Commercial Vehicles

Automotive Refinish

General Industrial Coatings

VOC-compliant 2K PUR Coating

in Low-temperature Cure Metal Applications
VOC-compliant 2K PUR Coatings in
Low-temperature Cure Metal Applications
Commercial Vehicles
Automotive Refinish
General Industrial Coatings
Efficiency
Quality Environment
Since their market introduction around 1960, solventborne, two-
component polyurethane coatings have become increasingly
important in the coatings market for automotive refinish, commer-
cial vehicles and general industrial applications, as is reflected by
increased market share. These coating systems have a wide range
of outstanding properties – from excellent film appearance and
high resistance to water, solvents and chemicals, to excellent
weathering and good scratch resistance. In addition to this high
quality level, they exhibit fast drying and good curing at ambient
temperature or under forced drying conditions (RT to 80° C), thus
perfectly matching the requirements of coatings for general indus-
trial, commercial vehicles and automotive refinish applications.
Whereas in the past maximum performance
and appearance were the main market
requirements, resulting in the development
of solventborne 2K-PUR systems, it is coat-
ings with reduced emissions which are now
increasingly in demand. This is the result of,
on the one hand, more stringent legislation
restricting emissions and residues and, on
the other hand, the heightened environmen-
tal awareness of end users.
In Germany (representative of other industri-
alized countries), the use of solvents has
become by far the greatest source of volatile
organic compounds (VOC) emissions. One
consequence of this is the European VOC
Directive: adopted by the EU Environment
Council in March 1999 and since incorporated
into the national legislation of individual
member states of the European Union, this
2
directive is intended to bring about a 70 %
reduction by the year 2007, based on the
1990 value for emissions of volatile organic
constituents from coatings.
Using high solids, very high solids and
waterborne 2K polyurethane coatings, it is
now possible to satisfy VOC requirements
without having to sacrifice quality. The
secret of the growing success of these
technologies lies in the development of
advanced raw materials, e.g. in the develop-
ment of a new generation of low-viscosity
as well as water-reducible polyisocyanate
hardeners; in the development of improved,
tailor-made polyol resins; and in improve-
ments in application technology.
With respect to 2K PUR waterborne technol-
ogy in particular, a deeper understanding of
the behavior during mixing, pot life, applica-
tion and film formation is a prerequisite for
improving performance. Even at room tem-
perature, aliphatic polyisocyanates react to
some extent with water to form CO2 and
urea groups. However, this reaction is rather
slow – during crosslinking of the film, for
example, it is distinctly slower than the
reaction of the isocyanate groups with the
hydroxy groups of the polyol to form the
polyurethane network. Furthermore, water
leaves the drying film quite quickly, thus
reducing the impact of the NCO water
reaction.
 Polyisocyanate

From a practical point of view, an important difference between

waterborne and solventborne 2K PUR coatings is that it is impossi-
ble to produce a stable, aqueous hardener solution or dispersion
due to the NCO water reaction. In waterborne 2K PUR coatings, the
hardener is therefore provided solvent-free or dissolved in an inert
organic solvent. The polyol is an aqueous, stable dispersion with
an average particle size of usually 50 – 250 nm. To formulate the
waterborne coating, the user not only has to mix but also disperse
the hardener (solution) into the aqueous polyol phase. The ease of
this emulsification step can be influenced by the chemistry of the
two components. in Water in Polyol dispersion

As a consequence, the designs of polyiso- speed). For 2K polyurethane high solids

cyanate hardeners and polyol dispersions
have to be adapted to each other to
restrain the concurrent reaction of iso-
cyanate groups with water, thus promoting
the isocyanate/polyol reaction pathway.
On the other hand, the coordinated synthe-
sis of a suitable polyol/polyisocyanate
combination is also crucial for an effective
emulsification step, resulting in a homoge-
neous distribution of hardener with low par-
ticle size in the polyol dispersion. Having
polyisocyanate crosslinkers as well as poly-
ol dispersions in their product range there-
fore is a clear advantage for a raw material
supplier.
With respect to solventborne low VOC coat-
ings, the challenge is to combine reduced
solvent content with acceptable application
properties (in terms of pot life and drying
coatings, resins have been designed which
exhibit fast drying and excellent appearance
despite the reduced molecular weight nec-
essary to achieve low viscosity. For very
high solids (reactive diluent-based) 2K
polyurethane coatings, the crucial step is to
find the right balance between pot life and
drying to control the application behavior of
the system.
This brochure includes information about raw
materials for waterborne, high solids and
very high solids 2K polyurethane coatings,
as well as some fundamental information on
these technologies. It is structured according
to raw materials chemistry. Please note that
low-viscosity, aliphatic polyisocyanates
(Desmodur® N), described in the waterborne
section, are also recommended for the high
solids and very high solids coatings.

Overview Page

VOC-compliant polyurethane coatings in low temperature cure applications 2

Waterborne 2K polyurethane coatings
Bayhydur® hydrophilic polyisocyanate hardeners 4
Low-viscosity Desmodur® polyisocyanates 8
Bayhydrol® polyol dispersions 12
Emulsification of polyisocyanate hardeners in waterborne 2K PUR coatings 16
Solventborne low-VOC coatings
Desmophen® polyols for high solids 2K polyurethane coatings 20
Reactive diluents for very high solids systems 24
• Product & application guide 28
• Technical service contacts 30

3
Bayhydur® Hydrophilic Polyisocyanate Hardeners
Easy emulsification plus good chemical resistance

Hydrophilic polyisocyanates are favorably used for

waterborne coating applications where low shear
energy for mixing of the polyisocyanate into the polyol
dispersion is required. The degree of hydrophilicity
that is necessary to ensure good film appearance
depends on the polyol as well as on the mixing condi-
tions.

