen cabinets, trim, and doors focuses on products designed to enhance the appearance and durability of wood and other commonly used materials. These coatings must meet stringent performance standards, including early block resistance, surfactant leaching resistance, body lotion resistance, and scrub resistance. Traditionally, per- and polyfluoroalkyl substances (PFAS) additives have been used to improve block resistance. However, due to increasing regulatory restrictions on these hazardous substances, there is a growing need for alternative solutions. This paper explores the current market landscape for kitchen cabinets, trim, and doors, and discusses our recent sustainability efforts to develop innovative waterborne acrylic latex binders specifically designed for these applications. We will also discuss general strategies to enhance key properties, including early block resistance, surfactant leaching resistance, and body lotion resistance.

Abstract

Sustainable products are designed to minimize negative impacts on the environment while meeting the needs of consumers. By choosing sustainable products, reduction of waste, conservation of resources, and improved performance may be achieved while protecting the planet for future generations. It is important to consider not only the use of sustainable materials but also the overall environmental impact of the product, including its production, application, and end-of-life disposal. Using examples from sustainable resin development, many of the considerations for defining sustainability and in developing eco-friendly waterborne coatings such as copolymer handprint vs. footprint, biobased vs. mass balance, and cost effectiveness vs. improved performance will be presented and discussed.

Co-Authors:  Kaden Stevens, Jeff Aguinaga, Derek Patton, Brent Sumerlin, and Tristan Clemons

Abstract

Carbon fiber has been established as one of the most important structural materials of the 21st century because of its remarkably high strength to weight ratio. As such, carbon fiber has found a wide range of applications in sporting goods, aerospace, construction, and medical device industries. Currently, approximately 90% of carbon fibers are derived from polyacrylonitrile (PAN) precursors due to the superior tensile strength that can be achieved when processed effectively. Traditional PAN synthesis is achieved by employing free radical polymerization in solution or by emulsion, resulting in broad molecular weight distributions. Additionally, PAN is insoluble in its own monomer and requires toxic organic solvents such as dimethylformamide (DMF), dimethyl sulfoxide, or ethylene carbonate for both solution polymerization and wet spinning into white fibers. Controlled radical polymerization techniques have demonstrated that narrow molecular weight distributions can provide favorable rheological profiles for fiber spinning but suffer from low monomer conversions and struggle to achieve molecular weights necessary for producing high quality carbon fibers. In this study, we present an aqueous photoiniferter (aqPI) polymerization of acrylonitrile, achieving high molecular weights of PAN at high monomer conversions, with significantly faster kinetics, and greater control of polymer dispersity when compared to traditional approaches reported. Polymerization kinetics were determined by 1H nuclear magnetic resonance (NMR) spectroscopy, and polymer molecular weight and dispersity (PDI) determined by gel permeation chromatography (GPC). Residual zinc content was quantified by X-ray photoelectron spectroscopy (XPS).