EPA-600/R-9 5-160
November 1995
RESEARCH AND PRODUCT DEVELOPMENT OF
LOW-VOC WOOD COATINGS:
FINAL REPORT
by
Eddy W. Huang
AeroVironment, Inc.
222 East Huntington Drive
Monrovia, California 91016
Prepared under subcontract to:
South Coast Air Quality Management District
EPA Cooperative Agreement CX-819072-01-2
(SCAQMD Subcontract No. S-C93101)
EPA Project Officer:
Robert C. McCrillis
National Risk Management Research Laboratory
Air Pollution Prevention and Control Division
Research Triangle Park, North Carolina 27711
Joint Sponsors:
South Coast Air Quality Management District
Planning and Technology Advancement Office
Diamond Bar, California 91765
Prepared for:
U.S. Environmental Protection Agency
Office of Research and Development
Washington, DC 20460

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FOREWORD
The U. S. Environmental Protection Agency is charged by Congress with pro-
tecting the Nation's land, air, and water resources. Under a mandate of national
environmental laws, the Agency strives to formulate and implement actions lead-
ing to a compatible balance between human activities and the ability of natural
systems to support and nurture life. To meet this mandate, EPA's research
program is providing data and technical support for solving environmental pro-
blems today and building a science knowledge base necessary to manage our eco-
logical resources wisely, understand how pollutants affect our health, and pre-
vent or reduce environmental risks in the future.
The National Risk Management Research Laboratory is the Agency's center for
investigation of technological and management approaches for reducing risks
from threats to human health and the environment. The focus of the Laboratory's
research program is on methods for the prevention and control of pollution to air,
land, water, and subsurface resources; protection of water quality in public water
systems; remediation of contaminated sites and groundwater; and prevention and
control of indoor air pollution. The goal of this research effort is to catalyze
development and implementation of innovative, cost-effective environmental
technologies; develop scientific and engineering information needed by EPA to
support regulatory and policy decisions; and provide technical support and infor-
mation transfer to ensure effective implementation of environmental regulations
and strategies.
This publication has been produced as part of the Laboratory's strategic long-
term research plan. It is published and made available by EPA's Office of Re-
search and Development to assist the user community and to link researchers
with their clients.
E. Timothy Oppelt, Director
National Risk Management Research Laboratory
EPA REVIEW NOTICE
This report has been peer and administratively reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Mention of trade names or
commercial products does not constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Information
Service, Springfield, Virginia 22161.
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ABSTRACT
Traditional wood furniture coating technologies contain organic solvents which become
air pollutants as the coating cures; mitigation by add-on control devices would be energy
intensive. Air emissions can be reduced through the pollution prevention approach of shifting to
low-VOC coatings, avoiding the energy penalty.
In this project, a new low-VOC wood coating technology, a two-component, water-based
epoxy, was evaluated by determining its performance characteristics, conducting application and
emissions testing, and assessing the cost benefits for energy conservation and air pollution
reduction. Polymer composition variations of the basic epoxy polymer in combination with
several curing agents were conducted.
The resulting top coat was as good as or better than other low-VOC waterborne wood
furniture top coats for adhesion, gloss value, dry time, hardness, level of solvents, and chemical
and stain resistance. The VOC content of the clear and the white pigmented top coats was less
than 10 g/1. Cost of this low-VOC wood coating is comparable to other low-VOC coatings.
Improved dry times was identified as a critical area for product improvement. A marketing plan
was developed. At least one major coatings manufacturer expressed interest in participating in a
product feasibility study.
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CONTENTS
Section Page
ABSTRACT	i i i
LIST OF TABLES	 v
ACKNOWLEDGMENT	vi
1.0 INTRODUCTION	1
2.0 PROJECT DESCRIPTION	3
2.1	Coating Characteristics 	3
2.2	Technical Approach	4
2.3	Task Description 	5
3.0 RESULTS OF LABORATORY DEVELOPMENT	7
4.0 RESULTS OF MARKET DEVELOPMENT	10
5.0 FUTURE DEVELOPMENT	12
6.0 REFERENCES 	12
APPENDIX A - EMISSIONS CHARACTERIZATION 	14
APPENDIX B - COATING CHARACTERISTICS AND PERFORMANCE PROPERTIES . . 16
APPENDIX C - MARKET SURVEY QUESTIONNAIRE 	19
APPENDIX D - MARKETING REPORT 	22
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LIST OF TABLES
Table	Page
1	Polymer/Curing Agent Screening Matrix 	7
2	Performance Characteristics of Low/No-VOC Coatings	8
3	Chemical and Stain Resistance of Low/No-VOC Coatings	9
4	VOC/Toxic Compounds Contained in Waterborne Coatings	10
A-l	VOC Content of Clear Topcoat	14
A-2	VOC Content of White-Pigmented Coating 	15
B-l	Physical Properties of Applied Finish	16
B-2	Physical Properties in the Can	17
B-3	Application Properties	18
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ACKNOWLEDGMENT
This report was prepared by Eddy W. Huang3 of AeroVironment, Inc., for SCAQMD's
Planning & Technology Advancement Office and U.S. EPA's Organics Control Branch. The
project officers were Ranji George of SCAQMD's Planning & Technology Advancement Office
and Robert McCrillis of U.S. EPA's Organics Control Branch.
This research was conducted under South Coast Air Quality Management District
Contract No. S-C93101 at the Center for Emissions Research & Analysis and continued at
University of California, College of Engineering - Center for Environmental Research &
Technology. This project was funded by the U.S. Environmental Protection Agency, the
Adhesive Coatings Co., and the South Coast Air Quality Management District.
a. The majority of the work on this project was completed while the author was employed
by the Center for Emissions Research and Analysis, City of Industry, CA.
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1.0 INTRODUCTION
It is estimated that the annual U.S. market for wood coatings is approximately 240,000 m3
(63 million gallons)1. If one assumes an average VOC content of 600 g/1 (5 lb/gal), 146 million
kilograms (315 million pounds) of volatile organic compounds (VOCs) are emitted into the air
each year from the use of presently used water-borne and solvent-bome systems for coating
wood. The use of "VOC-free" formulations where possible would reduce such air pollution.
The South Coast Air Quality Management District (SCAQMD) Rules 1104 and 1136 -
Wood Products Coatings require reduction of VOCs from such sources. It is estimated that
SCAQMD-wide compliance with these rules would reduce VOC emissions by about 18 Mg (20
tons) per day through a gradual shift from high to low VOC coatings. By phasing in low VOC
coatings, instead of requiring installation of add-on controls, SCAQMD believes that furniture
manufacturers will be able to comply with SCAQMD's rules without increased costs. To remain
competitive in the regulated South Coast Air Basin, coatings formulators and furniture
manufacturers have expressed interest in seeing further developments in low VOC coatings
technology. SCAQMD Rule 1136 currently limits the VOC content to 680 g/1 of clear topcoat
and 600 g/1 of pigmented coating, less water and less exempt compounds, A final compliance
limit of 275 g/1 for both clear topcoats and pigmented coatings is currently set to take effect by
July 1,19952.
The worldwide coatings market is estimated to be in excess of $34 billion annually. The
U.S. market is about $14 billion segmented in three main categories: (1) Architectural Coatings
(AC); (2) Product Coatings used by original equipment manufacturers (PC-OEM); and (3)
Special Purpose Coatings (SPC). In most markets, customers' needs are being satisfied by a
relatively small number of coatings companies, many with sales approaching $1 billion. A
significant number of coatings operations are part of large chemical groups such as AKZO
Nobel, Ashahi, BASF, DuPont, ICI, Mitsubishi, and PPG Industries. The industry also includes
a number of very large independents, like Beckers, Jotun, Kansai, Lilly, Nippon Oil & Fats,
Nippon Paint, Reliance, Sadolin, Sherwin Williams, and Valspar. The profile of the coatings
industry and the markets it serves has undergone dramatic change in the last decade. The
strongest thrusts have been forced by such things as huge business realignments, consolidations
and reductions in the number of coatings companies, and the impact of environmental
compliance.
The U.S. Environmental Protection Agency (EPA) is implementing regulations designed
to minimize the emissions of volatile organic compounds (VOCs) and hazardous air pollutants
(HAPs). EPA actions will affect the marketing of coatings, and the organic and inorganic
binders which are widely used in the industry. Some paint manufacturers, which have previously
switched to coatings thinned with "conforming" solvents such as chlorinated hydrocarbons, will
have to find other alternatives since these chlorinated solvents are now listed as HAPs.
There is an increasing use of durable water-borne and water reducible coatings which are
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in fact free of so-called "keying agent" or "coalescing agent" solvents. Finally, there is a
resurgence of interest in solvent-free coatings such as powder and radiation-cure (powder and
radiation cured coatings can still emit VOCs during curing, however), which would probably not
have reached such research intensity were it not for the air, water, and toxicity legislation on the
state and federal levels.
The wood coating industry can be separated into two categories having different
requirements with respect to application technique3. These are flat stock coating and the coating
of three dimensional objects. Coating of flat stock is usually done on a continuous coating line
of some type, while more complicated three dimensional objects, such as furniture, usually
require spray application and batch drying. The kitchen cabinet industry uses nitrocellulose
(N/C) for the high end products and conversion varnish/conversion lacquer for the bulk of its
finishing needs. Conversion varnishes and lacquers contain up to 50% of urea or melamine
formaldehyde resins which are only partially cured at the low temperatures allowable for wood
surfaces; thus there is a significant level of free formaldehyde emanating from the coating
throughout its use life. Formaldehyde has been designated by the EPA and California Air
Resources Board as a suspected carcinogen. The N/C must be replaced to meet VOC regulations
and the uncured urea/melamine formaldehyde containing coatings replaced to meet the very low
ppm of "free formaldehyde" requirements.
Water based products have been introduced to much of the lumber industry to replace the
high VOC materials previously used on plywood, hardboard, particle board, and regenerated
