Paint Resin in Thermoplastics Properties and Applications

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1 Paint Resin in Thermoplastics Properties and Applications Jennifer Lynch EPA Seminar Technology Review and Demonstration of Paint Resin Reclamation Technology for Use in Thermoplastics June 12, 2008

2 Overview Dried solid latex paint was successfully melt blended by extrusion and injection molding methods with : High density polyethylene (HDPE) Paint/HDPE Blends Poly methyl methacrylate (PMMA) Paint/PMMA Blends Mechanical properties in tension were determined for immiscible polymer blends (IMPB) of Paint/HDPE Paint/PMMA For comparison 100 % HDPE 100 % PMMA Immiscibility was determined by DSC

3 Background Problems for consumers (According to the USEPA) Unwanted paint is the largest component of residential household hazardous waste in the country 34 to 136 million gallons of leftover post consumer paint generated each year Cost to manage post consumer paint is estimated at $8.00/gallon! Potential cost of managing recycled paint is between $272 million to over $1 billion dollars each year!

4 Background Problems for paint retailers Primary component of paint retailers waste stream Unused full containers of paint that are returned as mis tints or other retailing errors Much of this paint can be re blended and converted into new paint for use by either government or private entities BUT

5 Re Blended Post Consumer Paint Re blended post consumer paint has not proven cost effective Sort by color and finish, etc Dark colors present a major challenge Inspect the contents (skims, rust, mildew, etc) Strain the paint Market has been slow to develop Reluctance to buy re blended paint Most effective re blender (Metro) runs at a loss and cannot sell all the paint they re blend

6 Post Consumer Latex Paint High volume of waste or unwanted latex paint in the municipal solid waste stream makes it an attractive material to recycle Latex Paint Collected and Recycled (Year) (Million Pounds) * In NJ alone, 15 million cans of latex paint are discarded annually

7 The Fate of Collected Latex Paint Reuse or re blended paint Landfill Latex paint manufactured after the 1980s may be legally disposed of in a dried, solid form Drying waste paint releases only water and fractional amounts of safe, non organic volatiles into the environment Energy intensive Time consuming and weather dependent Hazardous waste landfill If mercury and other contaminants are present Non traditional products!

8 Non Traditional Products Latex Paint Composition Component % Water 59.3 Latex 15.7 Titanium Dioxide Nano Particles 12.5 Pigments 11.4 Ethylene Glycol 1.1 *Polymeric solids are thermoplastic! Why not try and blend post consumer paint with other plastics using traditional polymer processing equipment to make a new useful material for non traditional products?

9 Objective Determine if dried solid latex paint can be Processed using conventional polymer processing equipment Manufactured into something useful Paint is difficult to process when molten due to very high surface energy Difficult to de mold, etc Path forward Melt blend paint with other polymers to solve demolding issues *Sponsored by Benjamin Moore

10 Selected Polymers: HDPE and PMMA HDPE Commodity plastic Inexpensive Plentiful in the post consumer recycling stream Easy to process by most methods PMMA Similar chemical nature with many of the polymers used in latex paints Easy to process Recently has become relatively inexpensive

11 Paint Preparation Collected post consumer paint and separated by gloss content Gloss Flat Poured the paint into baking sheets Dried the paint in an oven at 85 ºC for 24 hour increments until the mass loss reached an asymptotic state Mass (grams) Time (hours) Sample A Sample B

12 Compositions Blended various compositions of the dried, solid latex paint with two types of plastics to form dried Paint/Polymer immiscible blends Flat Paint/HDPE Gloss Paint/HDPE Paint (wt %) HDPE (wt %) Flat Paint/PMMA Gloss Paint/PMMA Paint (wt %) PMMA (wt %)

ºC The ground extrudate was injection molded into tensile

13 Processing Blends were extruded using a Brabender Intelli Torque Plasti Corder Single Screw Extruder at 50 RPM and 180 ºC The ground extrudate was injection molded into tensile specimens using a Negri Bossi V injection molding machine at 205 ºC

