The Waterborne Symposium 2025

Trends in sustainability and changing regulations result in an ongoing evolution of customer needs. New technology or new approaches are often needed to meet these evolving needs, presenting both challenges and opportunities to the coatings industry. A number of examples of technology innovations developed to address such needs will be shared including methods of reducing energy required for cure and approaches for removing materials of concern.

Abstract
Market-inspired research and development (R&D) plays a crucial role in driving innovation, addressing societal needs, and advancing technology. A deeper understanding of market segments and dynamics further sharpens the focus of R&D efforts and increases the chances of commercialization success. And when these efforts align with governmental objectives, an influx of significant funding can accelerate technological advancements. Government funding programs reduce risk and allow researchers to explore long-term breakthrough technologies that might not otherwise take place. In this talk we will explore how combining the tools of market intelligence with various funding mechanisms can effectively intersect to identify innovation gaps that are likely to yield greater results that benefit both society and the economy.

Co-Authors:  Yelone Liu and Hugo Wang

Abstract

The use of plastics in different applications, such as automotive interiors and consumer electronics, has increased mainly due to their low density and light weight, convenient processability and balance of cost and performance. However, many plastics require a coating to protect the surface from scratches and abrasion to maintain their surface appearance and quality. This is particularly challenging in low gloss coatings (≤ 5 gloss units at 60°) where the film damage is easily visible. The thin films used also limits the ability of some additive technologies to improve coating durability.

This paper presents a study of different synthetic silica matting agents in combination with other additives in four different plastic coating formulations and compares their effects on scratch and abrasion resistance of the final coating. Conventional silica matting agents offer good dispersibility and matting efficiency, but their scratch and abrasion resistance does not meet end-user expectations. Organic / polymeric matting agents have better scratch and abrasion resistance but are less efficient in matting. Combinations of silica matting agents with other technologies, such as nylon powders or polyethylene waxes can dramatically improve the scratch resistance without side effects. Abrasion resistance can be enhanced using combinations of matting agents with novel small-sized, spherical silica particles..

Co-Authors:
R. Severac, T.T. Tran, C. Kustner, A. Becker, G. Schlatter, S. Le Calve , A. Hebraud

Abstract
"Driven by environmental, health, and safety concerns, coatings technologies have undergone a dramatic shift in the past few decades driven by the reduction of VOCs and other hazardous materials in coating formulations. The continuous development and improvement of waterborne technologies has enabled many solvent-based systems to be replaced with waterborne chemistries that contain significantly lower VOC content than their solvent-based counterparts. VOC levels have been pushed even lower by the development of low-VOC and zero-VOC water-based formulations. A continuation of this trend emerging in the global coatings industry has been focused on the development of functional coatings that not only limit emissions of VOCs into the environment but actively extract and remove VOCs that have originated from other sources. A functional coating with VOC remediation capability could improve indoor air quality and provide a means to scavenge VOC emissions from sources that have proven to be more challenging to address.

This investigation is based on two different methodologies. In a first part, ISO 16000-23 European standard has been used as an initial demonstration of the formaldehyde scavenging efficiency of a conventional zero-VOC decorative paint containing tris (hydroxymethyl) aminomethane and 2-amino-2-ethyl-1,3-propanediol. Even if extended to 6 weeks, this dynamic test is not able to determine the real full scavenging capacity of the studied material. A new method has been developed with the intend to experimentally measure the full capacity of adsorption, and also to test several pollutants present in indoor environment over formaldehyde, enabling to characterize the scavenging versatility of these additives".

Abstract

Block copolymer (BCP) thin films have a wide range of applications from membrane technologies for gas separation to energy applications including solid electrolytes. The nanoscale morphology of BCPs plays a critical role in the bulk material properties and subsequent applications. In addition to chemical structure, various processing conditions have been demonstrated to impact BCP morphology and can be leveraged as tunable parameters. To achieve precise control over BCP solid state morphology, processing conditions require optimization. This talk presents a novel approach for the high throughput analysis of grazing incidence small-angle x-ray scattering (GISAXS) data and atomic force microscopy (AFM) images, characterizing BCP thin film morphology. The curated dataset was used to train 11 unique machine learning (ML) models to predict BCP morphological properties from processing parameters including solvent ratio and additive amount. ML models were able to relatively accurately predict the extent of ordering of BCP thin films measured by GISAXS but struggled with AFM measurements. The decreased performance by the models predicting the AFM-based measurements can be attributed to the variability within the AFM measurements. Despite this variability, a convolutional neural network (CNN) trained on the AFM images was highly accurate, correctly classifying over 93% of images into ordered/disordered categories. While performance of ML models is crucial, interpretability of the predictions is equally important. For this purpose, the Shapley Additive exPlanations (SHAP) was used to interpret the predictions of the models. Additive amount was the most influential processing parameter on morphological output predictions, which agrees with the physical understanding of the system. Additionally, the SHAP deep explainer demonstrated the successful interpretation of the AFM images by the CNN. This framework leveraging ML and high throughput data analysis lays the foundation for BCP thin film processing optimization with an expanded design space.

