RHOPLEX™ AC-3094 Emulsion

Thermosetting Binder for Hardboard Primers

Description

RHOPLEX AC-3094 emulsion, the preneutralized analogue of RHOPLEX AC-2573 emulsion, is specifically designed
as a more user-friendly and cost-effective vehicle for thermosetting factory-applied primers for exterior hardboard
siding products. Like RHOPLEX AC-2573, this versatile hydroxyl-functional, modified-acrylic emulsion produces
coatings that offer a high degree of resistance to blistering during the curing process. These coatings also
demonstrate good adhesion and water resistance along with broad formulating latitude. Primers based on
RHOPLEX AC-3094 emulsion demonstrate the required exterior durability on siding products which receive field-
applied topcoats. Performance data, suggested formulating techniques and starting point formulations are
presented in the following pages.

Performance Features

Primers formulated with RHOPLEX AC-3094 emulsion offer the following features:

z Handling ease and formulation latitude

z Blister resistance during curing
z Good water resistance
z Excellent cost/performance balance
z Excellent exterior primer durability
z Paintability with a variety of topcoats

Typical Physical Properties

These properties are typical but do not constitute specifications.

Appearance Milky white liquid

Total Solids, Wt.% 47.5
Brookfield viscosity, cP 275
pH 7.5
Neutralizing amine N,N-dimethylaminoethanol (DMAE)
Density, lb/gal 8.72
Dry bulking value, gal/lb 0.1089
Minimum Film Forming Temperature
24
(MFT), °C
Tukon hardness, KHN,
As supplied 3.5
As a blend with polymeric melamine, 7.0
90/10 AC-3094/melamine, solids on
solids, fully baked

Blister Resistance

Hardboard primers based on RHOPLEX AC-3094 emulsion are less prone to blistering during the curing process
than primers based on other vehicles. This has been demonstrated under stressed, high-intensity infrared curing
conditions to induce blistering in all the films. Moreover, with RHOPLEX AC-3094 emulsion, there is no sacrifice of
other critical properties such as water resistance or cure response.
Water Resistance and Adhesion

Primers based on RHOPLEX AC-3094 emulsion demonstrate excellent adhesion to hardboard. Tape adhesion was
determined using #250 Scotch tape both on dry board and panels soaked for 24 hours in water.
RHOPLEX AC-3094 based primers also possess excellent resistance to water penetration, as measured by the Cobb
Test (See Table 1). The panels were cured in a staged oven for 2 minutes at 195°F, 2 minutes at 300°F, and 3
minutes at 390°F to attain a peak surface temperature of 320°F.

Table 1
Blister Resistance, Water Resistance and Adhesion
Performance of 55 PVC Primers Based on
RHOPLEX AC-3094 vs Controls
Blister Water
Resistance Resistance Adhesion
scale of 1 to 10, with Cobb Test Wet/Dry
Vehicle 10=no blistering (perms) % Removal
RHOPLEX AC-3094
6 5.5 0/0
emulsion
RHOPLEX AC-2573
6 5.5 0/0
emulsion
RHOPLEX AC-1822
2 5.9 0/0
emulsion
RHOPLEX AC-2045
5 6.2 0/0
emulsion
Competitive A 5 7.3 0/0
Competitive B 2 5.9 0/0

Durabilty

RHOPLEX AC-3094 emulsion is designed for factory-applied primers for hardboard that receive field-applied
topcoatings. Since RHOPLEX AC-3094 is the neutralized analogue of RHOPLEX AC-2573, the durability data in
Tables 2 and 3 of primers based on RHOPLEX AC-2573 can be viewed as representative of the expected
durability of primers based on RHOPLEX AC-3094.

