Grantee Research Project Results
Final Report: Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings
EPA Contract Number: EPD18006Title: Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings
Investigators: Tarnavchyk, Dr. Ihor
Small Business: Renuvix, LLC
EPA Contact: Richards, April
Phase: II
Project Period: February 1, 2018 through October 31, 2020
Project Amount: $300,000
RFA: Small Business Innovation Research (SBIR) - Phase II (2017) Recipients Lists
Research Category: SBIR - Toxic Chemicals , Small Business Innovation Research (SBIR)
Description:
According to Grant View research, the global polyurethane market size was about USD 65.5 billion in 2018, with a CAGR of 7.0% over the forecast period. It is 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, etc. Unfortunately, most polyurethane coatings utilize toxic isocyanates that must be mixed with another component just prior to application to the substrate of interest. With increasing environmental regulation, the need for polyurethane resins that can be cured without the use of the toxic isocyanates and with low volatile organic components (VOC) is increasing. 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 as they are applicator friendly, reduces toxic waste generation, and they eliminate energy costs associated with the curing process. Also, one component coatings do not need specific mixing instructions like in the case of two-component systems thereby eliminating the risks of getting suitable pot life at the application sites. Further, it is desirable to incorporate renewable resources as much as possible 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 II project was to:
1) Optimize the sucrose soy urethane (SSU) resin composition to maximize utility as a binder for coatings with enhanced performance and lower VOC content;
2) Determine the weatherability of coatings produced from the most promising SSU resins;
3) Determine the utility of the most promising SSU resins for the protection of metal substrates from corrosion;
4) Optimize the process for producing the most promising SSU resins so that production cost and production waste can be minimized;
5) Produce and sample select SSU resins to those potential customers that have expressed a desire to evaluate the materials;
6) Obtain feedback on the most promising SSU resins from potential customers.
Summary/Accomplishments (Outputs/Outcomes):
Renuvix SSU resins are largely biobased, volatile organic compound-free resins that can be produced in a broad range of viscosities. A variety of low viscosity sucrose soy urethane (SSU) resins were successfully synthesized and characterized. Each resin was evaluated as a solvent-free system for its properties such as viscosity and curing behavior, and also coating performance. The produced SSU resins have shown up to five times faster curing compared to the commercial benchmarks. In terms of coating performance, the accelerated weathering and corrosion testing showed that cured SSU resins provide better or similar barrier protection to steel panels than solvent-free commercial alkyds. Select SSU resins even showed better UV tolerance and lower degradation compared to the current-state-of-the-art one component ambient cure coatings. Coating performance testing on steel also showed similar or better hardness and solvent resistance for SSU coatings. Stain resistance testing for SSU coating on a wood substrate resulted in better performance compared to commercial benchmarks.
By offering novel SSU resins to potential customers and discussing SSU products that could solve their application needs, Renuvix was able to identify which segments of the coating market SSUs could penetrate. Model coating formulations were prepared considering the market need and environmental regulations and their performance were compared to the currently available state-of-the-art products in the market.
Conclusions:
During the Phase II project several technical and economic aspects for the production of novel SSU resins were investigated. Towards the end of completion of the Phase II project, the optimization of the synthetic method was carried out leading to better control over the product quality and also reducing the overall production cost. Finally, all the proposed objectives were leading to the optimization of the most promising SSU resins compared to the commercial benchmarks. Thus, technical feasibility was demonstrated. In addition to offering samples to the potential customers the most appropriate market segments for these novel SSU resins were identified and a feasible commercialization plan was developed.
The novel isocyanate-free sucrose soy polyurethane resins with a specific range of compositions and viscosities 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. During the discussions with the potential customers including those that supported the technology, the segment of the coatings market that could benefit the most from these SSU resins was identified. Performance investigation of the SSU resins along with the resins currently used in this market clearly showed that the novel SSU resins technology overcomes the primary limitations of the current resin technology both in terms of performance and environmental safety. As a result, it was concluded that the SSU resin technology has very high commercial potential for applications that require one component low VOC ambient curing polyurethane resin. The global market size for this segment of the coatings market is worth about $2 billion.
SBIR Phase I:
Isocyanate-Free Polyurethane Resins for One-Component, Ambient-Cure Coatings | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.