Abstract
During roll coating application of water-based architectural paints, fibers are formed between roller and substrate. These fibers progressively thin and break up into several tiny droplets leading to the wastage of paints. This defect is widely known as spattering. In the current study, the propensity to spatter in fully formulated mid pigment volume concentration water-based architectural paints based on varying the type of thickeners, namely a combination of cellulosic with clay, cellulosic, and hydrophobically modified poly acetal/ketal polyether (HMPAPE), at similar and varying volume solids is investigated. The spatter tendency of paint is qualitatively assessed using ASTM D4707. Also, a new approach to quantify the spread area of spattered droplets is developed by thresholding-based image segmentation using an image processing toolbox of Mathematica. This newly developed quantitative approach will greatly help the formulator to better differentiate between formulations. Rheological tests, namely viscosity curve, amplitude sweep, frequency sweep, and first normal stress difference test, are carried out to unravel the flow and viscoelastic properties of paints in depth. An in-house custom-built fiber drawing device on a contact angle drop shape analyzer instrument is fabricated to study the extensional properties of paints. At the same volume solids, the paint based on a combination of cellulosic with clay thickener spatters the most, while the paint based on HMPAPE thickener spatters the least. This is mainly attributed to the chemistry, molecular weight, and thickening mechanism of thickeners. Eventually, a reliable correlation is established between observed spatter and the frequency-dependent elastic modulus outside the linear viscoelastic range at the same and varying solids for paints based on the different types of thickener. This correlation will help chemists to quickly screen formulations to minimize the spattering during roll coat application, thus saving time, cost, and manpower.
Similar content being viewed by others
References
Eley, RR, “Applied Rheology in the Protective and Decorative Coatings Industry.” Rheol. Rev., 173–240 (2005)
Glass, JE, “Dynamics of Roll Spatter and Tracking. 1. Commercial Latex Trade Paints.” J. Coat. Technol., 50 (640) 53–60 (1978)
Glass, JE, “Dynamics of Roll Spatter and Tracking. 2. Formulation Effects in Experimental Paints.” J. Coat. Technol., 50 (640) 61–68 (1978)
Glass, JE, “Dynamics of Roll Spatter and Tracking. 3. Importance of Extensional Viscosities.” J. Coat. Technol., 50 (641) 56–71 (1978)
Glass, JE, “Dynamics of Roll Spatter and Tracking. 4. Importance of g-Star Recovery and n1 in Tracking.” J. Coat. Technol., 50 (641) 72–78 (1978)
McKinley, GH, “Visco-Elasto-Capillary Thinning and Break-Up of Complex Fluid.” HML Report Number 05-P-04, (2005) Accessed on 18 Feb 2018
Fernando, RH, Xing, LL, Glass, JE, “Rheology Parameters Controlling Spray Atomization and Roll Misting Behaviour of Waterborne Coatings.” Prog. Org. Coat., 40 (1–4) 35–38 (2000)
Boger, DV, Walters, K, Rheological Phenomena in Focus, 4th ed. Elsevier, Amsterdam (2012)
Massouda, DF, “Analysis and Prediction of Roll-Spatter from Latex Paints.” J. Coat. Technol., 57 (722) 27–36 (1985)
Shay, GD, “Thickeners and Rheology Modifiers.” In: Koleske, JV (ed.) Paint Testing Manual, 15th ed. pp. 268–285 (Chapter 30) (2012)
Bhattacharya, SN, Kamal, MR, Gupta, RK, Polymeric Nanocomposites: Theory and Practice. Carl Hanser Publishers (2008)
White, JL, Czarnecki, L, Tanaka, H, “Experimental Studies of the Influence of Particle and Fiber Reinforcement on the Rheological Properties of Polymer Melts.” Rubber Chem. Technol., 53 (4) 823–835 (1980)
Sadeghy, K, James, DF, “Elasticity of Associative Polymer Solutions and Slip at High Shear Stress.” J. Non-Newtonian Fluid Mech., 90 (2–3) 127–158 (2000)
Soules, DA, Fernando, RH, Glass, JE, “Dynamic Uniaxial Extensional Viscosity (DUEV) Effects in Roll Application I. Rib and Web Growth in Commercial Coatings.” J. Rheol., 32 (2) 181–198 (1988)
Fernando, RH, Glass, JE, “Dynamic Uniaxial Extensional Viscosity (DUEV) Effects in Roll Application II. Polymer Blend Studies.” J. Rheol., 32 (2) 199–213 (1988)
Vanderslice, CW, Young, T-S, “Rheological and Applied Properties of Latex Paints Thickened with Conventional and Hydrophobically Modified Hydroxyethyl Cellulose.” In: Western Coatings Societies’ 20th Biennial Symposium and Show in San Francisco, California (1991)
Sharma, V, Haward, SJ, Serdy, J, Keshavarz, B, Soderlund, A, Threlfall-Holmes, P, McKinley, GH, “The Rheology of Aqueous Solutions of Ethyl Hydroxy-Ethyl Cellulose (EHEC) and Its Hydrophobically Modified Analogue (hmEHEC): Extensional Flow Response in Capillary Break-Up, Jetting (ROJER) and in a Cross-Slot Extensional Rheometer.” Soft Matter, 11 (16) 3251–3270 (2015)
Dexter, RW, “Measurement of Extensional Viscosity of Polymer Solutions and Its Effects on Atomization from a Spray Nozzle.” Atom. Sprays, 6 (2) 167–191 (1996)
ASTM D4707-97, “Standard Test Method for Measuring Paint Spatter Resistance During Roller Application.” (2003)
Patton, TC, Paint Flow and Pigment Dispersion: A Rheological Approach to Coating and Ink Technology, 2nd ed. Wiley, Hoboken (1979)
Bhavsar, R, Shreepathi, S, “Evolving Empirical Rheological Limits to Predict Flow-Levelling and Sag Resistance of Waterborne Architectural Paints.” Prog. Org. Coat., 101 15–23 (2016)
Jones, FN, Nichols, ME, Pappas, SP, Organic Coatings: Science and Technology. Wiley, Hoboken (2017)
Ramsay, JDF, “Colloidal Properties of Synthetic Hectorite Clay Dispersions: I. Rheology.” J. Colloid Interface Sci., 109 (2) 441–447 (1986)
Sau, AC, “Hydrophobically Modified Poly(acetal-polyethers).” US Patent 5574127, 1996
Hendel, RA, Yan, L, Cheng, L, “Methods for Controlling Silica Scale in Aqueous Systems.” US Patent 7316787 B2, 2008
Sau, AC, “Suppression of Aqueous Viscosity of Associative Polyacetal-Polyethers.” US Patent 6809132 B2, 2004
Eley, RR, “Applied Rheology and Architectural Coating Performance.” J. Coat. Technol. Res., 16 (2) 263–305 (2019)
Hyun, K, Wilhelm, M, Klein, CO, Cho, KS, Nam, JG, Ahn, KH, Lee, SJ, Ewoldt, RH, McKinley, GH, Prog. Polym. Sci., 36 1697–1753 (2011)
Ewoldt, RH, Hosoi, AE, McKinley, GH, J. Rheol., 52 1427–1458 (2008)
Bauman, T, Sullivan, T, Middleman, S, “Ribbing Instability in Coating Flows: Effect of Polymer Additives.” Chem. Eng. Commun., 14 (1–2) 35–46 (1982)
Barnes, HA, Huttton, JF, Walters, K, An Introduction to Rheology. Elsevier, Amsterdam (1989)
Chatterjee, T, Van Dyk, AK, Ginzburg, VV, Nakatani, AI, “Formulation-Controlled Positive and Negative First Normal Stress Differences in Waterborne Hydrophobically Modified Ethylene Oxide Urethane (HEUR)-Latex Suspensions.” ACS Macro Lett., 6 (7) 716–720 (2017)
Franck, AJ, “Normal Stresses in Shear Flow.” TA Instruments-Technical Note AN007 (Accessed on 18 Feb 2019)
Hoyt, JW, Taylor, JJ, Runge, CD, “The Structure of Jets of Water and Polymer Solution in Air.” J. Fluid Mech., 63 (4) 635–640 (1974)
Bouse, LF, Carlton, JB, Jank, PC, “Effect of Water Soluble Polymers on Spray Droplet Size.” Trans. ASAE, 31 (6) 1633–1639 (1988)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Electronic supplementary material
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Chaudhary, S., Bhavsar, R. & Chada, V.G.R. Investigating propensity of roller spatter during application of water-based architectural paints: effect of thickeners and volume solids. J Coat Technol Res 17, 413–425 (2020). https://doi.org/10.1007/s11998-019-00287-2
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11998-019-00287-2