Hardboard panels have been coated in our laboratory under controlled conditions to simulate factory application.
After exposure on our test fences at Spring House, Pennsylvania, a primer based on RHOPLEX AC-3094 emulsion
demonstrated good durability when compared to those based on RHOPLEX AC-658, RHOPLEX AC-1822 and
RHOPLEX AC-2045 emulsions. This comparison is shown on Table 2.
 Table 2
Durability of Primers Based on RHOPLEX AC-2573 Emulsion
After 7 Months Exposure

Effect of PVC in a South Vertical Exposure

Vehicle Drip Edge Dirt Pickup Mildew Fiber Raising Face Checking
PVC 45%
RHOPLEX AC-2573 9 8 10 10 10
RHOPLEX AC-1822 9+ 8 10 10 10
RHOPLEX AC-2045 9+ 10 10 10 10
RHOPLEX AC-658 8+ 10 10 10 10
PVC 55%
RHOPLEX AC-2573 8 9 8 10 10
RHOPLEX AC-1822 9 10 8 10 10
RHOPLEX AC-2045 8 10 10 10 10
RHOPLEX AC-658 8+ 9+ 8 10 10
Ratings: 10=no change, 1=complete failure

Exposure data:
Series: I-87B
Time: 7 months
Substrate: Masonite X-90, Laurel flat hardboard
Location: Spring House, PA
Direction: South vertical
Cure: 300°F/2 min, then 390°F/3 min to PST 320°F
Film thickness: 1.2 mils
Pigmentation: Ti-Pure™ R-960; Snowflake™; Tamsil™ 10
Melamine: Cymel™ 373 (acrylic/melamine 9/1) except RHOPLEX AC-658, a self-
contained thermosetting emulsion.

Even in the more demanding south 45° exposure direction, all primers were rated 10 (unchanged) for mildew,
fiber raising and face checking. Minor differences were noted in dirt pickup; these were attributed to variations in
the board supplied by different manufacturers.

Table 3 shows the results of an exposure series consisting of hardboard panels from different manufacturers. All
the test panels were primed with coatings based on RHOPLEX AC-2573 emulsion along with RHOPLEX AC-1822
and RHOPLEX AC-2045, two other well-established Rohm and Haas thermosetting emulsions.
 Table 3
Durability of 55 PVC Primers Based on RHOPLEX AC-2573
Emulsion After 8 Months Exposure, South 45°
Vehicle Drip Edge Dirt Pickup Mildew Fiber Raising Face Checking
Masonite X-90
Hardboard
RHOPLEX AC-2573 7 9 10 10 10
RHOPLEX AC-1822 9 9 10 10 10
RHOPLEX AC-2045 9 9 10 10 10
Abitibi Hardboard
RHOPLEX AC-2573 9 8+ 10 10 10
RHOPLEX AC-1822 9 8+ 10 10 10
RHOPLEX AC-2045 9 8+ 10 10 10
Ratings: 10=no change, 1=complete failure

Exposure data:
Series: I-87Q
Time: 8 months
PVC: 55%
Location: Spring House, PA
Direction: South 45°
Cure: 300°F/2 min, then 390°F/3 min to PST 320°F
Film thickness: 1.2 mils
Pigmentation: Ti-Pure R-960; Snowflake; Tamsil 10

Block Resistance

Primers based on RHOPLEX AC-3094 emulsion develop good block resistance when fully cured in commercial high-
velocity hot air or gas-fired infrared ovens. Based on extensive laboratory work with RHOPLEX AC-2573, we
concluded that the peak board surface temperature achieved during curing and the temperature at which the
board is stacked have a greater influence on blocking than do either the oven dwell time or the board stacking
pressure.

Formulating Guidelines

Dispersant

ACRYSOL™ I-62 resin is the recommended dispersing agent for coatings based on RHOPLEX AC-3094 emulsion
because it maximizes water resistance. It is a hydroxyl-functional, polymeric resin which reacts with melamine to
become part of the binder matrix. It has a high dispersing efficiency with a broad range of pigments.

