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    Features

    Transparent Ultrafine Mineral Filler Technologies

    Advancements for UV/EB Performance, Economics and Cure Rate

    Transparent Ultrafine Mineral Filler Technologies
    Figure 1. SEM photomicrograph of ultrafine nepheline syenite at 10,000x.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 2. R.I. comparison of mineral fillers (top) with binders (bottom).
    Transparent Ultrafine Mineral Filler Technologies
    Figure 3. Haze and optical clarity as a function of N.S. top-size and concentration in an aqueous UV-cure PUD with ~ 2 mil DFT.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 4. Acrylic high-solids UV-cure clear wood finish filled with 5 µm N.S. at 10 % by wt. based on resin solids over stained maple veneer (DFT = 3 mil).
    Transparent Ultrafine Mineral Filler Technologies
    Figure 5a. Pendulum hardness with increasing energy at 6% N.S by wt. in a UV PUD.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 5b. Acrylate double bond conversion as a function of cure time at 12% 5 µm N.S. in UV PUD spot oven curing.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 6. Three-dimensional spectra of a sample obtained by FTIR with real-time curing. Peak is at approximately 820 cm-1.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 7. Diagram of DOE showing levels of the two factors: 5 µm N.S. and photoinitiator level.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 8. Time (sec) for 50 % of the C=C in PUD-Acrylate to be converted.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 9. Percent cure rate of the unmodified UV-cure PUD and 5 µm N.S. filled (12% by wt.) with standard photoinitiator and 50% reduction of the photoinitiator level.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 10. Time (sec) for 50 % of the C=C in the unmodified UV-cure PUD and 5 µm N.S. filled (12% by wt.) with standard photoinitiator and 50% reduction of the photoinitiator level.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 11. Response surface for DOE measurements at IR bands 810-815 cm-1 and 1400-1410 cm-1.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 12. Contour plot of response surface showing the possibility of photoinitiator reduction from the addition of 5 µm N.S. in the 800-810 cm-1 and 1400-1410 cm-1 regions. Faster curing is indicated by higher desirability.
    Transparent Ultrafine Mineral Filler Technologies
    Figure 13. Pareto charts for 800-810 cm-1 (top) and 1400-1410 cm-1 (bottom).
    Transparent Ultrafine Mineral Filler Technologies
    Figure 14. Cost analysis of UV-Cure PUD coating vs. filler loading level.
    Transparent Ultrafine Mineral Filler Technologies
    Table 1. Typical properties of nepheline syenite.
    Transparent Ultrafine Mineral Filler Technologies
    Table 2. Nepheline Syenite test filler particle size.
    Transparent Ultrafine Mineral Filler Technologies
    Table 3. Stable resin-free pre-dispersion formulation.
    Transparent Ultrafine Mineral Filler Technologies
    Table 4. Clear aqueous UV-cure PUD formulation.
    Transparent Ultrafine Mineral Filler Technologies
    Table 5 - DOE and results from FTIR cure rate measurement for 800-815 cm-1 band.
    Transparent Ultrafine Mineral Filler Technologies
    Table 6 - DOE and results from FTIR cure rate measurement for 1400-1410 cm-1 band.
    S.P. Van Remortel, R.E. Ratcliff, D.D. Kragten, Unimin Corporation01.06.17
    Abstract

    Nepheline syenite, a durable, commonly employed hard feldspathic, is a crystalline silica-free functional filler used in all types of decorative, industrial, and OEM coating applications.  Previous research and mineral processing advancements showed that new ultrafine grades have superior optics at high loadings, contribute to improved mechanical properties, and assist UV curing in aqueous UV-cure clear PUD systems.  This paper builds on these previous findings using advanced FTIR techniques to better quantify the contributions that affect UV cure rate.  Moreover, this paper demonstrates the ability of ultrafine nepheline syenite to reduce formulation costs by replacing part of the expensive photoinitiators and resins without compromising coating performance.

    Introduction

    Nepheline syenite is a silica-deficient functional filler and additive widely employed in a variety of polymer-filled coating, adhesive, ink, and colorant applications.  Micronized sizes are valued for purity of color, gloss control, ease of dispersion with minimal

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