Bayhydur® 3100 is a universal standard hardener for water-

borne 2K PUR coatings for use in a wide
R contains additional NCO funtionality; RI= alkyl variety of applications where easy dis-
persibility is required. The product consists

NCO
of a hydrophilically modified HDI trimer

N
chemically linked to a medium amount of

O O
polyether as nonionic hydrophilic moieties.
Bayhydur® 3100 is characterized by a well-

N N N O CH 2
R
balanced property profile. Using this

H OR'
crosslinker, it is easy to achieve films with
6
O
O
good appearance and resistance properties
without the use of high-shear mixing equip-
ment.

Bayhydur ® VP LS 2319 represents a new generation of

nonionically modified polyisocyanate hard-
R contains additional NCO funtionality; RI= alkyl eners. In this product, the hydrophilic poly-
ether chain is chemically linked by an allo-

R
phanate bond to the HDI polyisocyanate

O N O
trimer structure, resulting in a higher NCO
functionality and molecular weight per mol-

OCN N N
ecule. The benefit is a better dispersibility/
chemical resistance ratio, allowing a reduc-

O 6
OCN
tion in the number of hydrophilic groups

O N O O NH
(➔ better drying/hardness/resistance prop-
erties) while retaining good dispersibility.

N N N O
Bayhydur® VP LS 2319 can be blended with
R OR'
6H
more hydrophobic (e.g. Desmodur® XP 2410
O
O
c.f.p. [9] ) as well as with more hydrophilic
crosslinkers (e.g. Bayhydur® XP 2570 c.f.p.
[5] ) to adjust hydrophilicity according to
the needs of the application.

4
 Bayhydur® XP 2487/1 and Bayhydur® XP 2570
are – in contrast to the aforementioned
I II
R contains additional NCO funtionality; R : R = alkyl crosslinkers – ionically modified HDI
trimers, hydrophilized by amine-neutralized
sulfonate groups. The products are free of

R
polyether segments. With this chemistry, it

O N O R'
is possible to significantly reduce the num-

-
ber of hydrophilic groups compared to

N N N N SO3
polyether modification. As a consequence,

R H X +
waterborne polyurethane coatings contain-

O
6 R''3NH
ing XP 2487/1 or XP 2570 as a crosslinker

O
exhibit faster drying, higher hardness and
better resistance properties. Due to the
higher NCO content, a smaller amount of
crosslinker is needed to achieve the same
crosslinking ratio compared to polyether-
modified, hydrophilic polyisocyanate
crosslinkers.

Whereas XP 2487/1 is comparable in dispersibility to VP LS 2319

(at a lower level of hydrophilicity), the more hydrophilic XP 2570 is
easily hand-mixable in waterborne systems. Thus, this new cross-
linker is perfectly suitable for applications where outstanding film
performance is required, but low-shear mixing is a prerequisite.

5
Property profile of HDI based hydrophilic polyisocyanate hardeners

easy dispersibility

NCO content fast drying

XP 2570
3100
VP LS 2319
good resistance high hardness XP 2487/1

Bayhydur® VP LS 2150 is a non-
ionically hydrophilized crosslinker based on
an IPDI trimer. The product exhibits excel-
lent dispersibility in waterborne systems,
yielding films with high hardness and very
good weather stability. Due to the higher
glass transition temperature of the IPDI
base structure, use of VP LS 2150 signifi-
cantly accelerates physical drying of the
films, especially for low temperature curing
(i.e. ≤ 90° C). On the other hand, chemical
crosslinking of IPDI-based hardeners is
somewhat slower compared to HDI types.
We therefore recommend using VP LS 2150
in a blend with HDI-based hardeners (e.g.
VP LS 2319) in amounts of 20 – 50 wt.% to
improve drying during low temperature cur-
ing. By using such hardener mixtures, films
with excellent appearance and chemical
resistance can be obtained.

6
Product Bayhydur® Bayhydur® Bayhydur® Bayhydur® Bayhydur®
XP 2570 3100 VP LS 2319 XP 2487/1 VP LS 2150/1

Type HDI timer HDI trimer HDI trimer HDI trimer IPDI trimer
hydrophilic hydrophilic allophanate hydrophilic hydrophilic
sulfonate non-ionic hydrophilic sulfonate non-ionic
non-ionic

Supply form 100 100 100 100 70 MPA/X

(% on solids)
Viscosity 3,500 2,800 4,000 6,000 600
(mPas)
NCO-content 20.5 17.4 18.2 20.5 13.4
(% on solids)
Functionality 3.0 3.2 3.8 3.4 3.0

Hydrophilicity
EINES yes yes yes yes yes
TSCA yes no yes yes yes

In addition to these hydrophilically modified
polyisocyanates, low-viscosity, hydrophobic
polyisocyanates can also be used for water-
borne 2K PUR coatings, provided sufficient
mixing of the hardener in the polyol disper-
sion is ensured. The advantages of using non-hydrophilic crosslinkers
are lower water uptake and better chemical and solvent resistance of
the films. Depending on the prevailing mixing conditions, blends of
low-viscosity, hydrophobic crosslinkers with hydrophilically modified
polyisocyanates may also be favorably used.

7
Low-viscosity Desmodur® Polyisocyanates
Crosslinkers for high performance coatings with low VOC

Low-viscosity, hydrophobic polyisocyanate crosslink-

ers can be used to formulate high solids as well as
waterborne 2K PUR coatings. Important for achieving
good film properties at a low VOC level is a combina-
tion of high NCO functionality with low crosslinker vis-
cosity.

Desmodur® N 3300 has been designed to yield two-com-

ponent polyurethane coatings for the high-
R contains additional NCO funtionality est performance requirements and repre-

O
sents the universal standard for solvent-
borne 2K PUR coatings. Due to its chemi-

R NCO
cally stable isocyanurate structure (“sym-

N N
metric HDI trimer”) and its high NCO func-
tionality, the resistance of the films against
chemicals and solvents as well as their

O N O
weather resistance and mechanical resist-
ance are extraordinarily high.

Desmodur® N 3600 is based on cosity is a prerequisite for the dispersibilty

the same ring structure as N 3300, thus
sharing the excellent resistance proper-
ties. Compared to Desmodur® N 3300, the
molecular weight distribution has been
optimized to reduce viscosity as much as
possible (1,200 mPas). A significant reduc-
tion of VOC can thus be achieved by using
this product as a crosslinker in high solids
PUR coatings for automotive and other
high performance applications. Low vis-
of a hydrophobic polyisocyanate in an
aqueous phase. Desmodur® N 3600 can
therefore also be used as hydrophobic
hardener in waterborne 2K PUR coatings
if efficient mixing of hardener into the
polyol dispersion is ensured. For applica-
tions with less efficient mixing equipment,
we recommend a combination of
Desmodur® N 3600 with a hydrophilically
modified polyisocyanate.

8
 Desmodur® XP 2410. The lowest possible viscosity while keeping the NCO func-
tionality above 3 was the development target for Desmodur®
R contains additional NCO funtionality XP 2410. This revolutionary product is based on an iminooxadiazin-
dione ring structure (“asymmetric HDI trimer”), an isomer of the

NCO
symmetric trimer structure. This asymmetric ring structure has the
N
same superior stability but a significantly lower viscosity (~ 700

R
mPas) than the symmetric one. NCO functionality is on the same

N O
high level as for the symmetric trimers, as well. Thus, using
Desmodur® XP 2410 in high solids 2K PUR coatings allows a further

O N O
reduction in VOC without sacrificing the high property profile of the
films. Desmodur® XP 2410 marks a big step forward for waterborne

R
PUR coatings: retaining the good resistance properties of
Desmodur® N 3600, the lower-viscosity, asymmetric trimer is signif-
icantly easier to disperse in waterborne systems, thus yielding
more homogeneous films with better film appearance.

Desmodur® N 3400. Due to its uretdione-based struc-

ture, Desmodur® N 3400 exhibits extremely
R contains additional NCO funtionality low viscosity combined with medium func-

O
tionality. This product is therefore perfectly
suited as a reactive diluent for higher-

R NCO
viscosity polyisocyanate hardeners, e.g.

N N
trimers, to bring down the VOC level of
solventborne 2K PUR coatings. As a com-
ponent of a polyisocyanate mixture for

O
waterborne 2K PUR coatings, it reduces
viscosity, resulting in easier emulsification
of the hardener blend.

In combination with a hydrophilic polyisocyanate, it increases

hydrophobicity (making the film less susceptible to humidity/
water) without having too great an affect on dispersibility.
Desmodur® N 3400 is recommended for use in low-temperature
cure applications (≤ 90° C ), as the stability of the uretdione ring
is limited at higher temperatures.

9
Property profile of HDI-based hydrophobic polyisocyanate hardeners

easy dispersibility (WB)

Low VOC fast drying

(High solids)

N 3300
N 3600
good resistance high hardness XP 2410
N 3400

Desmodur® XP 2565. The IPDI-based Desmodur ®

XP
2565 opens the field of high solids as well
R contains additional NCO funtionality; RI= alkyl as waterborne 2K PUR coatings for IPDI

O
chemistry. Due to its allophanate structure,
it contains less solvent at lower viscosity

R NCO
compared to other IPDI polyisocyanates.

N N
Favorably used as a blending partner for HDI
based polyisocyanates, Desmodur® XP 2565

H
can be used to accelerate physical drying

O O
and increase hardness of the films. As is
generally known, chemical crosslinking of

RI
IPDI-based hardeners is somewhat slower
compared to corresponding HDI products.
Thus, although films are quickly tack free,
at low crosslinking temperatures it takes
longer to reach the final film properties.
On the other hand, the use of XP 2565
extends pot life as a function of the ratio
of IPDI to HDI hardener.

10
Product Desmodur® Desmodur® Desmodur® Desmodur® Desmodur®
N 3300* N 3600 XP 2410 N 3400 XP 2565

Type HDI timer HDI trimer HDI trimer HDI IPDI

symmetrical symmetrical asymmetrical uretdione allophanate

standard low-viscosity low-viscosity

Supply form 100 100 100 100 80 in BA
[% on solids]
Viscosity 3,000 1,200 700 170 2,800
[mPa·s]
NCO-content 21.8 23.0 24.0 21.8 15.0
[% on solids]
Equivalent
weight 193 183 175 180 350
[% on solids]
Functionality 3.5 3.2 3.1 2.5 2.5

Global availability
EINECS yes yes yes yes yes

TSCA yes yes yes yes yes

* VOC > 420 g/l in clearcoats

11
Bayhydrol® Polyol Dispersions
Tailor-made resins for high-performance waterborne
PUR coatings
Under the tradename Bayhydrol®, Bayer offers a range
of hydroxy-functional polyol dispersions suitable as
binders for one- and two-component, waterborne
polyurethane coatings. Secondary dispersions based
on acrylic polymers are well-suited for primers, top-
coats and clearcoats for general industrial as well as
automotive refinishing and commercial vehicles appli-
cations. As a consequence of the polymerization pro-
cedure, the resins have comparatively low molecular
weights and contain chemically incorporated emulsify-
ing groups.
Due to these features, these dispersions are perfect
emulsifiers for polyisocyanate crosslinkers: they
facilitate the emulsification of the polyisocyanates in
the aqueous phase and stabilize them in small
droplets, minimizing the reaction of isocyanate groups
with water. On the other hand, the acrylic backbone –
crosslinked in a polyurethane network – provides the
excellent chemical resistance of the films.

Bayhydrol® A 145 can be considered a standard product
for low-temperature cure, WB 2K PUR coat-
ings. It is a universally useful resin for a
wide variety of applications, from primers
with good metal adhesion to clearcoats
and topcoats for industrial and commer-
cial vehicle applications. The coatings are
characterized by a good balance between
pot life and drying time; the resulting
films have good appearance and exhibit
good water resistance and weatherabili-
ty. Pigment wetting and good adhesion
on different metals are further benefits
of A 145.

Bayhydrol® XP 2469 has been developed for the fomu-
lation of cost-effective waterborne 2K PUR
coatings with good film appearance and
good drying. Due to the lower polyisocya-
nate demand, the films are somewhat soft-
er compared to A 145-based films; never-
theless, the water resistance and solvent
resistance of XP 2469-based films are quite
good. Furthermore, prolonged pot life can
be achieved. Bayhydrol® XP 2469 is there-
fore a resin with a favorable cost/perform-
ance ratio.

12
Bayhydrol® XP 2470 is characterized by a higher OH con-
tent and a higher Tg of the acrylic chains
compared to A 145. Due to its optimized
monomer composition and polymer archi-
tecture, clearcoats and topcoats based on
XP 2470 exhibit greater hardness, faster dry-
ing and significantly improved resistance to
water, solvents and chemicals than the stan-
dard. Film appearance is excellent; using a
suitable crosslinker component, WB 2K PUR
Bayhydrol® XP 2139/2 is a polyester-polyacrylic hybrid
dispersion. Using this hybrid technology,
it is possible to add new properties to the
performance of acrylic resin-based
coatings. An important advantage of
VP LS 2139/2 is the quite low content of
organic solvent (butyl diglycol, 2.5 wt. %
on dispersion), giving users maximum flexi-
bility in their formulations. Coatings based
Bayhydrol® VP LS 2290 is a polyester-polyacrylic
hybrid dispersion with a distinctly higher Tg
than VP LS 2139/2. The resulting films are
hard but not brittle due to the hybrid tech-
nology, and have good adhesion on plastic
clearcoats showing the gloss and haze
values of solventborne 2K PUR systems are
no longer just a dream. Additionally, this
resin has been designed to be a good emul-
sifier for hydrophobic polyisocyanates. By
using low-viscosity, hydrophobic polyiso-
cyanates in combination with a suitable
mixing technology, films with excellent
appearance as well as excellent resistance
properties can be achieved.
on this resin dry somewhat more slowly
than those using the acrylic resins (this
can, of course, be adjusted by the appro-
priate choice of crosslinkers). VP LS 2139/2
is thus favorably used for coating large
vehicles. A higher blister-free film thick-
ness as well as good adhesion, including
on plastic substrates, are some additional
advantages offered by this dispersion.
substrates. Chemical and solvent resistance
of VP LS 2290-based films are above stan-
dard. Additionally, the drying speed of the
films at low temperatures is distinctly higher
than with VP LS 2139/2 or A 145.
13
Product Bayhydrol® Bayhydrol® Bayhydrol® Bayhydrol® Bayhydrol®
VP LS 2139/2 VP LS2290 XP 2469 A 145 (VP LS 2235) XP 2470

Polyester/ Polyester/ Polyacrylate Polyacrylate Polyacrylate

Type Polyacrylate Polyacrylate

Application Topcoat Topcoat, Topcoat, Topcoat, Topcoat,

Clearcoat, Primer Clearcoat, Clearcoat
Primer Primer
Supply form 47 45 45 45 45
[wt.%]
OH-content 3.8 3.8 2.5 3.3 3.9
[wt.% on solids]
Co-solvent Butyl diglycol: Butyl glycol: 8 PnB: 8 Butyl glycol: 4 PnB: 4
[wt.%] 2,5 SN 100: 4 SN 100: 4
Neutralizing DMEA DMEA DMEA DMEA Triethanol
agent amine/DMEA
Viscosity 1,850 1,500 1,500 950 2,000
[mPa·s;
23°C, D=40 s-1]
pH-value ~ 7.4 ~7 ~ 8.4 ~8 ~ 7.8
Acid number 28 29 18 21 24
[on solids]
Avg. part. size 190 180 215 120 180
approx. [nm]
Tg [° C] 6 45 30 28 50

PnB = Propylene glycol-n-butyl ether

SN 100 = Solvent Naphtha 100
DMEA = Dimethylethanole amine

14
Property profile of waterborne 2K PUR coatings based on Bayhydrol® acrylic dispersions

OH-content %

film appearance fast drying

XP 2469
A 145
XP 2470

good resistance high hardness

OH-content %

film appearance fast drying

VP LS 2139/2
A 145
good resistance high hardness VP LS 2290

15
Emulsification of Polyisocyanate Hardeners in
2K PUR Waterborne Coatings:
Hydrophilicity versus shear energy
One key issue of waterborne 2K PUR coatings – proba-
bly the most important one – is the emulsification of
the polyisocyanate hardener into the aqueous system.
A fine dispersion of the polyisocyanate into the polyol
dispersion is essential for perfect coating properties.
Due to the high viscosity and the comparatively hydro-
phobic nature of a standard polyisocyanate (e.g. a
trimer like Desmodur® N 3300), mixing with a stirrer
may result in two separate phases.
Hydrophilic polyisocyanates contain surface-active,
External emulsifier Internal emulsifier
Linked to the polyisocyanate
16
There are two possible ways to
overcome this problem: the use of
low-viscosity ➔ hydrophobic hard-
eners in combination with higher
shear energy applied in the mixing
process, or the use of (internal or
external) emulsifiers with the hard-
ener (➔ hydrophilic hardeners).
Both approaches are possible and
recommended – depending on the
specific application and required
property profile.
hydrophilic groups. This can be achieved by
the use of external emulsifiers, which are
able to migrate through the film. The better
way with respect to film properties is to
chemically link the hydrophilic group to the
polyisocyanate core to minimize the num-
ber of hydrophilic groups. Hydrophilic poly-
isocyanates from Bayer MaterialScience are
synthesized using this internal emulsifica-
tion approach. Highly hydrophilic polyiso-
cyanate hardeners are self-emulsifying;
polyisocyanates with lower numbers of
hydrophilic groups need the assistance of
suitable polyol dispersions to form a stable
dispersion during pot life. It is easy to
understand that properly matching the
polyol and polyisocyanate is crucial for
obtaining a stable, homogeneous, aqueous
coating dispersion with sufficient pot life,
resulting in a homogeneous urethane
network after drying.
 As the main advantage of hydrophilic poly-
isocyanate hardeners is the ease of emulsi-
fication in the aqueous phase, resulting in
a well balanced property profile with low-
shear mixing, low-viscosity, hydrophobic
polyisocyanates yield films with maximum
resistance properties comparable to sol-
ventborne 2K PUR systems.

handmixed handmixed Jet dispersion

Hydrophilic polyisocyanate Hydrophobic polyisocyanate

Bayhydur® Desmodur®

– easy emulsification – better weather resistance

– homogeneous crosslinking – better chemical resistance
– broad range of applications – lower water uptake
– high gloss / transparency – higher hardness
easy to achieve

Hydrophobic hardeners: A somewhat closer look at the

emulsification of a hydrophobic component
in an aqueous medium (oil/water system)
Emulsification Process
reveals that sufficient shear energy is
important for obtaining a stable water-
Pre-emulsion Homogenization borne coating dispersion; but that is not
the whole story. During mixing of the poly-
isocyanate and polyol components, the
hydrophobic polyisocyanate phase is first
broken down into small droplets by the
Oil
shear energy applied. However, this is not
sufficient to produce a stable dispersion.
Water Emulsifier
The newly built surface has to be covered
immediately by a surface-active substance
to prevent recoagulation of the small
droplets. The binder molecules bearing a sufficient number of
hydrophilic groups now occupy the hydrophobic surfaces of the
polyisocyanate droplets and thus keep them in a stable state in
the aqueous phase.
This shell-like barrier around the reactive polyisocyanate prevents
the NCO/water reaction from dominating during pot life. In addi-
tion, some of the polyisocyanate migrates into the polyol droplets,
which triggers the crosslinking reaction, similar to conventional
2K-PUR systems.

17
Particle size distribution by ultracentrifugation This means that in contrast to the solvent-
borne 2K-PUR systems, the polyol in an
aqueous system has the additional function
Low shear of covering and stabilizing this surface, thus
polyisocyanate, polyol ensuring a sufficiently good dispersibility
numbers
hydrophobic of the comparatively hydrophobic polyiso-
5 cyanate in the aqueous binder dispersion.
4
3 emulsion Coarse particle The particle size of the resulting dispersion
2 size distribution should be as fine as possible with a narrow
1 particle size distribution to obtain film
0 diameter
10onm 1 µm 10µm properties such as high transparency or
High shear crosslinking density. Besides the extent of
shear energy, a low viscosity of the hydro-
numbers phobic polyisocyanate also dramatically
5
improves the particle size distribution of
4 the coating dispersion.
3 Coarse particle
2 size distribution
1
0 diameter
10onm 1 µm 10µm

A certain minimum energy is required to

Jet Stream Disperser break up an oil phase to droplets. The high-
er the energy density (shear energy per vol-
ume) of the dispersing device, the finer the
Pressure: 10 – 100 bar
Flow rate: 10 – 2000 ml/min particle size of the resulting emulsions. In a
comparison of various dispersion methods
currently used today with waterborne coat-
ing systems, jet dispersion proved to be the
Polyol dispersion most effective. The principle is simple:
First, the hardener is added to the polyol
Pre-emulsion
dispersion to obtain a relatively coarsely
Nozzle (0,2-0,5mm) disperse pre-emulsion, which is then
Fine dispersion passed under pressure through a nozzle
with a pair of opposed bores. Due to the
sharp drop in pressure within a very small
volume, the energy is used very efficiently,
yielding very fine dispersions. Because the
entire emulsion is forced through the jet
Hydrophobic polyisocyanate
nozzles in a continuous process, particle
size distribution is very narrow. This con-
cept (originally developed for automotive
OEM) is attractive for all industrial
or semi-automatic coating processes, e.g.
when 2K mixing equipment is used.

18
Wet film on glass Electron micrographs of the emulsions con-
firm the suitability of the jet dispersion
technology. If a dynamic mixer is used,
coarse particles of the hydrophobic polyiso-
cyanate up to 10 µm in diameter remain in
the emulsion. In contrast, the use of the jet
disperser results in a homogenous distribu-
tion with an average particle size of approx.
500 nm and a narrow particle size distribu-
tion. Film properties prove that this mixing
quality is adequate: Under these conditions,
low-viscosity, hydrophobic Desmodur® hard-
eners can be used for the formulation of
waterborne, two-component polyurethane
clearcoats with a haze value – for water-
Mixing by Mixing by borne coatings a reliable measure of mixing
jet stream dispersion by stirrer
quality – of less than 20 units, which is
within the range achieved by solvent-based
2K PUR coatings.

2K mixing equipment with/without jet disperser

WB 2K PUR clearcoat; polyol: Bayhydrol® A 145
Haze Desmodur® N 3600 Desmodur ® XP 2410 For comparison:
80% in MBA* 80% in MBA*
150 Bayhydur® solventbome
VP LS 2319 2K PUR coating
(hydrophilic)

100
Stirrer

50 Jet dispersion:

20 bar
20
50 bar
0
* MBA = Methoxybutyl acetate 100 bar

The advantage of these coatings – that their resistance properties

compare favorably to those of their solvent-based counterparts –
is attributable to the use of hydrophobic hardeners. Greater hard-
ness (which can be varied over a wide range by the selection of the
proper polyol) and the lower sensitivity of the films to moisture are
further advantages of these systems.

19
Desmophen® Polyols for High Solids
2K Polyurethane Coatings
How to reduce VOC without changing the technology
Triggered by the VOC legislation in Europe as well as
in other regions of the world (e.g. NAFTA, Japan,
Korea, ...), paint users and paint producers are increas-
ingly shifting their focus to the development of VOC-
reduced coatings. As the required amount of VOC
reduction in a coating differs according to the coating
layers, the applications as well as the countries where
the coating will be applied, different types of VOC-
compliant coatings are needed.

(VOC ≤ 420 g/l) are a valuable option for low temp-

Besides waterborne systems, high solids systems

erature curing applications. The big advantage of the

high solids approach is that the technology is most
similar to the medium solids systems currently used
and requires only minor changes in the application
process compared to other low VOC technologies.

Using our tailor-made, high solids Desmophen® resins

in combination with low-viscosity Desmodur® polyiso-
cyanate crosslinkers, it is possible to significantly
reduce VOC while retaining the high performance level
of the current 2K PUR systems.

Desmophen® A VP LS 2350 has been developed for excellent performance in automotive

high performance clearcoats and topcoats, clearcoats, VP LS 2350 shows the same
in particular for automotive refinishing excellent level of film appearance, weath-
applications. Using this resin in combina- ering, chemical and mechanical resist-
tion with Desmodur® N type crosslinkers, ance, at lower VOC. Drying speed, some-

with VOC levels < 420 g/l. Compared to

it is easy to formulate 2K PUR systems times a drawback of high solids systems,
and reactivity are also comparable to
Desmophen® A 870, which is known for its Desmophen® A 870.

20

Desmophen® A XP 2412 is the perfect synthesis of
high-performance property profile and
faster drying with low VOC. The main differ-
ence versus Desmophen® A VP LS 2350 is a
significantly lower OH content (2.7 wt.% vs.
4.0 wt.%), which opens the application
Desmophen® A XP 2475 is based on a monomer com-
position allowing a synthesis of good per-
formance and competitive resin price. High
solids topcoats based on this resin never-
theless show very good chemical and sol-
vent resistance comparable to Desmophen®
Desmophen® A XP 2474 offers a good solution for cost-
effective 2K PUR high solids topcoats.
Competitive resin price, moderate polyiso-
cyanate demand (OH content 3.0 wt.%)
and fast drying properties make this resin
Using these resins in combination with low-
viscosity Desmodur® N type polyisocyanate
crosslinkers in particular, it is possible to
formulate high solids clearcoats having
VOC levels below 420 g/l and topcoats
below 380 g/l in compliance with the EU
VOC legislation. For other countries with
range to more cost-sensitive applications
where excellent film appearance and out-
standing weathering performance must
also be guaranteed. With a favorable pot
life despite improved drying and good reac-
tivity, this resin offers an opportunity for
more robust high solids coatings with high
property profiles.
A VP LS 2350. UV resistance of the films is
good, but does not reach the top level of
VP LS 2350-based films. On the other hand,
drying speed is comparable, as is the
excellent film appearance.
an attractive choice, especially for industri-
al applications. Due to perfect film appear-
ance and reasonable durability of the films,
Desmophen® A XP 2474 offers an excellent
price/performance ratio at a low VOC level.
®
different VOC limits, Desmophen A 870
may also be used to formulate high solids
coatings with an excellent property profile.
21
 Desmophen® Desmophen® Desmophen® Desmophen® Desmophen®
A 870* A VP LS 2350 A XP 2412 A XP 2475 A XP 2474

Structure Polyacrylate Polyacrylate Polyacrylate Polyacrylate Polyacrylate

Application Automotive Automotive Automotive Transportation Gen. Industrial

refinishing refinishing refinishing Gen. Industrial
Automot. OEM Transportation Transportation
Transportation Gen. Industrial
Supply form 70 70 75 75 75
[wt.%]
Solvent Butyl acetate Butyl acetate Butyl acetate Butyl acetate Butyl acetate
OH-content 4.3 4.0 2.7 4.1 3.1
[wt.% on solids]
Viscosity 3,500 1,200 5,000 6,000 5,000
[mPas;
23°C, D=40 s-1]
Acid number ~11 ~ 11 ~ 11 ~ 17 ~ 11
[on solids]
Color value < 50 < 50 < 100 < 100 < 70
[APHA]

* VOC > 420g/l in clearcoats

22
Desmophen® Polyols for High-Solids 2K PUR Coatings

Weathering

LS 2350

XP 24 12 A 870

XP 2474 XP 2475

Size of bubbles: OH content

Chemical/Solvent Resistance

For high solids resins in particular, it might be necessary to fur-

ther improve the drying properties. In this case, we recommend
replacing 10-30 % of the HDI-based crosslinker with an IPDI-based
one, e.g. Desmodur® XP 2565.

(≤ 250 g/l), reactive diluents (e.g. aspartic

For considerably lower VOC-levels

esters, aldimines, ketimines) and water-

borne systems are possible solutions.

23
Reactive Diluents for Very High Solids Systems
(≤ 250 g/l VOC)

Amine functional reactive diluents can be used to

formulate high and very high solids 2K PUR coatings
with an outstanding fast curing speed.

The implementation of the new European

H3 C NH2
H3 C
VOC legislation opens the door for the vari-
Aldimine + ous raw materials of this technology into
H3 C
NH2 Ketimine the focus of current coating developments.
O O CH 3
2 IPDA 2
With the market introduction of ketimines
CH3
H 3C CH 3 like Desmophen® VP LS 2965 and aldimines
H3C CH3 - 2 H2 O
CH 3
- 2 H 2O
CH3 like Desmophen® VP LS 2142, raw materials
H3 C N H 3C N CH 3
H3C H3C CH 3
are now available which react with poly-
isocyanates during spray application, either
H3C H 3C CH 3
N N CH 3 by means of hydrolytic cleavage to the
CH3
Desmophen® Desmophen®
CH 3
respective amines (caused by humidity)
H3 C
VP LS 2142 VP LS 2965
or directly without deblocking.

A detailed analysis of the reaction mecha- 1) Reaction via hydrolysis

nisms of aldimines and ketimines with CH 3

H 3C N CH 3 H 3C NH 2
O CH 3
isocyanates shows that the hydrolysis
H3 C R + 2 H 2O H3C
route plays a minor role for the ketimines + 2 R CH 3
H 3C R - 2 H 2O H3 C
(~ 25%) and can be largely neglected
N CH 3 NH 2
for the aldimines (< 5%).
CH 3 IPDA

Crosslinking with
Despite this, moisture acts as a catalyst 2) Reaction via imine-enamine tautomerism
polyisocyanate
CH3 CH 3
for the alternative reaction mechanism via
the tautomeric enamine. Therefore the H
H 3C N CH3 H 3C N CH 3
curing speed of such systems is a function H3C R catalyst H 3C R

H 3C R H3C R
of humidity. Drying at higher temperatures
(e.g. 60 °C) is slow because the water N CH3 N CH3
H
evaporates quickly and can no longer act CH 3 CH 3
as a catalyst.

24
 In combination with polyols, the impact of humidity on curing
speed is distinctly reduced and curing at 60 °C is also possible. In
this case, the acid groups of the polyol catalyze the curing reaction
with the polyisocyanate hardener. As the color value of such com-
binations increases significantly during storage for even a few
days, such aldimine or ketimine/polyol combinations are not suit-
able for two-component clearcoats. In contrast, primers and
surfacers with a VOC value of less than 250 g/l can be formulated.

OEt
OEt 500
Set to touch [min]

400
465
300
195 210
200 105
7°C Very High Solid
OEt
100 Polyaspartate System
60 15 45 45 35°C e
ur
0 rat
40% 90% 40% 90% pe Medium Solid
m
Te 2K PUR System
Relative Humidity

Polyaspartic ester

Another possible raw material class O O

for very high solids coatings are the H 2N X NH2
polyaspartic esters, which can be EtO OEt
described as sterically hindered, EtO OEt 500
electron-deficient, secondary aliphatic
400
amines. Polyaspartic esters do not O O 465

contain any deblocking agent, are 300

O.... H H. . . . O
odor-free, have a low color value, and 200 105
show good compatibility with other EtO N X N OEt
100
resins. 60 15
0
OEt 40% 90%
EtO
O O

25
By varying the spacer group X, structures of very different reactivity
are possible. Sterically very demanding, substituted cycloaliphatic
bridges lead to medium reactive products (Desmophen® NH 1521/
VP LS 2973), whereas an unsubstituted cycloaliphatic spacer group
leads to higher reactivity (Desmophen® NH 1420).

X= CH2 CH2
H3C CH3

Viscosity ~ 1,200 mPas ~ 1,500 mPas < 100 mPas

Desmophen® NH 1520 NH 1420 NH 1220

NH 1521 (VP LS 2973)
(90% in BA)

Type: medium reactive reactive extremely reactive

^
^

Pot life: 24 h ~ 3h 5 min

1:1 combinations: ~ 6h ~ 30 min

Polyaspartic esters based on linear aliphatic
bridges are extremely reactive
(Desmophen® NH 1220), but reactivity can
easily be adjusted by blending with the less
reactive types. The reaction of the polyas-
partic esters with polyisocyanates can also
be catalyzed by water. This means that reac-
tivity is not only a function of temperature
but also of atmospheric humidity and the
moisture content of other raw materials,
e.g. pigments or extenders. Therefore the
pot life of such systems can be extended by
the use of moisture scavengers, e.g. molec-
ular sieves.
On the other hand, the reactivity of polyaspartic esters can be
increased by the use of catalysts other than water. As with the
aldimines and ketimines, acids as well as acid-containing polyols
accelerate the crosslinking reaction in a 2K system cured with a
polyisocyanate. Thus curing at 60 °C becomes possible. As is
the case with aldimines and ketimines, combinations of polyaspar-
tic esters with polyols lead to a significant increase in color value
during storage. Therefore they cannot be used to formulate 2K
clearcoats or color-sensitive topcoats, whereas 250 g/l VOC
primers, fillers, surfacers or less color-sensitive topcoats can be
obtained. It is possible, however, to formulate 3K systems
where the polyaspartic ester is added as a diluent to the polyol
component shortly before application.

26
As an alternative to aspartate/polyol combinations, blends of
polyaspartic esters with an aldimine can be used for 2K clearcoats
and topcoats. Such mixtures are color-stable during storage and
can be adjusted in reactivity by the choice of the polyaspartic ester.
Combinations of the aldimine Desmophen® VP LS 2142 with the
medium reactive Desmophen® NH 1521 (VP LS 2973*) result in a
2K system with a pot life of approximately three hours, whereas
the pot life of a combination of VP LS 2142 with the more reactive
Desmophen® NH 1420 is about one hour, with significantly faster
drying speed.

Reactive diluents product overview:

Type Supply Viscosity at Equivalent Reactivity

form [%] 23°C [mPas] weight
Desmophen® Aldimine 100 ~25 139 ++
VP LS 2142
Desmophen® Ketimine 100 ~80 167 ++(+)
VP LS 2965
Desmophen® Polyaspartate 90 in BA ~150 326 +
NH 1521
(VP LS 2973*)
Desmophen® Polyaspartate 100 ~1,200** 290 +
NH 1520
Desmophen® Polyaspartate 100 ~1,500** 279 ++
NH 1420
Desmophen® Polyaspartate 100 < 100** 230 ++++
NH 1220
*: current product code in Europe
**: viscosity at 25° C [mPas]

27
Product & Application Guide

Polyol Resins

Product Type Application Clearcoat Topcoat Primer Special

Surfacer properties
Bayhydrol® OH functional polyester- waterborne blister-free
VPLS 2139/2 acrylic hybrid dispersion film thickness

Bayhydrol® OH functional polyester- waterborne Fast drying

VP LS 2290 acrylic hybrid dispersion

Bayhydrol® OH functional acrylic waterborne Cost effective

XP 2469 dispersion

Bayhydrol® OH functional acrylic waterborne Standard, uni-

A 145 dispersion versally useful

Bayhydrol® OH functional acrylic waterborne High quality

XP 2470 dispersion

Desmophen® A OH functional acrylic solventborne Standard for

870 resin medium solids

Desmophen® A OH functional acrylic solventborne High quality

VP LS 2350 resin high solids (autom. refinish)

Desmophen® A OH functional acrylic solventborne Low OH content

XP 2412 resin high solids good weathering

Desmophen® A OH functional acrylic solventborne Cost effective

XP 2474 resin high solids

Desmophen® A OH functional acrylic solventborne High quality

XP 2475 resin high solids (industrial)

28
Reactive Diluents
(•: recommended use in combination with):
NH 1520/
NH 1521
Desmophen® VP LS 2142 VP LS 2965 (VP LS 2973) NH 1420 NH 1220 Polyol
Full solid systems
e.g. putties
250 g/l primer Polyester*
250 g/l filler
250 g/l clearcoat
250 g/l topcoat
2K, color sensitive
Topcoat, 3K or Poly-
less color sensitive acrylate°
*: e.g. Desmophen® 1150 °:e.g. Desmophen® A VP LS 2350, Desmophen® A XP 2474

Polyisocyanate Crosslinkers

Product Type Application Clearcoat Topcoat Primer Special

Surfacer properties
Bayhydur® hydrophilically modified waterborne Excellent
XP 2570 HDI polyisocyanate dispersibility
Bayhydur® hydrophilically modified waterborne Standard, uni-
3100 HDI polyisocyanate versally useful
Bayhydur® hydrophilically modified waterborne High NCO-
VP LS 2319 HDI polyisocyanate functionality
Bayhydur® hydrophilically modified waterborne Fast drying &
XP 2487/1 HDI polyisocyanate good resistance
Bayhydur® hydrophilically modified waterborne * * * Hard & very
VP LS 2150/1 IPDI polyisocyanate fast drying

Desmodur® HDI polyisocyanate solventborne Standard for

N 3300 medium solids
Desmodur® low-viscosity high solids / Low viscosity &
N 3600 HDI polyisocyanate waterborne high functionality
Desmodur® low-viscosity high solids / Low viscosity &
XP 2410 HDI polyisocyanate waterborne high functionality
Desmodur® low-viscosity high solids / * * * Very low
N 3400 HDI polyisocyanate waterborne viscosity
Desmodur® low-viscosity high solids / * * * Low viscous
XP 2565 IPDI polyisocyanate waterborne IPDI type

*: in combination with other hardeners

29
Technical Service contacts:

Europe:
Commercial Vehicles:

Martin Melchiors Sandra Hackbarth Jürgen Lippemeier

Tel: +49(0)214-30 52435 Tel: +49(0)214-30 22584 Tel: +49(0)214-30 28358
Fax: +49(0)214-30 58526 Fax: +49(0)214-30 58526 Fax: +49(0)214-30 58526
mail: martin.melchiors@ mail: sandra.hackbarth@ mail: juergen.lippemeier@
bayerbms.com bayerbms.com bayerbms.com

Automotive Refinish

Reinhard Hertrampf Michael Ehlers

Tel: +49(0)214-30 55578 Tel: +49(0)214-30 56473
Fax: +49(0)214-30 58526 Fax: +49(0)214-30 58526
mail: reinhard.hertrampf@ mail: michael.ehlers@
bayerbms.com bayerbms.com

General Industrial:

Ulrich Freudenberg Robert Reyer

Tel: +49(0)214-30 71983 Tel: +49(0)214-30 42363
Fax: +49(0)214-30 58526 Fax: +49(0)214-30 58526
mail: ulrich.freudenberg@ mail: robert.reyer@
bayerbms.com bayerbms.com

NAFTA:

Scott Grace Dave Zielinski

Tel: +1-412-777-7657 Tel: +1-412-777-7652
Fax: +1-412-777-7682 Fax: +1-412-777-7682
mail: scott.grace@ mail: david.zielinski@
bayermaterialscience.com bayermaterialscience.com

Asia-Pacific:

Osamu Kirihara Sharon Feng

Tel: +86-21-53594888 ext. 2910 Tel: +86-21-53594888 ext. 2949
Fax: +86-21-53594888 ext. 3910 Fax: +86-21-53594888 ext. 3949
mail: osamu.kirihara@ mail: sharon.feng@
bayermaterialscience.com bayermaterialscience.com

30
 For more information
on two component
polyurethane coating
raw materials also see:

or visit us at our website: www.bayercoatings.com

www.bayercoatings.com
Bayer MaterialScience AG
Coatings, Adhesives and Sealants
51368 Leverkusen
Germany
www.bayermaterialscience.com
info@bayercoatings.com
This information and our technical advice – whether verbal,
in writing or by way of trials – are given in good faith but
without warranty, and this also applies where proprietary
rights of third parties are involved. Our advice does not
release you from the obligation to verify the information
currently provided – especially that contained in our safety
data and technical information sheets – and to test our
products as to their suitability for the intended processes
and uses. The application, use and processing of our pro-
ducts and the products manufactured by you on the
basis of our technical advice are beyond our control and,
therefore, entirely your own responsibility. Our products are
sold in accordance with the current version of our General
Conditions of Sale and Delivery.
Edition: 09-2005 Order no.: MS 005526
Printed in Germany · E