wood-finger jointed wood products. These products, however, exhibit lowered performance
properties such as hardness, toughness, adhesion, and solvent and stain resistance. Their second
weakness is in energy consumption (i.e., they require long time/temperature exposure for cure).
They may or may not meet the free formaldehyde requirements which become more exacting
each year.
The purpose of this study was to evaluate a new low-VOC wood coating technology by
determining its performance characteristics, conducting application and emissions testing, and
assessing the cost benefits for energy conservation and air pollution reduction. The low-VOC
wood top coat selected for this demonstration project was a two-component, water-based epoxy
coating developed by Adhesive Coatings Co. (ADCO), San Mateo, California. Polymer
composition variations of the basic epoxy polymer in combination with each of several curing
agents were conducted.
The resulting top coat showed excellent performance characteristics in terms of adhesion,
gloss value, dry time, hardness, level of solvents, and chemical & stain resistance. The VOC
contents of both the clear top coat and the white pigmented top coat were less than 10 g/1. The
coating performance characteristics, and properties in finished material were compared with
other low-VOC waterborne wood coatings. Finally, the cost benefits of this low-VOC wood
coating, critical areas for product improvement, market development plan, and future research
work are addressed in this report.
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The complete absence of organic solvents means that this new coating system is not only
less hazardous to use but emits no detectable VOCs and therefore does not contribute to air
pollution. This new two component water-based epoxy wood coating system has the potential to
set a new standard and therefore replace a very significant share of current organic solvent
systems in use.
This new low-VOC coating's high gloss and excellent chemical resistance properties are
ideal for the wood manufacturing industry for flat stock, for particle, chip, and wood flower
products; spray primers for door skins; and finishing systems for interior wood products such as
furniture and kitchen cabinets. This material can be manufactured using readily available raw
materials and standard resin manufacturing equipment without polluting the atmosphere.
Several large companies that manufacture and supply products used in the wood coatings
industry have been contacted. The product marketing discussions have centered on how best to
commercialize specific ultra-low VOC finished coating applications. Discussions are underway
with two major corporations, both of which are worldwide suppliers of industrial products and
services to the coatings, adhesives, and polymer industry and recognized as leaders in providing
coatings and ancillary products for the wood industry.
2.0 PROJECT DESCRIPTION
This new wood coating system consists of an epoxy component (Part A) and an amine
curing component (Part B). The complete absence of organic solvents means that this new
coating system is not only less hazardous to use but emits no detectable VOCs and therefore does
not contribute to air pollution. The ultra low VOC content of these new wood coatings was
confirmed by tests at the Center for Emissions Research & Analysis (see Table A-l and A-2).
This new two component water-based epoxy wood coating system has the potential to set a new
standard and therefore replace a very significant share of current organic solvent systems in use.
2.1 Coating Characteristics:
The most important properties for low VOC coating technologies are as follows:
*	"Dial-a-Cure" (control cure speed through selection/matching of curing agent)
ultra-fast cure (air cure in minutes)
high speed application (forced cure in seconds)
*	Friendly to adverse application conditions
cures under broad temperature range
cures on wet or dry surfaces
*	Liquid
water emulsions with water as the continuous phase, no solvents, no keying
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agents, no film coalescing aids present or required
high solids
* Environmentally sound
water reducible & water clean-up of materials
no solvent (low VOC)
no or very low free formaldehyde
no free isocyanate
The attractive coatings characteristics noted above make this new two component water-
based epoxy coating a potential replacement for solvent-based systems.
This new ultra-low VOC wood coating system is a high performance, two-part,
chemically cured, water reducible, fast drying, epoxy product (can be used as a sealant and as a
high gloss, durable top coat that gives a lacquer like, clear finish). It has the following
performance properties:
(a)	Less than 10 g/1 (0.12 lb/gal) VOCs (Method 24 detection limit is 10 g/1),
(b)	Liquid with rapid initial drying characteristics upon application,
(c)	Hardness,
(d)	Flexibility, and
(e)	Chemical resistance.
2.2 Technical Approach:
The coating development steps were to make the necessary formulation adjustments,
continue with application testing to improve the product characteristics, and overcome the
shortcomings. The goal of the project was to develop a wood coating system that will set new
industry standards for VOC levels.
The results of the research procedures and laboratory tests were documented and written
status reports were prepared detailing the work completed to date along with the identification of
areas that may require further investigation.
The technical approach centered around the following activities:
1. Work towards reformulating ADCO's patented epoxy polymer in combination
with different curing agents.
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2.	Identify those compositions that yield the best overall coating performance in
terms of gloss value, drying time, hardness/flexibility, and chemical and stain
resistance.
3.	Conduct the emission tests required to determine whether the compositions
selected have less than 20 g/1 VOCs.
4.	Formulate emulsions with white pigment for those compositions that meet the
performance criteria and emissions limits.
5.	Identify those pigmentations that yield the best overall coating performance in
terms of gloss value, drying time, hardness/flexibility, and chemical and stain
resistance.
6.	Conduct the emission tests required to determine whether the pigmentations
selected have less than 20 g/1 VOCs.
7.	Prepare different finished wood panel coupons, both clear and pigmented, to
demonstrate finished coatings that meet the performance criteria and emissions
limits.
8.	Assess the market acceptance by a written survey and develop two annual
marketing reports to summarize the survey results, manufacturer acceptance, cost
benefits, and any application limitations.
2.3 Task Description:
The program for making formulation adjustments and undertaking the necessary
application testing to meet the desired product characteristic goals were outlined in the following
tasks:
Task 1 - Formulation variations
Polymer composition variations of the basic epoxy polymer in combination with each of
several curing agents were conducted. The resulting emulsion was analyzed through laboratory
tests to measure gloss value, drying time, hardness/flexibility, level of solvents, and chemical and
stain resistance. All test results were documented.
Product coating characteristic criteria used in this project included but are not limited to:
1.	The product will contain VOCs < 20 g/1.
2.	The product will have a gloss value in the 90-100 range as measured on an 80
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degree gloss meter.
3.	The product will "dry to the touch" in 10 minutes or less and "dry to handle" in 15
minutes or less for temperatures in the range of 45 to 60°C with a relative
humidity not to exceed 80%.
4.	The product will have a demonstrated pencil hardness of at least 2H.
5.	The product will have a demonstrated chemical, water stain, and chip resistance
comparable to other products for the same general use.
Work on variations of the patented epoxy polymer in combination with different curing
agents was finalized. The synthesis of the resin into a new resin was completed and was
followed by the emulsification of the product in water. Analysis was structured by selecting
those additional curing agents not previously evaluated but which were known to be sufficiently
reactive to achieve proper film formation and acceptable properties. Each resulting film was
characterized as to its properties.
Task 2 - Variations in pigmentation
An emulsion was formulated with white pigment for the best epoxy polymer/curing agent
ratios selected in Task 1. Laboratory tests were conducted to measure gloss value, drying time,
hardness/flexibility, level of solvents, and chemical and stain resistance. All test results were
documented.
Task 3 - Preparation of finished coating samples
The existing two-component spray application system developed by Binks Manufacturing
Inc. was modified and the application of the coatings was evaluated to determine if it meets the
production requirements of wood furniture manufacturers. The results were shown in Appendix
B.
Cure conditions including curing rate, extended pot-life, and rheology modifications to
include use of thickeners in the formulation for adjusting the flow of coatings will be evaluated.
Both "clear" and "white" finished wet samples for emission testing will be prepared utilizing a
two-component variable ratio spray application gun.
Task 4 - Market development
Several wood furniture manufacturers and coating suppliers were contacted to identify
wood coating concerns, current application methods, costs, and critical areas for product
improvements. Marketing information related to the wood coatings market was collected. The
market segments in turn are further segmented into wood furniture, kitchen cabinets, new case
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goods, plywood (hardboard), regenerated wood products, flat stock finishes, and specialty
finishes. This information was reviewed to establish what specific data still need to be collected
and how they should be used in structuring the planned market survey of wood coating suppliers.
3.0 RESULTS OF LABORATORY DEVELOPMENT
Polymer variations of ADCO's basic EnviroPolymer (A) in combination with each of
several proprietary curing agents (B) were conducted. All combinations contained low or no
VOCs. Up to eight different ratio's were evaluated for each combination and the best ratio
observed was then selected for further evaluation by applying this coating on solid oak.
Four variations of EnviroPolymer A-l (EP 180-60), A-2 (EP 200-60), A-3 (EP 510-60),
and A-4 (EP H-60) were used in this project. Four proprietary curing agents B-l (80-70), B-2
(65-71), B-3 (65-99), and B-4 (81-93) were identified as being the most likely to yield promising
results. The initial ratings used to identify the most promising ratios for further evaluation were
(1) excellent/very promising, (2) good/somewhat promising, (3) fair/possible, and (4)
poor/unlikely.
Formulation A-l/B-2 and A-2/B-1 were judged to be the most likely to yield promising
test results when applied to a substrate for further determination of the coatings performance
characteristics (dry time, gloss, parallel groove adhesion, scrape/mar, chemical and stain
resistance).
TABL
E 1. POLYMER/CURING AGENT SCREENING MATRIX