When ACRYSOL I-62 is used as the dispersing resin, it must first be diluted to at least 25% solids and then
neutralized prior to the addition of pigments to the millbase. The dispersant demand for ACRYSOL I-62 will vary
depending on the pigment level and pigment type required. A level of about 2% ACRYSOL I-62 solids based on
pigment weight is recommended as a starting point.

Melamine

For hardboard primers, the use of a polymeric melamine is suggested for optimal durability, wax migration
resistance, cure response, and block resistance. Cymel 373 has been used in most of the Rohm and Haas studies
performed on RHOPLEX AC-2573 emulsion, the unneutralized form of RHOPLEX AC-3094 emulsion.
Coalescent

Ethylene glycol monobutyl ether at 15% on binder (acrylic plus melamine) solids is the coalescent generally
recommended for best film formation, viscosity control, formulation stability, and block resistance. Naturally, the
type and level of coalescent that is ultimately selected by the formulator will depend on how the primer is to be
used.

Defoamers

Bubble Breaker™ 3056A should be added to the grind to prevent the development of foam in primers formulated
with RHOPLEX AC-3094 emulsion.

Amine Selection/Level

Tertiary amines should be incorporated in all coatings containing melamine for optimal stability. Since RHOPLEX
AC-3094 emulsion contains DMAE, we recommend that the formulator control pH of the formulation within the
range of 8.3 to 9.0, by adding approximately 1% DMAE (solids on solids). This will ensure a good balance between
storage stability and curing rate.

Choice of Pigmentation

Like its precursor RHOPLEX AC-2573 emulsion, RHOPLEX AC-3094 emulsion has the pigment binding ability to
handle a wide variety of grades of titanium dioxide and extender pigments to meet specific objectives.

Formulation P-3094-1 55 PVC Primer Based on RHOPLEX AC-3094

Materials Pounds Gallons
Cowles Grind:
ACRYSOL I-62 (50%) Premix 25.4 2.92
Water 124.6 14.97
Dimethylaminoethanol (DMAE)/water, 1/1 2.5 0.3
Add to the above:
Bentone™ LT 1.0 0.06
Bubble Breaker 3056-A 4.5 0.61
Titanium dioxide 100.3 3.11
Snowflake 266.0 11.81
Tamsil 10 265.9 12.04
Aurasperse™ W-7012 1.0 0.1
Letdown:
RHOPLEX AC-3094 (47.5%) 387.3 44.41
DMAE/water = 1/1 3.6 0.46
Cymel 373 (85%) 24.1 2.28
Ethylene glycol monobutyl ether/water, 80/20 38.4 5.00
Total: 1260.4 100.0
Formulation Constants:
PVC, % 55
Volume solids, % 48.9
Weight solids, % 67.9
pH 9.0
Viscosity, #4 Ford cup, seconds 42
Acrylic/melamine (solids ratio) 90/10
Pigment/binder 75/25
Coalescent on binder, % 15
VOC, calculated minus water
g/L 82.0
lb/gal 0.7
 Formulation P-3094-3 55 PVC Primer Based on
RHOPLEX AC-3094 Optimized for Blister and Water Resistance
Materials Pounds Gallons
Cowles Grind:
ACRYSOL I-62 (50%) Premix 25.4 2.92
Water 129.8 15.58
Dimethylaminoethanol (DMAE)/water, 1/1 2.5 0.33
Add to the above:
Bubble Breaker 3056-A 4.5 0.61
Titanium dioxide 100.1 3.10
ASP™-400 40.8 1.90
Tamsil 10 441.2 19.99
499™ Talc 42.7 1.90
Aurasperse W-7012 1.0 0.10
Bentone LT 1.0 0.06
Letdown:
RHOPLEX AC-3094 (47.5%) 384.5 44.10
DMAE/water = 1/1 3.6 0.46
Cymel 373 (85%) 23.9 2.27
Ethylene glycol monobutyl ether/water, 80/20 38.1 4.96
Water 14.3 1.72
Total: 1253.4 100.0
Formulation Constants:
PVC, % 55
Volume solids, % 48.7
Weight solids, % 67.4
pH 9.0
Viscosity, #4 Ford cup, seconds 60
Acrylic/melamine (solids ratio) 90/10
Pigment/binder 75/25
Coalescent on binder, % 15
VOC, calculated minus water
g/L 83.9
lb/gal 0.7

