Development of high performance, water-based emulsion coatings for can coatings applications
A new manufacturing process for high performance, water-based emulsion coatings for can coating application was developed, which includes emulsification of an epoxy resin by the phase inversion method with or without a hardener by incorporation of an acrylic resin. It is possible by this new process to emulsify a variety of resins with minimum effects of the surfactant (acrylic resin) on the film properties of the cured coating. Thus, the latitude to design a formulation is widened and the performances of the epoxy resin and hardener are fully developed. It was found that the composition of the solvents in the resin solution prior to emulsification is critical to obtaining a stable emulsion with a fine particle size. The effects of surfactant and neutralizer on adhesion performance were also studied, it was found that the effect of the acrylic resin concentration was relatively small, but that the effects of the neutralizer were significant. It was confirmed that the usage of ammonia or amines with a branched alkyl group is required to achieve balanced dry and wet adhesion. It was also found, by the characterization of the emulsion and the cured films, that there exists a layer of acrylic polymer near the substrate and that most of the acrylic polymer forms a dispersed phase in the epoxy/phenolic polymer matrix.(Author abstract)
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