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

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. 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

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

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

8. BEWOID BLADE

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®)

10. 50 g/L VOC TINTABLE STAIN FORMULATION

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

12. PENETRATION TEST

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
OBSERVE

14. LAPPING – 20 MINUTES BETWEEN COATS

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

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

17. EXTERIOR STAIN – ONE YEAR OUTDOOR EXPOSURE – CARPENTERSVILLE, IL
GLOSS RETENTION 20 DEGREE
GLOSS RETENTION 60 DEGREE
DELTA E
ALKYD EMULSION
100%
65%
3.8
STAIN #1
44.4%
3.0
STAIN #2
50%
34.2%
4.05
STAIN #3
44.9%
3.6
STAIN #4
22.5%
2.5
STAIN #5
92.3%
4.0
STAIN #6
83.4%
2.3

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……