Suppliers of Suggested Raw Materials

Trade Name Type Supplier
Englehard Corp.
ASP-400 Extender pigment Iselin, NJ
Rohm and Haas Co.
ACRYSOL I-62 Dispersing resin Philadelphia, PA
Englehard Corp.
Aurasperse W-7012 Colorant Iselin, NJ
Witco Corporation
Bubble Breaker 3056A Defoamer New York, NY
Rheox Inc.
Bentone LT Thixotrope Hightstown, NJ
Melamine- American Cyanamid Co.
Cymel 373 formaldehyde resin Wayne, NJ
RHOPLEX AC-658
RHOPLEX AC-1822
RHOPLEX AC-2045 Rohm and Haas Co.
RHOPLEX AC-2573 Binders Philadelphia, PA
ECC International, Calcium Pdts.
Snowflake CaCO3 Extender pigment Atlanta, GA
Whittaker, Clark & Daniels, Inc.
499 Talc Extender pigment S. Plainfield, NJ
Unimin Specialty Minerals, Inc.
Tamsil 10 Extender pigment Elco, IL
Health and Safety Information

Safe Handling Information

Based on its composition, RHOPLEX AC-3094 emulsion is not expected to be toxic via single acute oral, dermal, or
inhalation exposure. It may be a slight to moderate skin, eye and/or inhalation irritant.

Melamine-formaldehyde resins such as the Cymel products recommended in this bulletin can release free
formaldehyde, a suspect animal carcinogen, under some processing conditions. It is very important to use good
ventilation when working with these products. Safety handling information should be obtained from the company
that supplies these products.

Material Safety Data Sheets

Rohm and Haas Material Safety Data Sheets (MSDS) contain pertinent information that you may need to protect
your employees and customers against any known health or safety hazards associated with our products.

Under the OSHA Hazard Communication Standard, workers must have access to and understand MSDS on all
hazardous substances to which they are exposed. Thus, it is important that you provide appropriate training and
information to your employees and make sure they have available to them MSDS on any hazardous products in
their workplace.

Rohm and Haas Company sends MSDS on non-OSHA hazardous as well as OSHA-hazardous products to its
customers upon initial shipment (including samples) of all its products (whether or not they are considered OSHA-
hazardous). If you do not have access to one of these MSDS, please contact your local Rohm and Haas
representative for an additional copy.

Updated MSDS are sent upon revision to all customers of record. In addition, MSDS are sent annually to all
customers receiving products deemed hazardous under the Superfund Amendments and Reauthorization Act.

MSDS should be obtained from your suppliers of other materials recommended in this bulletin.

Rohm and Haas Company is a member of the American Chemistry Council (ACC) and is committed to ACC's
Responsible Care® Program.

ACRYSOL and RHOPLEX are trademarks of Rohm and Haas Company, or of its subsidiaries or affiliates and are intended to designate goods
marketed in North and South America; the same goods may be marketed in other countries, generally under other company trademark
designations.

These suggestions and data are based on information we believe to be reliable. They are offered in good faith, but without guarantee as
conditions and methods of use of our products are beyond our control. We recommend that the prospective user determine the suitability of
our materials and suggestions before adopting them on a commercial scale.

Suggestions for uses of our products or the inclusion of descriptive material from patents and the citation of specific patents in this
publication should not be understood as recommending the use of our products in violation of any patent or as permission to license to use
any patents of the Rohm and Haas Company.

©Rohm and Haas, 2008 All rights reserved. December 1993

82BP1