Abstract

The colloidal capability team at PPG focuses on understanding how colloidal properties such as particle size and particle-particle interactions drive the stability and performance of paint formulations. The colloidal system emphasized in this talk is pigments, which are ubiquitous in the coatings industry and play a crucial role by providing properties such as color, opacity, protection, and durability. Furthermore, pigment stability against sedimentation and aggregation is essential to ensure that these properties remain consistent over time, even when exposed to changing environmental conditions. In this talk, we will present techniques that efficiently assess the stability of pigments and fundamental properties that drive it. 

Co-Authors: Hieu Ngo, Daniel Scholz

Abstract:
The market demand to replace dyne pens for faster, more accurate contact angle and surface energy results which can be made directly in the production area has fueled the development of very sophisticated portable, handheld contact angle goniometers. These devices are growing in popularity and allow immediate measurement of contact angle and surface energy with minimal operator expertise or training required. However, the question arises as to how results obtained using such a handheld device with two test liquids will compare in accuracy and repeatability to the more traditional, lab-scale devices which offer the ability to make high-speed movie measurements of droplet spreading and use as many as three or even four different test liquids. This lecture will compare and contrast contact angle and surface energy results obtained using both a handheld versus a lab-style research-grade contact angle goniometer. Real-world advantages and disadvantages of these two types of measurement devices will be presented.

Abstract
"When considering flexible coatings, polyurethane often comes to mind. Polyurethane's flexibility is derived from its unique structure, featuring a combination of hard and soft segments, as well as hydrogen bonding within the hard segment. While polyurethane possesses diverse chemical structures and finds applications in various coatings, 2K polyurethane commonly grapples with several limitations, including the handling of often toxic isocyanates, sensitivity to moisture, yielding soft coatings, moderate curing speed, and constraints on coating thickness. Additionally, 2K polyurethane often necessitates the use of solvents to reduce viscosity for ease of application, resulting in high volatile organic compounds (VOC) emissions.

Epoxy systems are not typically associated with flexibility, as they are primarily recognized for their excellent mechanical properties, chemical resistance, and adhesion to substrates. Epoxy coatings have found widespread use in applications aimed at protecting substrates, enhancing resistance to various chemicals, and extending the service life of materials and assets. Compared to 2K polyurethane, epoxy presents advantages in terms of ease of handling, lack of moisture sensitivity, and the ability to formulate low VOC and low emission solutions. Furthermore, epoxy can be rendered flexible by incorporating a substantial amount of long-chain not environmentally and not user-friendly phenolic plasticizers. The need for fast return to service is a driving force in the coatings industry, often leading to the use of accelerators that, while speeding up curing, can compromise flexibility.

This paper introduces a novel EHS friendly flexible epoxy technology designed to bridge the performance gaps in current flexible epoxy systems using sustainable bio-based raw material. It yields coatings with rapid curing capabilities while maintaining high flexibility, even at low temperatures. These coatings exhibit high hardness, excellent substrate adhesion, substantial tensile and tear strength, all while maintaining an environmentally and user-friendly product profile. Catering to the demand for rapid return to service with minimal emissions and extended working time. The paper will also delve into key performance attributes and provide comparisons with 2K polyurethane and conventional epoxy systems.
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Co-Authors: Franklin Leal, and Dan Weinmann

Abstract

Epoxy resins have been used for decades in applications demanding excellent adhesion and corrosion resistance, but historically have not been suitable for coatings where ultraviolet (UV) resistance is needed. A direct-to-metal coating, comprised of a novel modified cycloaliphatic epoxy resin combined with a lower yellowing amine curing agent, was designed to deliver superior performance in corrosion resistance and adhesion. Additionally, this epoxy resin system offers improved gloss retention and color stability compared to standard epoxy coatings. Both the resin and curing agent are optimized to minimize dry time while maximizing hardness development. The relationship between epoxy-amine stoichiometry and coating performance was evaluated to further improve the system. Comparative testing with a commercially available epoxy-polyamide DTM coating showed that the novel epoxy system performs well against the competitive material while significantly improving the UV resistance, as determined by gloss and color retention.
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Abstract

"2K coatings are being heralded as an innovative means to increase the move towards 100% solids materials and reduce the need for thermal curing, thus reducing the energy required for the coating process. While the benefits are indisputable, there are issues associated with these technologies that can make them difficult to process in the manufacturing environment. All of these must be dealt with as part of the application process and, if not properly handled, can result in production delays that reduce throughput, reduce quality, and increase costs. Obviously, this runs counter to the objectives of these advanced technologies.
In this presentation we will:
 define induction time and pot life and the relationship between them.
 discuss the implications these pose to the modern manufacturing process.
 identify novel methods to leverage these properties, turning them from adversaries to allies in the application process.
 identify opportunities to minimize waste, reduce rework, increase throughput, and improve the quality of the coating process."

