Grantee Research Project Results

Final Report: Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings

EPA Contract Number: EPD17005
Title: Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings
Investigators: Tarnavchyk, Dr. Ihor
Small Business: Renuvix, LLC
EPA Contact: Richards, April
Phase: I
Project Period: November 1, 2016 through April 30, 2017
Project Amount: $100,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2016) RFA Text |  Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR - Toxic Chemicals

Description:

Due to their exceptional properties, polyurethane coatings are used extensively in our society. Application examples for polyurethane coatings include automotive top/clear coatings, top coatings for aircraft, and top coats for wood furniture and hardwood flooring. Unfortunately, most polyurethane coatings utilize toxic isocyanates that must be mixed with another coating component just prior to application to the substrate of interest. Thus, there is a need for polyurethane resins that can be cured without the use of the toxic isocyanates. It is also desirable to produce non-isocyanate polyurethanes that enable the production of one-component coatings that can cure at ambient conditions. One-component, ambient-cure coatings are highly desired because they are applicator friendly, low in waste generation, and they eliminate energy costs associated with the curing process. Further, it desirable to utilize renewable resources for the production of polyurethanes as opposed to petrochemicals. The utilization of renewable resources reduces dependence on oil and gas and is better for the environment.

The purpose of the Phase I project was to:

1. Determine the feasibility of producing novel non-isocyanate, bio-based polyurethane (BBP) resins for the production of one-component, ambient-cure coatings;
2. Produce a series of BBP resins possessing systematic variations in composition;
3. Compare the properties of the BBP resins and their corresponding one-component, ambient-cure coatings to the current state-of-the-art in coating resins for one-component, ambient-cure coatings;
4. Based on the properties obtained, identify the segment of the coatings market that could benefit the most from the attributes of the BBP technology.

Summary/Accomplishments (Outputs/Outcomes):

Sixteen different BBP resins with systematic variations in chemical composition were successfully produced and characterized. Characterization using Fourier transform infrared spectroscopy showed that these novel bio-based polyurethane resins did not contain the isocyanate functionality. Eight of the sixteen different BBP resins were used to produce one-component, ambient-cured clear coatings and the properties of these eight different BBP-based clear coatings compared to coatings produced using commercial resins that represent the current-state-of-the art for producing one-component, ambient-cured coatings. Specific BBP resin compositions were found to exhibit very desirable properties that were not obtainable with the current state-of-the-art. Compared to the current-state-of-the-art, these specific BBP resins provided coatings with dramatically lower levels of volatile organic compounds (VOCs), dramatically shorter drying times, and equivalent or better hardness and solvent resistance.

Based on the results obtained and extensive discussions with industry experts, the segment of the coatings market that could benefit the most from the BBP resin technology was identified. Model coatings were produced specifically for this application and compared to analogous coatings based on resins representing the current state-of-the-art. Application specific testing was conducted and the BBP resin technology was shown to overcome the primary limitations associated with the current state-of-the-art.

Conclusions:

At the beginning the Phase I project, the approach for producing the novel BBP resins had not been reduced to practice. As a result of completing the Phase I project, the synthetic method was demonstrated and all of the objectives were met. Thus, technical feasibility was demonstrated. In addition, the most appropriate segment of the coatings market for these new resins was identified and their utility in this market segment demonstrated.

Commercialization:

Novel non-isocyanate BBP resins with a specific range of compositions were found to have properties that could not be achieved using the current state-of-the-art in coatings resins designed for one-component, ambient-cured coatings. As a result of discussions with industry experts, which included both coating formulators and coating end users, the segment of the coatings market that could benefit the most from the BBP resin technology was identified. Side-by-side comparisons between model coatings based on specific BBP resins and resins currently used in this market clearly showed that the BBP resin technology overcomes the primary limitations of the current resin technology. As a result, it was concluded that the BBP resin technology has very high commercial potential for this application. The global market size for this segment of the coatings market is worth about $2 billion.

SBIR Phase II:

Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings  | Final Report