A-l
A-2
A-3
A-4
B-l
Good
Excellent
Poor
Poor
B-2
Excellent
Good
Fair
Poor
B-3
Good
Good
Good
Good
B-4
Good
Good
Good
Fair
Dry time was measured as the amount of time that was taken for the coating to harden
before it can be sanded and re-coated. To be objective, a gloss meter was used to put a measured
value on the degree of gloss. The method described in ASTM D 523-894 was followed.
Evaluation of adhesion to different surface treatments, or different coatings to the same
treatment is extremely important to the furniture manufacturing industry. The method described
by ASTM D 3359-935 was followed. After parallel grooves were cut into the coating, tape was
applied over the grooves and removed. The cross-hatch pattern was inspected through a
magnifying glass and rated against the standards. Gt 0/5B was the best rating followed by Gt
1/4B, Gt 2/3B, Gt 3/2B, Gt 4/1B, and Gt 5/0B.
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A modified ASTM D 21976 was followed to differentiate the degree of coating hardness.
After complete curing, the scrape/mar resistance was determined by pushing the panels beneath a
round stylus or loop that was loaded in increasing amounts until marring of the coatings was
detected.
Resistance to various household chemicals is an important characteristics of organic
finishes. The methods described by ASTM D 1308-877 were followed. This evaluation covers
the effects household chemicals have on organic finishes such as discoloration, change in gloss,
blistering, softening, swelling, and loss of adhesion.
A cooperative study on the evaluation of low VOC coatings for wood furniture showed
several water based clear topcoats met the VOC content requirement of 275 g/18. The
performance characteristics of the new ADCO low-VOC coating are compared with those of
other low-VOC waterborne coatings in Tables 2 and 3.
TABLE 2. PERFORMANCE CHARACTERISTICS
OF LOW/NO-VOC COATINGS
MANUFACTURER/
TOPCOAT
ADHESION
DRY TIME
(minutes)
GLOSS
60° SHEEN
SCRAPE/MAR
(R)
ADCO TOPCOAT
GT 0/5B
20-25
80.0
1050
AKZO 680-60C018-115
W/B
GT 0/5B
30-35
34.3
300
AMT 01TC-0090-50
W/B
GT 0/5B
30-35
62.0
500
GUARDSMAN 45-
1065-40 W/B
GT 0/5B
30-35
46.8
800
LILLY 787W43 W/B
GT 0/5B
30-35
23.9
300
PINNACLE 137-CL-l
GT 0/5B
30-35
79.4
500
SHERWIN-WILLIAMS
T70C510 W/R
GT 0/5B
30-35
44.0
500
SINCLAIR WL 14-9
GT 0/5B
30-35
38.6
400
WATERCOLOR
TOPCOAT
GT 0/5B
30-35
37.1
600
As seen in Table 2, ADCO's new low-VOC coating showed excellent performance
characteristics in terms of adhesion, dry time, gloss, and scrape/mar resistance. The scrape/mar
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resistance was especially remarkable (twice as good as the average of other waterborne coatings).
SCAQMD method 304-91 (Determination of Volatile Organic Compounds (VOC) in
Various Materials) was used to conduct VOC analysis9. ASTM D 147510 was used to determine
the density of coatings. Total volatile content was measured by ASTM D 236911 and water
content was determined by ASTM D 379212.
Most wood furniture is finished with nitrocellulose resin-based coatings averaging 750 g/1
VOC and 375 g/1 hazardous air pollutants (HAPs). In the finishing of an average dining room
table (4 ft X 6 ft), about 9 kilograms of VOCs and 4.5 kilograms of HAPs are emitted. While
progress has been made to formulate low VOC coating systems, many of these use ethylene
TABLE 3. CHEMICAL AND STAIN RESISTANCE
OF LOW/NO-VOC COATINGS
MANUFACTURER/
TOPCOAT
ACETONE
COFFEE
MUSTARD
HOT
TAP
WATER
NAIL
POLISH
REMOVER
ADCO TOPCOAT
1
1
2
1
2
AKZO 680-60C018-
115 W/B
3
1
2
1
2
AMT 01TC-0090-50
W/B
2
1
2
1
2
GUARDSMAN 45-
1065-40 W/B
2
1
2
1
3
LILLY 787W43 W/B
2
1
2

3
PINNACLE 137-CL-l
2
1
2
1
1
SHERWIN-
WILLIAMS
T70C510 W/R
2
1
2
1
2
SINCLAIR WL 14-9
2
1
2
1
2
WATERCOLOR
TOPCOAT
1
1
1
1
2
LEGEND: 1. NO EFFECT
2.	SLIGHT EFFECT
3.	MEDIUM EFFECT
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glycol ethers (see Table 4), some of which are more toxic than most of the solvents used with
nitrocellulose systems.
TABLE 4. VOC/TOXIC COMPOUNDS
CONTAINED IN WATERBORNE COATINGS
TOPCOAT
VOC
(g/D
AIR TOXIC
SUBSTANCES
Wt
(%)
ADCO TOPCOAT
<10
NONE
0
AKZO 680-
60C018-115 W/B
210
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
6.2
3.9
AMT 01TC-0090-
50 W/B
240
PROPYLENE GLYCOL N-BUTYL ETHER
1-10
GUARDSMAN
45-1065-40 W/B
270
DIETHYLENE GLYCOL MONOBUTYL ETHER
PROPYLENE GLYCOL N-BUTYL ETHER
6.0
3.0
LILLY 787W43
W/B
240
PROPYLENE GLYCOL N-BUTYL ETHER
3.4
PINNACLE 137-
CL-1
270
TRIETHYL AMINE
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
<5.0
3.0
3.0
SHERWIN-
WILLIAMS
T70C510 W/R
270
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
4.8
9.2
SINCLAIR WL
14-9
200
DIETHYLENE GLYCOL MONOBUTYL ETHER
3.0
WATERCOLOR
TOPCOAT
100
PROPYLENE GLYCOL N-BUTYL ETHER
1-10
4.0 RESULTS OF MARKET DEVELOPMENT
The wood coating market is segmented by the industry into wood furniture, kitchen
cabinet, new case goods, plywood/hardboard/regenerated wood products, flat stock finishes, and
specialty product finishes. The wood furniture industry is faced with a dilemma. Other than
special small segments of the paper coating industry, wood furniture coatings consume almost
100% of the nitrocellulose coatings produced. The coatings, by the very nature of the high
intrinsic viscosity of nitrocellulose, are very low in solids and thus are very high in solvent (i.e.,
VOCs and HAPs).
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The high emission rate has caused the loss of all operating permits in some states and
some permits in every state; and wood furniture manufacturers are either moving off-shore or
concentrating in the Southeast. Radiation-cure techniques and coatings have made some
penetration, although small, because the shape of the item produced does not lend itself to use of
existing technology such as UV or EB equipment.
One approach used by the furniture industry to "stay-in business" has been introduced in
Europe. This is a modified case goods approach where most of the pieces are prefinished in flat
stock, assembled, and then given a final finish and touch-up. Radiation cured coatings are often
used to finish the pre-assembled flat stock. The final finish introduces the same VOC problems.
The new ADCO low-VOC finishes developed in this project meet the same cure rate without the
radiation equipment investment cost, hazard to the eyes of the employees, and skin sensitivities.
In the low-VOC wood coating market research, the needs for new products were
discussed with the leaders in the manufacture of regenerated wood products, i.e., particle board,
chip board, and wood flower products. There are many product opportunities for application of
this new technology. Efforts were focused on such promising possibilities as binders for particle,
chip, and wood flower products; spray primers for door skins; surfacers for concrete form boards
to replace paper laminate; and finishing systems for interior wood products such as furniture and
kitchen cabinets.
It is anticipated that this new low-VOC wood coating will set new industry standards by
addressing the following manufacturers' problems:
*	The formaldehyde problem. All manufacturers seek low or no formaldehyde
exposure to their employees, to the atmosphere surrounding the manufacturing
site, or to the customer or user.
*	Lower moisture transmission problem. All manufacturers seek to reduce the
degradation caused by swelling and warping from changes in product dimension
from water evasion.
*	Exterior market problem. All manufacturers seek to upgrade their product line to
achieve penetration into the exterior product market.
*	The down-time clean-up problem. All manufacturers of regenerated board must
shut down periodically, for clean-up, so as to reduce the unacceptable green board
rejection rate and fire hazard.
*	The energy problem. All of the products used by the mills require extensive
time/temperature cure or drying cycles. Low temperature or fast air dry would
lend improved economics to the industry or provide a large competitive
advantage.
11

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* The toxic air emissions problem. Some facilities in the furniture industry may use water-
based formulations which contain toxic compounds, most notably, glycol ethers13. Most
waterborne wood coatings used glycol ethers in their formulations to stay in compliance.
Many resin and coatings manufacturers have done research on very low VOC coatings for
the wood furniture industry. Penetration into the market place has been slow due to resistance to
change by the furniture manufacturers. Without regulatory pressure, there is no incentive to
switch from traditional high VOC nitrocellulose coating systems.
Several wood furniture manufacturers and coating suppliers were contacted to identify
wood coating concerns, current application methods, costs, and critical areas for product
improvements. Marketing information related to the wood coatings market was collected. This
information was reviewed to establish what specific data still need to be collected and how they
should be used in structuring the planned market survey of wood coating suppliers. The product
marketing discussions have centered on how to commercialize specific low/no VOC finished
coating applications resulting from this wood coating project.
Based on the contacts to date with these marketing entities, at least one coatings
manufacturer will participate in joint product feasibility studies. Upon development of priority
high-value-added products for potential sale and use in the U.S. wood products market as
contemplated at the conclusion of this project, ADCO is prepared to enter into either joint
venture agreements or licensing arrangements for commercialization of its low-VOC wood
products worldwide.
5.0 FUTURE DEVELOPMENT
Low/no VOC "stain" and "sealer" wood coatings need to be developed so that a complete
low/no VOC wood coating system will be available for public use. It is desirable to determine
the compatibility of coating components (a stain and a sealer to go with the topcoat). The extra
developmental work will center on reformulating wood base coatings for a new fast drying,
solvent-free sanding sealer. Evaluation of cure conditions will include curing rate, extended pot-
life, and rheology modifications for adjusting the flow of coatings.
Follow-on work would focus on adapting this new low-VOC coating to other furniture
lines. Some effort might also be needed to combine this new coating with other components
(stains and sealers) to comprise complete low/no VOC coating systems. The transition to
widespread application across the U.S. and world-wide will require extended technology transfer
efforts.
6.0 REFERENCES
1. Huang, E.W., L. Watkins, and R. McCrillis. Formulating Ultra-Low-VOC Wood Furniture
Coatings, Modern Paint and Coatings. Volume 83, Number 12, 41-43, 1993.
12

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2.	Proposed Amended Rule 1136 - Wood Products Coatings, June 23, 1994. South Coast Air
Quality Management District, Diamond Bar, California.
3.	Kinzer, K.E. Dual Cure Low-VOC Coating Process, DOE/ID/12692-6, December 1993.
4.	D 523-89, "Standard Test Method for Specular Gloss," American Society for Testing and
Materials, 1916 Race St., Philadelphia, PA.
5.	D 3359-93, "Standard Test Method for Measuring Adhesion by Tape Test," American
Society for Testing and Materials, 1916 Race St., Philadelphia, PA.
6.	D 2197-86, "Standard Test Method for Adhesion of Organic Coatings by Scrape Adhesion,"
American Society for Testing and Materials, 1916 Race St., Philadelphia, PA.
7.	D 1308-87, "Standard Test Method for Effect of Household Chemicals on Clear and
Pigmented Organic Finishes," American Society for Testing and Materials, 1916 Race St.,
Philadelphia, PA.
8.	A Cooperative Study - Evaluation of Low VOC Coatings for Wood Furniture. South Coast
Air Quality Management District, Southern California Edison Company Customer
Technology Application Center, and California Furniture Manufacturers Association
(released in June 1994).
9.	Choa, C.B. and S. Horn. Laboratory Methods of Analysis for Enforcement Samples.
"Method 304-91, Determination of Volatile Organic Compounds (VOC) in Various
Materials," South Coast Air Quality Management District, Diamond Bar, CA, June 1991.
10.	D 1475-90, "Standard Test Method for Density of Paint, Varnish, Lacquer, and Related
Products," American Society for Testing and Materials, 1916 Race St., Philadelphia, PA.
11.	D 2369-93, "Standard Test Method for Volatile Content of Coatings," American Society for
Testing and Materials, 1916 Race St., Philadelphia, PA.
12.	D 3792-91, "Standard Test Method for Water Content of Water-Reducible Paints by Direct
Injection into a Gas Chromatograph," American Society for Testing and Materials, 1916
Race St., Philadelphia, PA.
13.	Supplemental Environmental Assessment for: Proposed Amended Rule 1136 - Wood
Products Coatings, June 1994. South Coast Air Quality Management District, Diamond Bar,
California.
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APPENDIX A
Emissions Characterization
TABLE A-l. VOC CONTENT OF CLEAR TOPCOAT
SAMPLE DESCRIBED AS:
ADHESIVE COATINGS CO.
PART A 76-64 (WHITE)
PART B 65-99 (CLEAR)
SOURCE:
2755 Campus Drive, Suite 125
San Mateo, CA 94403
ANALYTICAL WORK PERFORMED, METHOD OF ANALYSIS, AND RESULTS:
SCAQMD Method 304-91: Determination of Volatile Organic Compounds (VOC).
Volatile content by ASTM-D-2369, density by ASTM-D-1475, water by ASTM-D-3792
(GC).			
VOCs content
VOCs, g/1 (of coating) = <10
VOCs, g/1 (of material) = <10
REMARKS:
1.	The detection limit for VOCs is 10 g/1.
2.	The two products (76-64 and 65-99) were mixed 5 : 1 prior to actual analysis.
14

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TABLE A-2. VOC CONTENT OF WHITE-PIGMENTED COATING
SAMPLE DESCRIBED AS:
ADHESIVE COATINGS CO.
PART A 77-82A (WHITE)
PART B 77-82B (CLEAR)
SOURCE:
2755 Campus Drive, Suite 125
San Mateo, CA 94403
ANALYTICAL WORK PERFORMED, METHOD OF ANALYSIS, AND RESULTS:
SCAQMD Method 304-91: Determination of Volatile Organic Compounds (VOC).
Volatile content by ASTM-D-2369, density by ASTM-D-1475, water by ASTM-D-3792
(GC).	
VOCs content
VOCs, g/1 (of coating) = <10
VOCs, g/1 (of material) = <10
REMARKS:
1.	The detection limit for VOCs is 10 g/1.
2.	The two products (77-82A and 77-82B) were mixed 10 : 1 prior to actual analysis.
15

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APPENDIX B.
Coating Characteristics and Performance Properties
TABLE B-l. PHYSICAL PROPERTIES OF APPLIED FINISH
COLOR
Clear or pigmented white
SERVICE
TEMPERATURE LIMITS
-18 to 120° C(0 to 250° F).
May discolor over 60° C (140° F) after a long
period of baking
GLOSS
Clear coating - 90 @ 80° meter
Pigmented coating - 75 @ 80° meter
HARDNESS
Pass 2H pencil
FLEXIBILITY
Pass 3 mm (1/8 in.) mandrel bend on steel
IMPACT RESISTANCE
Direct - Pass 3 m/kg (60 in./lb)
Indirect - Pass 1.5 m/kg (30 in./lb)
ADHESION
Pass Crosshatch 100%
STAIN RESISTANCE
(After 1 hour of exposure)
Coating is resistant to:
Coffee
Grape juice
Mustard
Ketchup
Carbonated cola beverage
100 proof vodka
Shoe polish
Laundry spot cleaner
Detergent
1,1,1 trichloroethane
Acetone
Petroleum solvents
Ethyl alcohol
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TABLE B-2. PHYSH
:al properties in the can
APPEARANCE
Milky white, single-phase, creamy liquid
VISCOSITY
Part A: 0.9 Pas (900 centipoise)
PartB: 0.9 Pas
PH
5.5 to 7.5
TYPE
Two components:
Part A - Epoxy emulsion
Part B - Curing agent
DENSITY
Clear: 1030 g/1 (8.60 lb/gal)
White: 1500 g/1 (12.5 lb/gal)
SOLIDS
50% by volume
FLASH POINT
over 150° C (300° F)
SHELF LIFE
> 6 months
VOC CONTENT
< 10.0 g/1 (0.1 lb/gal)
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TABLE B-3. APPLICATION PROPERTIES
MIX RATIO
Clear Topcoat: Part A - 5 parts
Part B - 1 part
White-Pigmented: Part A - 10 parts
Part B - 1 part
THINNING SOLVENT
Water
CLEANUP
Warm soapy water
FILM THICKNESS
75-125 |jm (3.0-5.0 mils) wet
40-65 |jm (1.5-2.5 mils) dry
THEORETICAL COVERAGE
9 m2/l (360 ft2/gal) @ 50 |am (2 mils)
DRYING TIME @ 50° C
To touch: 10 min
Torecoat: 20 min
Tack free: 15 min
Full cure: 60 min
RECOATABILITY
Very good
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APPENDIX C.
MARKET SURVEY QUESTIONNAIRE
Wood Furniture / Kitchen Cabinets
Company Name:
Address:
Name of Contact:
Tele #:
Type of Wood Products Manufactured:
Furniture		
Kitchen Cabinets 	
Other		
Types of Substrates Normally Used: 	
% Clear Coated	 % Stain	 % Solid Colors
Manufacturing Process Used:
Application Method Used:
Spray ~ Curtain ~ Roll ~ Other ~
Spray Application Equipment Used: Gun Type 	
Mfg
Steps/Materials Used for Existing Coating Process:
Step 1
Step 2
Step 3
Stains
Ground Coats
Wash Coats
Sealers
Topcoats
~
~
~
~
~
~
~
~
~
~
~
~
~
~
~
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Usage/Physical Properties:
Annual Usage
(gals)
Stains		
Ground Coats 	
Wash Coats 	
Sealers		
Topcoats*		
voc
(lb/gal)
Density
(lb/gal)
Viscosity
% Solids
(wt)
* Please State Major Top coating Concerns:

YES
NO
Reason
Durability
~
~

Appearance
~
~

Cure Times
~
~

Repair
~ ~


Applic. Equip.
~
~

Material Cost
~
~

Mfg. Cost
~
~

Energy Cost
~
~

Handling/Stack
~
~

Health/VOC Lvl
~
~

Other Concerns
~
~

Please State Performance Level of Current System:


YES
NO
1. Appearance Satisfactory?
~
~ Tvpical Gloss Reading:
2. Durability Satisfactory?
~
~ Tvpical Hardness Value:
3. Resistance Satisfactory?
YES
NO

Staining Agent A
~
~

Staining Agent B
~
~

Staining Agent C
~
~

Chemical A
~
~

Chemical B
~
~

Chemical C
~
~

Other
~
~
4. Repair/Touch-up Satisfactory

YES NO

Spot Repair
~
~

Place Repair
~
~

Buff
~
~
Other
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5.	Cure Times: Dry-to-Touch		Min
Dry-to-Handle 	Min
Stack Time		Min
Through Cure	Hours
6.	Other Shortcomings of Present System:
General Comments:
Please state performance level for a water-borne system (i.e., would prefer and/or consider using
if available):
1.	Appearance Requirements:	Gloss Level Reading		
2.	Durability Requirements:	Typical Hardness Value 	
3.	Resistance Requirements:
Staining Agent A 	
Staining Agent B		
Staining Agent C		
Chemical A		
Chemical B		
Chemical C		
Other		
4. Repair/Touch-up Requirements:
Spot Repair 	
Piece Repair 	
Buff
Other
5.	Cure Requirements: Dry-to-Touch 	Min
Dry-to-Handle 	Min
Stack Time		Min
Through Cure	Hours
6.	Other Shortcomings of Existing Water-borne Systems:
General Comments:
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APPENDIX D.
MARKETING REPORT
RESEARCH AND PRODUCT DEVELOPMENT OF LOW VOC WOOD COATINGS
SCAQMD CONTRACT NO. S-C93101
October 15,1994
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-Appendix D
TABLE OF CONTENTS
Section	Page
LIST OF TABLES		24
I BACKGROUND	25
H WOOD COATING SUPPLIERS 	25
m MARKETPLACE FOR WATER BORNE COATINGS 	 26
IV	COMMERCIALIZATION/MARKET INTRODUCTION	29
V	COST/BENEFIT COMPARISON	33
VI	PRODUCT/MARKET ASSESSMENT 		34
VH SUMMARY AND CONCLUSIONS 	38
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LIST OF TABLES
Table	Page
D-1	EMISSION BENEFIT/KITCHEN CABINET MFG	40
D-2	EMISSION BENEFIT/FURNITURE MFG 	41
D-3	VOGTOXIC COMPARISON		42
D-4	PERFORMANCE CHARACTERISTIC COMPARISON	43
D-5	CHEMICAL/STAIN RESISTANCE COMPARISON	44
24

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I BACKGROUND
In excess of 240 million liters or 63 million gallons of water and solvent borne wood
coatings are sold in the United States every year. These coatings contain and emit varying
degrees of volatile organic compounds (VOC's) — approximately 125-200 million pounds per
each year. South Coast Air Quality Management District (SCAQMD) Rules 1104 and 1136 -
Wood Products Coatings require reduction of VOC's from such sources. It is estimated that
SCAQMD - wide compliance with these rules would reduce VOC emissions by about 20 tons
per day through a gradual shift from high to low VOC coatings By phasing in low-VOC
coatings, instead of requiring installation of add-on-controls, furniture and kitchen cabinet
manufacturers will be able to comply with SCAQMD's rules without incur ring increased costs.
Therefore, in order to remain competitive in the regulated South Coast Air Basin, coating
formulators and furniture manufacturers expressed interest in seeing further developments in
low-VOC coatings technology.
Currently, Adhesive Coatings Co. (ADCO) a company specializing in the development
and commercialization of low-VOC water-based epoxy coatings has developed various wood
coating formulations which comply and/or exceed the emissions standards set forth in
SCAQMD's Rules 1104 and 1136. Under CONTRACT NO. S-C93101, ADCO continued
development work on one of its formulations. It determined performance characteristics,
conducted application and emissions testing and worked with selected coatings suppliers to
assess for possible commercialization and market acceptance as a wood finish top coating.
II WOOD COATING SUPPLIERS
ADCO, upon development in the laboratory of its low-VOC wood finish coating,
contacted several major coating suppliers, each of whom had a significant market position and/or
interest in a low or no VOC wood coating. The approach taken with each company was to
mutually agree on a joint testing program for investigating ADCO's environmentally friendly
water-based epoxy wood coating. Each company was seeking a low VOC wood coating that they
could introduce into the marketplace and thereby enhance their market position.
The investigation covered a discussion of current application methods and costs, coating
concerns, critical areas for product improvement, and a cost/benefit analysis to establish product
performance and economics. Based upon the results of the joint testing program, the level of
interest for instituting a market development program to address the marketplace concerns,
potential cost benefits and limitations in commercialization of such a coating was ascertained.
Over a period of some twelve to 24 months, ADCO worked with five (5) companies. Each of
these companies, as a condition for working with ADCO, stipulated that their names must remain
confidential.
Company A - Large industrial finishes supplier.
The personnel involved in the program included the Chairman, Senior Vice President,
Director of Research and the Senior Project Manager.
Company B - One of the largest international fully integrated coatings companies.
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The personnel involved in the program included the Technical Manager for Industrial and
Maintenance Products.
Company C - Major fully integrated paint company with a wood finishes division.
The personnel involved in the program included the Manager of the Wood Coating
Laboratory and selected laboratory staff.
Company D - International paint company and leading finishes supplier.
The personnel involved in the program included the Marketing Manger and Technical
Director of Wood Finishes Division.
Company E - International supplier of coatings resins.
The personnel involved in the program included the Manager of resin products and
selected laboratory personnel.
Ill MARKETPLACE FOR WATERBORNE COATINGS
Opportunities for reduce emissions:
In general, the companies indicated that the demand for changes in finishing materials
and manufacturing practices has definitely created the opportunity for them as manufactures to
consider more extensive use of the waterborne technologies for kitchen cabinets and furniture
coatings. Offering low-VOC products options that meet the long-term regulatory compliance
with the appropriate mix of appearance and physical performance is appealing.
The kitchen cabinet/furniture industry uses nitrocellulose (N/C) for the high end or
conversion varnish/conversion lacquer for the bulk of its finishing needs. Conversion varnishes
and lacquers contain up to 50% of urea or melamine formaldehyde resins which are only partially
cured at the low temperature allowable for wood surfaces. Thus, free formaldehyde emanates
from the coating throughout its use life. Formaldehyde has been designated by the EPA and
California Air resources Board as a suspected carcinogen. The N/C must be replaced to meet
VOC regulations and the uncured urea/melamine formaldehyde containing coatings replaced to
meet the very low ppm of "free formaldehyde" requirements.
Each of these companies told ADCO that they are striving to reduce their VOC level of
existing solvent-borne coatings in response to the proposed MACT standard for the wood
furniture industry developed under the Regulatory Negotiation (Reg-Neg) process. The no-VOC
wood finish top coat as developed by ADCO was of great interest to them since the furniture and
kitchen cabinet markets use over 227 million liters or 60 million gallons of coatings each year in
the U.S. alone. The potential to reduce emission is very significant. Because ADCO's
water-borne wood finish coating dramatically reduces the level of VOC's, it has excellent
potential for long term emission compliance. It does not contain HAP's which are specifically
targeted as toxic materials.
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The impact of using a no-VOC sealer and topcoat as developed in this project for a
"hypothetical manufacturer" of semi-custom kitchen cabinets with an annual usage of 100,000
liters per year of conventional finishing materials is very significant (i.e., 92% emission
reduction when compared to current 7-1-95 VOC limits and 83% emission
reduction when compared to 7-1-96 VOC limits as shown in Table D-l).
Similarly, the impact of using a no-VOC sealer and topcoat as developed in this project
for a "hypothetical manufacturer" of fine furniture with an annual usage of 100,000 liters per year
of conventional finishing materials is very significant (i.e., 79% emission reduction when
compared to current 7-1-95 VOC limits and 57% emission reduction when compared to 7-1-96
VOC limits as shown in Table D-2).
Performance Requirements:
The companies emphasized that the finishing on wood has two primary purposes -
appearance and protection. The appearance must appeal to the customer's vision and sense of
touch. The durability must withstand various chemical and physical tests. Durability
requirements usually are more stringent with kitchen cabinets and office furniture than with
household furniture.
Broadly there are three performance levels available in waterborne systems now on the
market.
Performance Level #1 - Comparable in film properties to nitrocellulose lacquers. These
sealers and topcoats are based on typical thermoplastic resin technology. Cost is
minimized. Typical systems costs are only incrementally higher than nitrocellulose
lacquer. The coatings typical water, detergent and stain resistance are modest but better
than nitrocellulose lacquer. However, due to the absence of chemical crosslinking, the
ultimate hardness and the speed with which it is developed is limited. Adequate drying
temperature must be provided, along with time and air movement to eliminate blocking,
mar and print problems.
Performance level #2 - Relies on more sophisticated resin technology and achieves
properties meeting the Kitchen Cabinet Manufacturers Association finishing
specification. Options are limited. PPG's Aquarlink system is based on sophisticated
single resin technology. Cost is nominally higher than nitrocellulose lacquer materials on
an overall systems basis. Performance is decidedly improved as is resistance to mar, print
and block.
Performance Level #3 - Requires chemical crosslinking or thermoset technology to
achieve the highest levels of stain, solvent resistance and hardness. Most are two
component materials which exhibit metering, mixing and pot life concerns. There are also
single package water-borne spray applied coatings that achieve crosslinking through UV
cure. Capital expenditure considerations are a key factor in selection however.
The companies with whom ADCO worked are seeking a low or no-VOC waterborne
coating that would fall in Performance Level #3 (i.e., a coating that will have an acceptable gloss
27

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finish, have physical properties good or better than what is on the market, have a fast dry to-
handle during manufacturing and be cost effective). Currently, they indicated that no such
competitive product is in the marketplace.
Concerns with Existing Waterborne Wood Coatings:
In general, they all agreed that water borne coating still "have not yet arrived" based on
their experiences to date. The most notable concerns are:
Contamination - Potential contamination of the waterborne coatings with oil-based
coatings (i.e., such contamination can cause havoc in a repair situation and bring
equipment problems). The window of forgiveness is 25%-40% less than with
conventional coatings. Waterborne coatings are difficult to repair after they are cured.
They are tough to "wash off'.
Appearance - Water-borne coatings in appearance-formulation steps will raise the grain
of wood and cause blotchiness (i.e., water introduced into some wood finishing formulas
can be tolerated in limited amounts). Current water-borne systems have been able to
eliminate the grain raise, roughness or wood swell that occurs when water contacts wood.
These problems have been minimized through finishing component formulation
adjustments that has resulted in completely acceptable appearance for much of the
ready-to-assemble and kitchen cabinet market segments. Hybrid systems are also being
used whereby solvent-borne stains and sealers are followed by waterborne topcoats. This
method retains the superior wipeability of solvent-borne stains and minimizes grain raise
due to the wood's reduced direct contact with water. It should be emphasized that
finishing component materials are not always fully compatible. Both solvent borne and
water-borne components of any hybrid must be formulated for compatibility.
Temperature/Humidity Variations - Waterborne materials have wide variations in
performance and appearance (i.e, primarily caused by varying temperature and humidity
conditions during application). Fortunately, through proper polymer formulation, some
"user-friendliness" can be built in.
Market Introduction Considerations:
The companies indicated that a market introduction program of such a low-VOC or
no-VOC wood coating can only be set up and implemented once acceptable product
characteristics have been established and fully market tested. New product introduction
decisions must be based on practical material costs, capital outlays and process labor
costs and productivity.
In discussions with the personnel of these companies, they indicated that they take into
account many factors when they consider selecting a wood coating for market introduction.
These factors of course were given differing weights by each company's management. The
primary five (5) factors are the following:
(1)	Improvements in film performance,
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(2)	Lower materials cost "per unit finished",
(3)	Lower labor costs with improved productivity,
(4)	Minimization of changes to the finishing materials and manufacturing
processes,
(5)	Minimization of capital outlay.
IV COMMERCIALIZATION/MARKET INTRODUCTION
Product Characteristics:
The wood coating formulations developed in ADCO laboratory under SCAQMD
Contract No. S-C93101 were used to prepare finished wood samples, both clear and pigmented.
These samples were presented to each of the companies to demonstrate the finished wood
coating. The wood coatings based on the laboratory tests to date had the following product
coating characteristics:
(1)	The coating contained less than 20 g/1 VOC's.
(2)	The coating "dries to the touch" in less 10 minutes or less and "dries to
handle" in 15 minutes or less for temperatures in the range of 45°C to 60°C
with a relative humidity not to exceed 80% RH.
(3)	The coating had a demonstrated pencil hardness of at least 2H.
(4)	The coating had appeared to have a demonstrated chemical, water stain, chip
resistance and gloss levels comparable to other products in the same general
use.
(5)	The coating can be adaptable to current spray finishing lines with
modifications, (i.e., requires stainless steel hardware).
Guidelines for Market Evaluation:
In working with these companies to investigate possible commercialization of the
technology, the laboratory results (as outlined above) were used as the guidelines for making an
assessment. Specifically, the guidelines covered both air dry and forced dry finishes for wood.
Air Dry Finishes for Wood
Goal: Develop and commercialize air drying, odorless, no VOC, 'two-in-one' component
water-based epoxy systems in which each component is stable (has a shelf life of) at least
6 months.
Application: The mixed material can be applied by brush, roller or single component
29

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spray gun yielding applied films, with replicated properties regardless of the time applied
after mixing, demonstrating an effective pot life in excess of 8 hours.
Pigmentation: The "A" or Epoxy component can be pigmented to achieve white, inert
and normal full color pigments. 'Two-in-one' mixed paints made up of the pigmented "A"
components with ADCO selected "B" components yield coatings, (applied by spray,
brush or roller), equal to two component solvent-based epoxy maintenance coatings.
Properties: After seven days air dry, the final one mil dry film on unsealed, self-sealed,
base coated, or primed wood, has excellent adhesion, flexibility, hardness, water
resistance, boiling water resistance, solvent resistance, and stain resistance.
Markets: Coatings with the properties described above have a ready place in the
maintenance coatings market including such end uses as protective and decorative
coatings for wood furniture, kitchen cabinets, and nitrocellulose replacement coatings.
Force Dry Finishes for Wood
Goal: This is said to be a baking or force dried, odorless, no VOC, 'two-in-one'
component water-based epoxy in which each component is stable for at least 6 months.
Application: The mixed material can be applied by brush, roller or single component
spray gun yielding applied films, with replicated properties regardless of the time applied
after mixing, demonstrating an effective pot life in excess of 8 hours.
Pigmentation: The "A" or Epoxy component can be pigmented to achieve white, inert
and normal full color pigments. 'Two-in-one' mixed paints made up of the pigmented "A"
components with ADCO selected "B" components yield coatings, (applied by spray,
brush or roller), equal to two component solvent based epoxy maintenance coatings.
Properties: After a bake for 10 minutes at 150 degrees F (or equivalent time/temperature
combination), the final one mil dry film on wood or regenerated wood products has
excellent adhesion, flexibility, hardness, water resistance, boiling water resistance,
solvent resistance, flash rust resistance, and salt spray/corrosion resistance.
Markets: Coatings with the properties described above have a ready place in the general
industrial and wood coatings market including such end uses as protective and decorative
coatings for wood furniture, kitchen cabinets, factory finished wood products, case goods,
regenerated wood products, plywood products, and lumber mill and highly automated
finishing line wood products.
Product Tests:
ADCO conducted extensive tests prior to submitting substrate samples to each of the five
companies. The testing protocol as developed by ADCO laboratory was designed to evaluate the
performance and appearance of the newly developed low-VOC wood top coating. The following
laboratory tests were conducted:
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1.
VOC:
The VOC content of the samples was determine to insure the VOC content met the limits
of Rule 1136 of 275 g/L. SCAQMD method 304-91 (Determination of Volatile Organic
Compounds in Various materials) was used to conduct VOC analysis. ASTM D-1475
was used to determine the density of coatings. Total volatile content was measured by
ASTM D-2369. Water content was determined by ASTM D-3792. In regard to any
quantifiable substances in the coating pursuant to AB2588, there are no toxic substances
or solvents contained in the emulsion.
2.	Material and application of Coating:
Solid oak and birch panels of 4-Vi x 8 inches were used as substrates of both clear and
pigmented coatings. Coatings were applied in a paint booth using Binks High Volume
Low Pressure (HVLP) cup gun with a 97 P tip and nozzle with an orifice of 0.070 inches
and air pressure at 70 psig. One coating of sealer and one coating of clear topcoat were
applied to each substrate. Panels were stored face up for air drying. Evaluation was done
after allowing several days for curing.
3.	Sanding:
The panels were sanded with 180 grit sandpaper prior to coating. After the sealer was
applied and allowed to dry, panels were sanded with 240 grit sandpaper prior to spraying
the topcoat.
4.	Grain Raising:
Grain raising was minimized by application of a dust coat to seal the pores of the
substrate prior to applying the first wet coat.
5.	Wet Film Thickness:
It was observed that the wet film thickness (mils) greatly influenced the quality of the
finished panels. ADCO applied the top coat to a thickness of between 2-3 mils because it
ensured ease of spraying and good flow characteristics. Film thickness of the freshly
applied coatings were measured in the wet state following method ASTM D-1212.
6.	Dry Times:
Air dry time was defined as the amount of time necessary for the coating to harden before
it could be sanded. Also the "dry-to-touch/dry-to-handle" times were measured.
7.	Dry Film Thickness:
The dry film thickness (mils) was measured after the top coat was fully cure.
8.	Gloss:
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ASTM D-523 test was followed using a BYK Tri-gloss meter. Gloss was measured 24
hours after spraying.
9.	Blocking:
A laboratory test developed by ADCO blocked the panels at 2 psig. This test was used to
evaluate the resistance of a coating to printing under conditions of packaging, shipping
and warehousing.
10.	Parallel Groove Adhesion:
ASTM test method D-3359 was followed with ratings against five (5) standards ranging
from a Gt 0/5B best (i.e., none of the squares of lattice are attached) to a Gt 5/0B worst
(i.e., flaking and detachment is greater than 65% of the squares of the lattice.) It was
found that surface preparation had a major effect on adhesion.
11.	Adhesion/Scrape/Mar:
A modified version of ASTM test method D-2197 was followed only on the substrates.
The value given is the weight in grams applied to the stylus before marring is detected.
The mean value for the amount of weight which it took to mar the surface of a
water-based clear or pigmented coating was 500 grams and 300 grams for solvent based
coatings. This method has been found useful in differentiating the degree of hardness of
coatings.
12.	Orange Peel:
Orange peel is an irregularity in the surface resulting from the inability of wet film to
"level out" after being applied. The method described by the instructions for the BYK
Wave-Scan were followed. The R scale was used as the measurement which is a relative
value based on a scale of 0 to 10.5 (best).
13.	Hot/Cold Check:
ASTM test method D-1211 was followed as modified with the Atlas XR-35-A
Weatherometer to measure resistance to checking, crazing and cracking of coatings
applied to solid oak substrates only when subjected to sudden changes from high to low
temperatures. For each test the cycle was repeated 8 times, each cycles taking 3 hours to
complete. Relative humidity was maintained at 50%.
14.	Household Chemicals:
The methods described in ASTM D-1308 were used. The open spot method of
evaluation was used (i.e., the agent was placed directly on the surface and allowed to sit
uncovered for 1 hour). Chemicals used were catsup, mustard, coffee, acetone, margarine,
vinegar, cold tap water, hot tap water, and nail polish. Ratings were (1) no effect, (2)
32