Bio: Brian Vest, Linda Adamson, Celine Burel

Abstract
"Perfluoro and Polyfluorinated-Alkyl Substances (PFAS) have been extensively utilized across various industries due to their exceptional ability to resist heat, oil, grease, and water. Among these PFAS chemicals, Fluorocarbon Surfactants (FCS) have been particularly effective in waterborne coatings to enhance early ""hot block"" resistance. However, increasing regulatory pressures and risk management considerations are pushing formulators to phase out these substances. This shift necessitates a careful balance between maintaining performance and adopting more sustainable alternatives.

Our study focuses on the development and application of novel phosphate ester wetting agents that offer improved early hot block resistance without the environmental drawbacks associated with fluorocarbon chemistry. These innovative additives are APE-free and have very low or zero VOC content, contributing to better colloidal stability. This stability enhances the wetting, dispersing, and compatibility properties of the final water-based coating. Our data will demonstrate the overall performance of the paint and explore the structure/property relationships that contribute to enhanced anti-blocking performance."

Abstract

Dirt pick-up resistance (DPUR) is a critical property in surface coatings, particularly for outdoor applications. Additives play a crucial role in enhancing DPUR by improving both the visual appearance and durability of coated surfaces. Silicone-based compounds, hydrophobic agents, and nanoparticles have been shown to reduce surface energy, thereby minimizing the adhesion of dirt particles and dirt slurries. In addition, certain polymeric and film-forming additives can improve surface smoothness and reduce porosity, further preventing dirt accumulation. The incorporation of modified surface additives  has also been explored, leveraging their self-cleaning properties under sunlight exposure. This paper reviews the different types of additives used to enhance DPUR, their mechanisms of action, and their effectiveness with various methods. The optimization of additive in the formulations is key to achieving a balance between surface protection, durability, and environmental considerations, making them necessary in modern surface coating technologies.”

Co-Authors:
Tom-Seung Cheung, and Yanjun Luo

Abstract
PFAS compounds provide surface tension (ST) reduction, coefficient of friction (COF) reduction, hydrophobicity, oleophobicity and chemical stability.  These fundamental properties result in applications such as stain resistance, block resistance, oil resistance, lubricity, release, AFFF and many others.  
Siltech have presented previously on replacing PFAS components with organomodified silicones which provide similar and satisfactory performance on ST, COF and hydrophobicity. The difficult challenge is oleophobicity. We have had some success in this category and will report this here. We will emphasize some UV cured acrylate structures which are giving strong performance in this critical category.

Abstract

Stability under low shear storage and shipment conditions can be critical to the stability of waterborne coatings and dispersions against sedimentation and syneresis. Judicious selection of a fit-for-purpose low shear thickener plays a crucial role in preventing sedimentation, especially in cases where dense pigments are incorporated into waterborne formulations. During the application process, traditional thickeners enhance sag resistance and influence leveling to facilitate robust film build. More importantly for longer-term storage, low shear thickeners can prevent syneresis in colorant-tinted coating systems. This presentation introduces an innovative rheology modifier technology based on a novel zirconium complex that eliminates sedimentation and syneresis under extremely low shear conditions associated with coating storage and transport. This technology offers the user-friendly option of post-addition under moderate mixing conditions, in contrast to other rheology modifiers that require neutralization and high-speed mixing processes. This presentation shows results illustrating the valuable outcomes achievable through the utilization of this unique low shear thickener platform.

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

"Regulatory activity in both the EU and USA is targeting a large group of chemicals known as PFAS (per- and polyfluoroalkyl substances). As a result, formulators in many industries are working to replace additive powders based on PTFE and PTFE hybrids with alternative materials that provide the same level of performance.
This presentation will detail a unique nanocomposite approach to eliminate PTFE in surface additives by replacing PTFE with hard, inert, durable materials such as aluminum oxide and ceramics. Data will be presented to show that this portfolio of over 8 additives provides equal or (in most examples) improved surface durability (lubricity, scratch & abrasion resistance) without the use of PTFE."

Abstract

The increasing demand for sustainable solutions in coatings has prompted the development of innovative renewable defoamer technologies. This presentation explores the formulation of a cutting-edge defoamer derived from bio-based resources, focusing on its physical and chemical attributes that optimize defoaming effectiveness without compromise in wetting. The new defoamer achieves significant regulatory compliance and boasts a renewable bio-based content exceeding 75% while being mineral oil- and siloxane-free. This development redefines performance standards for renewable defoamers.

Join us for our fourth annual lightning round style Graduate student poster competition Sponsored by Evonik. Each student will be given five minutes to present his/her poster to the judges and audience and answer questions about their work.

Moderated by Tristan Clemons

Our students will also be available during all the coffee breaks.

Abstract: