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    Acrylic Resin Fundamentals

    Posted on April 22, 2016 by Ron Lewarchik

    Coatings utilizing acrylic resins are the leading polymer technology in the
    coatings industry. Historically alkyd finishes have held the leading
    position in coatings for decades. Acrylics are utilized in architectural
    coatings, product finishes for original equipment manufacture including
    automotive (OEM) and refinish, as well as special-purpose coatings.

    Acrylic resins are primarily based on acrylate and methacrylate


    monomers and provide good weather resistance, resistance to
    hydrolysis, gloss and color retention in exterior applications. Due to their
    versatility and performance, acrylic coatings account for over 25% of all
    coatings and global sales approaching $25 billion. Acrylic resins can be
    thermoplastic or thermosett and are used in organic solvent born,
    waterborne, powder and radiation-curable coatings

    Three broad classes of liquid coatings utilizing


    acrylic resins include thermoplastic, thermoset
    and waterborne. Many acrylic resins may also
    include other vinyl monomers such as styrene
    or vinyl acetate primarily to reduce cost. Acrylic
    monomers have a lower Tg than their analogous
    methacrylate monomers (for example compare
    the Tg for n-butyl acrylate versus n-butyl
    methacrylate see Table I and Table II). As Table
    II suggests, the glass transition temperature of
    the monomers selected for synthesis of a resin
    can be selected to enhance multiple properties
    that may include weather resistance, moisture
    Table I – Tg of Nonfunctional Homopolymers
    resistance, oxygen permeability, flexibility
    reactivity, cure and hardness. In addition,
    acrylics can be functionalized with a variety of monomers to provide
    improved adhesion to metal, or to react for example with aminoplast or
    isocyanate crosslinkers.
    Thermoplastic acrylic polymers (TPA) in general
    have excellent properties including exterior
    durability. Such resins were widely used in
    automotive OEM and Refinish topcoats from the
    50’s to the 70’s, but their use has dramatically
    declined due to the high molecular weight
    necessary to provide properties, they require a
    high amount of organic solvent to enable air
    Table II Relationship of Tg to Physical Properties
    atomized spray application. Accordingly these
    paints apply at about 20% weight solids.
    Thermoplastic resins typically use a high level of methyl methacrylate in
    their polymer backbone to provide excellent hardness and exterior
    durability.

    Figure I – Structure of poly MMA and poly MA

    Thermosetting acrylic resins (TSA) are designed with functional


    monomers to either react with themselves when exposed to heat or
    moisture, or with that of a cross-linker to form a cross-linked film.
    Thermoset resins as a group are lower molecular weight and thus have
    higher application solids. Once cross-linked, as a class they offer films
    with excellent resistance to organic solvents, moisture and UV light and
    do not soften appreciably when exposed to moderately high
    temperatures as thermoplastics do. An example of acrylic monomers
    with functional groups that can be used to functionalize acrylic polymers
    to provide properties such as crosslinking, self-crosslinking, improved
    adhesion or pigment wetting are provided in Table III.
    Being able to functionalize an acrylic resin with
    a wide range of reactive moieties provides the
    ability to tailor the performance of the resin
    backbone to provide improved adhesion over a
    variety of substrates, improved pigment wetting
    and/or the ability to provide crosslinking or self-
    crosslinking. Other acrylic monomers are also
    available to impart sulfonic acid, or phosphoric
    acid functionality to the acrylic resin.
    Table III – Functional Acrylic Monomers

    Being able to functionalize an acrylic resin with


    a wide range of reactive moieties provides the ability to tailor the
    performance of the resin backbone to provide improved adhesion over a
    variety of substrates, improved pigment wetting and/or the ability to
    provide crosslinking or self-crosslinking. Other acrylic monomers are
    also available to impart sulfonic acid, or phosphoric acid functionality to
    the acrylic resin.

    Looking for acrylic resins for your coatings


    formulations?
    Prospector has over a thousand listings for acrylic resin materials. View
    product data sheets, request samples and more now…

    Search Acrylic Resins

    Carbamate functional acrylics can also be made for example by reacting


    an isocyanate functional acrylic with hydroxypropyl carbamate. Many of
    the acrylics in the category of functionalized acrylic resins are used in
    automotive OEM and refinish clearcoats to provide an excellent
    combination of mar resistance, chemical resistance and light stability.

    Acrylic polymers are also used extensively to make water reducible and
    emulsion resins. Water reducible acrylic resins typically have acid
    numbers of 40 to 60. An example of a water reducible TSA would have a
    resin composition comprised of MMA/STY/BA/HEMA/AA in a weight
    ratio of 40/20/22/10/ 8 prepared by free radical polymerization in a
    water reducible solvent such as a glycol ether solvent like 2-butoxy
    ethanol with butyl alcohol. To begin the process of making paint, a
    suitable amine is used to neutralize the acrylic acid in the resin backbone
    to provide an acid salt. The amine is used at less than the theoretical
    level of neutralization using for example 2-(dimethyl amino) ethanol
    (DMEA) or 2-Amino-2-methyl-1-propanol (AMP). The next step in the
    paint making process involves the addition of water. Please refer to a
    previous Prospector article concerning waterborne resins:
    https://knowledge.ulprospector.com/3069/pc-fundamentals-waterborne-
    resin-technology/ as well as additional information on viscosity versus
    reduction characteristics of waterborne resins:
    https://knowledge.ulprospector.com/639/flow-leveling-viscosity-control-
    water-born-coatings/.

    Acrylic emulsion polymerization is carried out in water with monomers, a


    water soluble initiator and surfactants. Many of the same monomers are
    used in emulsion polymerization as that in solution polymerization,
    however the properties of the latex can be greatly affected by changes in
    the: polymerization conditions, monomer structure and solubility,
    monomer concentration, surfactant type and level, temperature, initiator
    type and initiator concentration are all variables that can effect the
    emulsion particle size, structure and molecular weight of the final
    polymer. A detailed examination of latex polymerization is a significantly
    large subject and is thus out of scope for this article. Acrylic polymers
    are also used in powder coatings along with acrylate functional acrylic
    resins for radiation cure coatings. The fundamental influence of
    monomer Tg, molecular weight and functional monomers remain the
    same for all the applications described herein.

    In summary it is the goal of this article to provide a heightened


    understanding of acrylic resin technology and its ramifications on paint
    performance characteristics and mechanical properties.

    The views, opinions and technical analyses presented here are those of the
    author or advertiser, and are not necessarily those of UL’s Prospector.com
    or UL LLC. All content is subject to copyright and may not be reproduced
    without prior authorization from UL or the advertiser. While the editors of
    this site may verify the accuracy of its content from time to time, we
    assume no responsibility for errors made by the author, editorial staff or
    any other contributor.

    Filed Under: Paint & Coatings


    About Ron Lewarchik
    Ronald J. Lewarchik, President and CEO of Chemical Dynamics, LLC,
    brings 40 years of paint and coatings industry expertise to his role as a
    contributing author with the Prospector Knowledge Center. As a
    contributing writer, Ron pens articles on topics relevant to formulators in
    the coatings industry. He also serves as a consultant for the Prospector
    materials search engine, advising on issues related to optimization and
    organization materials within the database.

    Copyright © 2021 Prospector Knowledge Center

    Find Ingredients Faster on ULProspector.com

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