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slight effect, (3) medium effect, and (4) heavy effect.
15. Aesthetics:
A subjective evaluation was made by personnel of the wood coating companies.
Appearance - 10 characteristics (1 is good)
Barrier Coat Compatibility (paper veneer substrate only)
Color - 6 characteristics (1 is good)
Clarity - 2 characteristics good or milky.
V COST/BENEFIT COMPARISON
In order to make a cost/benefit analysis, ADCO submitted selected samples to the
Southern California Edison Company Customer Technology Application Center in Los Angeles,
California. They has previously undertaken a cooperative study (released in June 1994) for the
South Coast Air Quality Management District. The purpose was to evaluate low VOC coatings
for Wood Furniture.
This Cooperative study showed several water based clear topcoats met the VOC content
requirements of 275 g/1. The performance characteristics of ADCO's new low to no VOC
coating were compared with those of other low-VOC water-borne coatings. The physical
properties of ADCO's clear finish coating when applied to solid oak compares very favorable
with the 25 wood coatings evaluated. Table D-3, D-4, and D-5 showed a comparison of ADCO's
wood coating formulation with other topcoat formulations.
(1)	Most wood furniture is finished with nitrocellulose, resin-based coatings
averaging 750 g/1 VOC and 375 g/1 hazardous air pollutants (HAPS). For
example, in the finishing of an average dining room table (4 ft X 6 ft), about 9
kilograms of VOC's and 4.5 kilograms of HAP's are emitted. While progress
has been made to formulate low VOC coating systems, many of these systems
use ethylene glycol ethers which are more toxic than most of the solvents used
with nitrocellulose, systems. The comparison of the new wood coatings for
VOC/toxic compounds with other coatings now on the market is shown in
Table D-3.
(2)	The new zero-VOC coatings showed excellent performance characteristics in
terms of adhesion, dry time, gloss and scrape/mar resistance. The scrape/mar
resistance was particularly remarkable (twice as good as the average of other
waterborne coatings). The comparison of the new wood coatings for these
performance characteristics against other coatings now on the market is shown
in Table D-4.
(3)	The new zero-VOC coatings showed acceptable chemical and stain resistance.
33

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The resistance to acetone was particularly good in comparison to the other
water-borne coatings. The comparison of the new wood coatings for chemical
and stain resistance against other coatings now on the market is shown in
Table D-5.
In summary, while ADCO's coating showed comparable results in appearance, clarity and
appearance, the wood coating appeared to show advantages in three areas:
(1)	The finish top coats contain no solvents with a VOC level of <10 g/1. Almost
all of the other coatings tested were in the 200-270 range and just barely under
the level of 275 per the 7-1-95 SCAQMD Rule 1136 requirement,
(2)	Tests of top coats indicated an adhesion/scrape/mar result that was superior to
any of the other 25 coatings tested (Table D-4). For ASTM test D-2197, the
mean value for water-borne was 500 grams. ADCO's coating was 1050 grams
thus indicating a coating that is extremely tough and scratch resistant.
(3)	The finish top coating can be competitively priced in the $15-25 per gallon
range.
VI PRODUCT/MARKET ASSESSMENT
The following is a company by company market assessment based on laboratory testing
and review of the formulation and panels as developed in this contract:
Company A
Company A was supplied with one gallon of ADCO's new two component water borne
clear wood coating material along with MSDS and Technical Data Sheets covering the materials.
Test Program:
The Company screening tests included the following:
Substrate - Wood (oak and birch), self sealed, and standard solvent based sealer.
Application Method - Single component spray gun.
Control Standards - Company standard kitchen cabinet solvent-based catalyzed alkyd
system, nitrocellulose system, and an experimental proprietary water base system.
Drying Schedule - Varying levels of humidity controlled forced dry.
Test Evaluation - Hardness, mar resistance, stain resistance, solvent resistance, chemical
resistance, adhesion, and inter/coat adhesion, and color retention.
Test Results:
34

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The Company's description of the results of the evaluation and prognosis for developing a
commercial kitchen cabinet finish generally were positive.
1.	Their reported results on hardness, mar resistance, solvent resistance, chemical resistance,
adhesion, and color retention were outstanding and extremely encouraging.
2.	They identified several areas of concern relating to inter-coat adhesion, short 'pot life',
marginal stain resistance, (i.e. not superior to the solvent based alkyd control), and
clogging of the air gun used for laboratory application status.
Based upon the positive results to date, Company A signed a "Letter of Intent" to proceed
to the next step. They indicated that they would like to focus upon the concerns and two central
development aspects focusing on achieving extended 'pot life' and an increase in stain resistance
and plan were made to begin further investigation on a joint basis.
However, after due deliberation, Company A indicated that they would not invest in
further development/commercialization studies. Such investment would necessarily replace
other R&D work. As a matter of management judgement, Company A elected to give
preference to other research work since attaining VOC's lower than the SCAQMD Rule 1136
requirements were not top priority.
Company B
Company B was supplied with ADCO's new two component clear water borne clear
wood coating material.
Test Program:
The Company screening tests included the following:
Substrate - Wood and steel.
Application Method - Single component spray gun. Immediately place the test panels in
variable temperature/humidity drying cabinets (low humidity, medium humidity and over
80% humidity with air temperatures between 40°F and 140%).
Control Standards - Standard epoxy maintenance coatings.
Test Evaluation - Hardness, toughness, solvent resistance, chemical resistance, and
corrosion resistance.
Test Results:
The Company's description of the results of the evaluation and prognosis for developing a
commercial product kitchen were positive.
35

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1.	Their reported results on hardness, toughness, and solvent resistance were excellent.
2.	They identified several areas of concern relating to a marginal to unsatisfactory water
resistance and a unacceptable dry rate under conditions of high humidity.
Status:
Company B requested that ADCO resubmit and repeat the program with materials that
would have an improved water resistance with faster dry times at higher levels of humidity.
ADCO management is considering this request pending the outcome of the evaluation program at
the other companies.
Company C
Company C was supplied with ADCO's new two component water-borne clear wood
coating material along with MSDS and Technical Data Sheets covering the materials.
Test Program:
The Company's test protocol was termed a feasibility screening evaluation. The screening
tests included the following:
Surface - Kitchen cabinet doors; (a) with and without stain (b) self sealed and © with
Company sealer.
Application Method - Manual and or suction cup gun spray.
Control - Standard Company kitchen cabinet doors.
Cure and finishing Schedule - Apply self seal, air dry and hot air knife, IR, sand and cure
(surface temperature 140°F) Note: They indicated that they were looking for coating that
would be "tack free" in something under 2 minutes as opposed to ADCO tests of 15
minutes bake at 50°C.
Test Evaluation - Hot block resistance, hardness, mar resistance, stain and chemical
resistance.
Test Results:
The Company's evaluation and prognosis for developing a commercial product were not
encouraging. The ADCO clear wood finish did not pass their hot block resistance test. In
fairness, they indicated that no other water based product passes their block test. They undertook
screening the ADCO material on what they consider to be the really tough test on the basis that if
it passed, perhaps further work might be justified. As a result they did not proceed with the other
additional planned tests.
36

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Status:
The Company would not invest in further work unless the material passed the block test.
ADCO was invited to return if such a material was formulated. Although ADCO could elect to
allocate additional resources to address the hot blocking issue in its laboratories, ADCO
management has deferred such research pending the outcome of the evaluation programs with the
other companies. Company C indicated that based upon the current environmental requirements,
there is not a clear need for a no-VOC wood coating.
Company D
Company was D supplied with ADCO's new two component water-borne clear wood
coating material along with MSDS and Technical Data Sheets covering the materials.
Test Program:
The Company's feasibility screen evaluation was almost identical to Company C. The
screening tests included the following:
Surface - Kitchen cabinet doors; (a) with and without stain (b) self sealed and © with
Company sealer.
Application Method - Manual and or suction cup gun spray.
Control - Standard Company kitchen cabinet doors.
Cure and finishing Schedule - Apply self seal, air dry and hot air knife and/or IR, sand
and cure (surface temperature 140°F).
Test Evaluation - Hot block resistance, hardness, mar resistance, stain and chemical
resistance.
Test Results:
The Company's evaluation and prognosis for developing a commercial product again
were not encouraging. The ADCO clear wood finish did not pass their hot block resistance test.
They also undertook screening the ADCO material on what they consider to be the really tough
test on the basis that if it passed, perhaps further work might be justified. As a result they did not
proceed with the other additional planned tests for hardness, mar resistance, stain and chemical
resistance.
Status:
The Company would not invest in further work unless the material passed the block test.
Again, ADCO was invited to return if such a material was formulated. Although ADCO could
elect to allocate additional resources to address the hot blocking issue in its laboratories, ADCO
management has deferred such research pending the outcome of the evaluation programs with the
37

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other companies.
Company D also indicated that based upon the current environmental requirements, there
is not a clear need for a no VOC wood coating.
Company E
Company E was supplied with ADCO's new two component water-borne clear coating
material along with MSDS and Technical Data Sheets covering the materials. The Company
currently is not a supplier to the wood industry. Their primary focus is on serving the industrial
maintenance coatings market worldwide. Nevertheless, they expressed interest in the basic
coating technology and were willing to undertake a testing program.
Test Program:
A feasibility study was undertaken jointly with ADCO for application of the two
component water-borne coating material.
Surface - Steel, aluminum and wood.
Application Method - Spray gun.
Control - Standard epoxy maintenance coatings.
Drying - Air dry.
Test Evaluation - Hardness, mar resistance, stain resistance, solvent resistance, chemical
resistance, and adhesion.
Test Results:
The Company's description of the results of the evaluation and prognosis for developing
commercial coating products were positive. The test results demonstrated excellent air dry clear
films for wood, steel and aluminum surfaces.
Status:
Whereas the initial work showed considerable promise, Company E abandoned the
project at the time EPA issued VOC guidelines changes allowing epoxy systems with VOC up to
approximately 300 grams per liter. In fact the Company put a commercial system into the market
some six months later with a VOC of approximately 150 grams per liter. ADCO concluded that
the legislation was not tight enough to force the Company into undertaking further research to
develop a "Zero" VOC water base epoxy for introduction into the marketplace.
VII SUMMARY AND CONCLUSIONS
Company Conclusions:
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The major conclusions for commercialization of such a low-VOC water-borne wood
coatings based on the thousands of hours of work done by ADCO alone, and in cooperation with
these various companies are as follows:
(1)	The chemistry of the ADCO technology is unique and possibly even
revolutionary and is patentable,
(2)	The finishes obtained showed outstanding performance properties,
(3)	The costs of the wood finishes appear to be competitive with current
commercial materials,
(4)	The coatings as actually developed in the laboratory and subsequently
evaluated by these companies will require additional work, (meaning
additional investment in laboratory development time), to meet customer end
use requirements.
Future Commercial Plans:
Each of the companies basically indicated that the current legislation controlling the
solvent emissions allowed VOC's in the range of 250 or possibly even 300 grams per liter plus
the manufacturing and marketing costs associated with wood finishing operations would not
support their research spending to achieve a "Zero" VOC coating when their competition could
continue to sell higher VOC materials.
In addition, each company alluded to the possibility that if "Zero" VOC coating was
required for manufacturer or supplier of wood finishes to stay in business, investment in low or
no VOC coatings would be required. Since no requirements exist, no further commercialization
work would be undertaken.
39

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TABLE D-l. EMISSIONS BENEFIT
OF ZERO-VOC WOOD COATINGS
FOR KITCHEN CABINET MANUFACTURER
Coating Type
Stain
(Low Solid)
Sealer
Topcoat
(Clear)
Total
Annual Usage
(1000 Liters)
30%
40%
30%
100%
VOC Limits (g/1)
7/1/95 Compliance
480
550
275
-
VOC Emissions
(1000 Grams)
144
220
82.5
446.5
VOC Limits (g/1)
7/1/96 Compliance
120
240
275
-
VOC Emissions
(1000 Grams)
36
96
82.5
214.5
ADCO/BAT Coatings
VOC Content (g/1)
120
-
-
-
VOC Emissions
(1000 Grams)
36
-
-
36
Emissions Reduction
7/1/95 Compliance
-
-
-
92%
Emissions Reduction
7/1/96 Compliance
-
-
-
83%
40

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TABLE D-2. EMISSIONS BENEFIT
OF ZERO-VOC WOOD COATINGS
FOR FURNITURE MANUFACTURER
Coating Type
Stain
(High Solid)
Washcoat
Sealer
Topcoat
(Clear)
Total
Annual Usage
(1000 Liters)
40%
8%
16%
36%
100%
VOC Limits (g/1)
7/1/95 Compliance
700
480
550
275
-
VOC Emissions
(1000 Grams)
280
38.4
88
99
505.4
VOC Limits (g/1)
7/1/96 Compliance
240
120
240
275
-
VOC Emissions
(1000 Grams)
96
9.6
38.4
99
243
ADCO/BAT
Coatings
VOC Content (g/1)
240
120
-
-
-
VOC Emissions
(1000 Grams)
96
9.6
-
-
105.6
Emissions Reduction
7/1/95 Compliance
-
-
-
-
79%
Emissions Reduction
7/1/96 Compliance
-
-
-
-
57%
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TABLE D-3. VOC/TOXIC COMPOUNDS COMPARISON
MANUFACTURER/
TOPCOAT
VOC
w
AIR TOXIC
SUBSTANCES
WEIGHT(%)
ADCO TOPCOAT
<10
NONE
0
AKZO 680-60C018-115 W/B
210
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
6.2
3.9
AMT 01TC-0090-50 W/B
240
PROPYLENE GLYCOL N-BUTYL ETHER
1-10
GUARDSMAN 45-1065-40
W/B
270
DIETHYLENE GLYCOL MONOBUTYL ETHER
PROPYLENE GLYCOL N-BUTYL ETHER
6.0
3.0
LILLY 787W43 W/B
240
PROPYLENE GLYCOL N-BUTYL ETHER
3.4
PINNACLE 137-CL-l
270
TRIETHYLAMINE
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
<5.0
3.0
3.0
SHERWIN-WILLIAMS
T70C510 W/R
270
ETHYLENE GLYCOL MONOBUTYL ETHER
DIETHYLENE GLYCOL MONOBUTYL ETHER
4.8
9.2
SINCLAIR WL 14-9
200
DIETHYLENE GLYCOL MONOBUTYL ETHER
3.0
WATERCOLOR TOPCOAT
100
PROPYLENE GLYCOL N-BUTYL ETHER
1-10

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4^
U)
TABLE D-4. PERFORMANCE CHARACTERISTICS COMPARISON
MANUFACTURER/
TOPCOAT
ADHESION
DRY TIME
(MINUTES)
GLOSS
60° SHEEN
SCRAPE/MAR
(GRAMS)
ADCO TOPCOAT
GT 0/5B
20-25
80.0
1050
AKZO 680-60C018-115 W/B
GT 0/5B
30-35
34.3
300
AMT 01TC-0090-50 W/B
GT 0/5B
30-35
62.0
500
GUARDSMAN 45-1065-40 W/B
GT 0/5B
30-35
46.8
800
LILLY 787W43 W/B
GT 0/5B
30-35
23.9
300
PINNACLE 137-CL-l
GT 0/5B
30-35
79.4
500
SHERWIN-WILLIAMS
T70C510 W/R
GT 0/5B
30-35
44.0
500
SINCLAIR WL 14-9
GT 0/5B
30-35
38.6
400
WATERCOLOR TOPCOAT
GT 0/5B
30-35
37.1
600

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TABLE D-5. CHEMICAL AND STAIN RESISTANCE COMPARISON
MANUFACTURER/
TOPCOAT
ACETONE
COFFEE
MUSTARD
HOT TAP
WATER
NAIL POLISH
REMOVER
ADCO TOPCOAT
1
1
2
1
2
AKZO 680-60C018-115 W/B
3
1
2
1
2
AMT 01TC-0090-50 W/B
2
1
2
1
2
GUARDSMAN 45-1065-40 W/B
2
1
2
1
3
LILLY 787W43 W/B
2
1
2

3
PINNACLE 137-CL-l
2
1
2
1
1
SHERWIN-WILLIAMS
T70C510 W/R
2
1
2
1
2
SINCLAIR WL 14-9
2
1
2
1
2
WATERCOLOR TOPCOAT
1
1
1
1
2
LEGEND: 1. NO EFFECT
2.	SLIGHT EFFECT
3.	MEDIUM EFFECT
4.	HEAVY

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TECHNICAL REPORT DATA 			 		
(Please read Instructions on the reverse before completii || | |||| || ||||| ||| 1II111 III II III
1. REPORT NO. 2.
EPA-600/R-95-160
3. F II1 llll II Hill III 1II111 III || III
F PB96-12152 0
4. TITLE AND SUBTITLE
Research and Product Development of Low-VOC Wood
Coatings
S. REPORT DATE
November 1995
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Eddy W. Huang
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING OROANIZATION NAME AND ADDRESS
AeroVironment, Inc.
222 East Huntington Drive
Monrovia, California 91016
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
EPA Cooperative Agreement
CX-819072-01-2
(with SCAOMD)
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air Pollution Prevention and Control Division
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final: 9/92-10/94
14. SPONSORING AGENCY CODE
EPA/600/13
^.supplementary notes APPCD project officer is Robert C. McCrillis, Mail Drop 61, 919/
541-2733. SCAQMD project officer is Ranji George, South Coast Air Quality Manage-
ment District, Diamond Bar, CA 91765.
16. abstractpaper discusses a project, cofunded by the South Coast Air Quality Man-
agement District (CSAQMD) and the U. S. EPA, to develop a new low volatile organic
compound (VOC) wood coating. Traditional wood furniture coating technologies con-
tain organic solvents which become air pollutants as the coating cures; mitigation by
add-on control devices would be energy intensive. Air emissions can be reduced
through the pollution prevention approach of shifting to low-VOC coatings, avoiding
the energy penalty. This project evaluated a new low-VOC wood coating technology
(a two-component water-based epoxy) by determining its performance characteris-
tics, conducting application and emissions testing, and assessing the cost benefits
for energy conservation and air pollution reduction. The composition of the basic
epoxy polymer was varied in combination with several curing agents. The resulting
top coat was as good as, or better than, other low-VOC waterborne wood furniture
top coats for adhesion, gloss value, dry time, hardness, level of solvents, and chem-
ical and stain resistance. The VOC content of the clear and the white pigmented top
coats was less than 10 g/L. The cost of this low-VOC wood coating is comparable
to that of other low-VOC coatings. Improved dry times were identified as being cri-
tical for product improvement. A marketing plan was developed.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. cosati Field/Group
Pollution Solvents
Epoxy Coatings Curing
Wood
Organic Compounds
Volatility
Furniture
Pollution Prevention
Stationary Sources
Volatile Organic Com-
pounds (VOCs)
13B 11K
11C 13 H
11L
07C
20M
15E
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
50
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)

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