The Future of Formulation

Light on layers, heavy on performance: WB 2K DTM development

In pursuit of sustainable solutions for industrial coatings, the industry has long sought a single-layer waterborne system that delivers both corrosion protection and adhesion as well as topcoat aesthetics—traditionally achieved through multi-layer applications. Among waterborne DTM coatings, 1K acrylates are favored for their simplicity, but they often fall short in delivering the high-performance demands of harsher environments. This work introduces a strategically designed hydroxyl functional acrylate dispersion for 2K waterborne polyurethane systems that unifies primer and topcoat capabilities. The resulting solution provides formulations that offer robust metal protection, excellent chemical resistance, and a high-gloss finish—all within a single layer. This innovation not only simplifies application but also supports sustainability goals by reducing material usage and process steps, marking an advancement in driving sustainability in protective coatings.

Advancing Pigment Dispersion with Innovative Resin Architecture

Achieving optimal pigment dispersion remains a cornerstone of high-performance coatings. This study introduces a resin architecture designed to function as a universal grinding medium across a wide spectrum of pigment chemistries and coating technologies. Characterized by low polarity, high solubility, and excellent pigment wetting capabilities, the resin system enables efficient dispersion without the need for specialized dispersants. 

Through comparative analysis with conventional grinding resins, the study demonstrates enhanced color strength, gloss retention, yellowing resistance, robust heat stability, and long-term durability in coating formulations. The resin’s compatibility with organic and inorganic pigments, as well as its adaptability across coating platforms, supports a streamlined formulation approach. 

This work proposes a shift toward universal grinding resin systems that simplify pigment dispersion workflows while maintaining high performance standards. Sustainability is addressed through mass balance approaches, VOC reduction, and alignment with certification requirements. The findings offer a foundation for future innovations in sustainable and efficient coating formulations. 

Film formation and stratification in latex polymer dispersion and acid rich oligomer blends 

Oligomers in latex polymer dispersion and oligomer blends can uniformly distribute, stratify, or phase-separate into domains during film formation. In this study, we examine film formation from acrylic latex polymer and acid rich oligomer blends, and the distribution of acid-rich oligomers in the resulting films. Film formation and oligomer distribution were studied by Förster resonance energy transfer (FRET), confocal laser-scanning microscopy (CLSM), and atomic force microscopy (AFM). The results reveal that the distribution of acid-rich oligomers depends on the blend pH and drying conditions. At high pH and low humidity, the acid-rich oligomers stratify to the film surface, whereas at lower pH and higher humidity, oligomers mainly occupy the interstices of latex polymer particles. Greater electrostatic repulsion between oligomers and latex particles at higher pH promotes vertical stratification of oligomers to the surface. Oligomers in the interstices act as mortar between latex particles and increase the Young’s modulus of the film. Thus, this study provides a fundamental understanding of film formation and strategies to promote acid-rich oligomer stratification in acrylic polymer films.

Novel UVA/HALS for the Stabilization of Coatings on Cementitious Substrates

Organic UV-absorbers (UVA) and sterically hindered amine light stabilizers (HALS) find widespread use as coating additives to prevent UV-induced photodegradation during outdoor weathering and exposure. In water-based coating formulations, many of the well-established non-polar light stabilizers are difficult to incorporate due to insolubility and/or incompatibility with the aqueous coating or paint formulations. Getting a storage-stable uniform dispersion, leading to homogeneous coating formulations upon storage and use without syneresis of the light stabilizers is critical. Several undesired phenomena such as sedimentation and gelation may occur if the light stabilizers are incompatible in the water-based coating formulations, leading to detrimental coating performance. Additionally, coatings over cementitious substrates can be especially challenging due to the high alkaline environment which can lead to undesired discoloration of the light stabilizer after coating and cure.

A new waterborne UVA/HALS blend light stabilizer system, containing a highly photo permanent UV absorber and a non-interacting hindered amine light stabilizer, has been developed for use in waterborne coatings over cementitious substrates. The new waterborne light stabilizer system is designed to meet the high performance and durability requirements of these coating applications.

Shear and Extensional Rheology of Associative polymers in Paint systems

Paint and coating applications often require the use of multicomponent complex fluids containing particles, macromolecules, and additives to manage storage stability, rheology, and processing behavior. Rheological studies typically examine the behavior of coatings under shear flows, and rheology modifiers are frequently used to enhance viscosity at medium or high shear rates.  However, paint application consists of various processes, such as brush loading, brushing, rolling, spreading, sagging, and spraying, which involve extensional flows arising within pinching necks or near free surfaces. The extensional rheological behavior of coating fluids is not fully understood, in part due to the complexities associated with characterizing the response of viscoelastic suspensions. In this contribution, we complement the characterization of ingredient-dependent shear rheology by analyzing the extensional rheology response of a series of model coating fluids using dripping-onto-substrate rheometry protocols that rely on the analysis of capillarity-driven pinching flows. We elucidate how the concentration and choice of associative polymers and particles affect rheology.

One Layer, Full Protection: Dispersants for High-Performance DTM Systems

The transition towards more sustainable industrial coatings has accelerated the development of waterborne direct-to-metal (DTM) systems, which enable significant layer reduction by combining primer and topcoat functionalities into a single application process. This study investigates formulation methodologies and systematically assesses system performance, with a particular emphasis on the role of additives - especially dispersing agents - in modulating key functional outcomes. Dispersing agents are essential in stabilizing pigment particles. They facilitate optimal color development and promote homogeneous film formation, factors that are critical in single-coat applications, where surface defects cannot be masked by additional layers.

The performance of different dispersant chemistries is assessed through standardized coatings durability tests - such as salt spray and humidity exposure - and correlated with Electrochemical Impedance Spectroscopy (EIS) data, which enables faster and predictive evaluation of corrosion protection.

Results demonstrate that optimized dispersants not only improve pigment dispersion and rheology as processing aids but also contribute to enhanced barrier properties of the paint film. Furthermore, interactions with other formulation components -such as anti-corrosion pigments and coalescing agents - can have a synergistic effect on film integrity and long-term durability. These findings highlight the importance of an integrated formulation approach, where customized additives are key to addressing the specific requirements of DTM systems.

Evaluating Paint Failure and Advancing Latex Development for Chalky Surfaces Resulting from Degraded Paint

Exterior paints of inferior quality are susceptible to surface chalkiness with age, presenting unique challenges and failure modes during recoating. These surfaces require specially engineered latexes to achieve optimal performance. Developing reliable correlations between laboratory evaluations and real-world outdoor performance on chalky substrates remains a significant challenge. This presentation will outline our systematic approach to developing testing methodologies for assessing paint behavior on chalky substrates, examine potential modes of failure, and leverage these findings to inform the development of enhanced latex products.

Enhancing Primer Performance: Tackling Tannin in Industrial Wood Coatings

This study investigates the performance of tannin blocking primers formulated for industrial coatings applications, with an emphasis on fast block resistance and hardness development. Comparative testing was conducted on white oak, both with and without zinc- and zirconium-based tannin blocking additives. A key focus was placed on color stability metrics, specifically Δb and ΔE, within the primer layer and in combination with a topcoat, highlighting which resins are more effective at either locking in tannin bleed-through or blocking it entirely. Three environmental conditions were used to simulate different scenarios: controlled temperature and humidity, thermal exposure, and combined heat with high humidity. The results demonstrate that formulating choices and resin selection can significantly improve color stability against tannin migration under various conditions, while maintaining key properties necessary for industrial applications. Furthermore, a low VOC formulation based on a specific dispersion technology enabled high tannin blocking and block resistance without the need for metal salts.