14 Experiments Tensile mechanical properties MTS QTest/25 Elite Controller ASTM D 638 Thermal properties TA Instruments Q 1000 DSC in (MDSC mode) under an atmosphere of dry nitrogen Heat Cool Reheat cycle Heating Rate Amplitude Period DSC Conditions 3 ⁰C/min 2 ⁰C 40 seconds

15 Immiscibility: Paint/HDPE Blend Heat Flow (W/g) Paint Tg 14 ⁰C HDPE Tm 130 ⁰C Der Rev Heat Flow (W/(gC)) Temperature (C) 0

16 Immiscibility: Paint/PMMA Blend Heat Flow (W/g) Paint Tg PMMA Tg 104 ⁰C Der Rev Heat Flow (W/(gC)) ⁰C Temperature (C)

Sample Mechanical Properties Young s Modulus Ultimate Strength (MPa) Maximum Measured % Strain Fractured (MPa) 100 % HDPE 720 14.5 20.

0 0/5 30/70 % Flat/HDPE 715 13.7 22.0 0/5 35/65 % Flat/HDPE 615 12.6 14.0 0/5 100 % PMMA 3480 65.0 2.5 5/5 20/80 % Gloss/PMMA 3200 54.8 6.

17 Sample Mechanical Properties Young s Modulus Ultimate Strength (MPa) Maximum Measured % Strain Fractured (MPa) 100 % HDPE /5 20/80 % Gloss/HDPE /5 30/70 % Gloss/HDPE /5 35/65 % Gloss/HDPE /5 20/80 % Flat/HDPE /5 30/70 % Flat/HDPE /5 35/65 % Flat/HDPE /5 100 % PMMA /5 20/80 % Gloss/PMMA /5 30/70 % Gloss/PMMA /5 35/65 % Gloss/PMMA /5 20/80 % Flat/PMMA /5 30/70 % Flat/PMMA /5 35/65 % Flat/PMMA /5

18 Modulus: Paint/HDPE Modulus (GPa) % Paint in HDPE Gloss/HDPE Flat/HDPE

19 Ultimate Strength: Paint/HDPE Ultimate Strength (MPa) % Paint in HDPE Gloss/HDPE Flat/HDPE

20 Stress Strain: Paint/HDPE 20 Stress (MPa) % HDPE 20/80 Gloss/HDPE 20/80 Flat/HDPE 35/65 Gloss/HDPE 35/65 Flat/HDPE % Strain

HDPE Composition: (20% Paint / 80% HDPE) 20 Stress (MPa) 15 10 5 0 Mechanical properties of

21 HDPE Composition: (20% Paint / 80% HDPE) 20 Stress (MPa) Mechanical properties of paint/hdpe are similar to 100 % HDPE 100 % HDPE 20/80 Gloss/HDPE 20/80 Flat/HDPE % Strain

22 Modulus: Paint/PMMA Modulus (GPa) % Paint in PMMA Flat/PMMA Gloss/PMMA

23 Ultimate Strength: Paint/PMMA Ultimate Strength (MPa) % Paint in PMMA Flat/PMMA Gloss/PMMA

24 Stress Strain: Paint/PMMA Stress (MPa) % PMMA 20/80 Gloss/PMMA 20/80 Flat/PMMA 35/65 Gloss/PMMA 35/65 Flat/PMMA % Strain 4 5

much tougher than 100 % PMMA 0 1 2 3 4 5 6 %

25 PMMA Composition (20 % Paint / 80 % PMMA) Stress (MPa) Paint/PMMA blend is much tougher than 100 % PMMA % Strain 100 % PMMA 20/80 Gloss/PMMA 20/80 Flat/PMMA

26 Summary Flat and gloss latex paint Collected Dried into a solid form Successfully melt blended with HDPE and PMMA Injection molded to form immiscible polymer blends Paint/HDPE Paint/PMMA

27 Conclusions Post consumer latex paint materials are potentially useful Can be recycled, re used, and processed as polymer feedstock materials Do not sacrifice the mechanical properties of neat HDPE or neat PMMA Paint/HDPE blends Mechanical properties are similar to HDPE Paint/PMMA blends Stiffness and strength are similar to PMMA Enhanced or higher toughness than PMMA!

28 Applications: Paint/HDPE Direct replacement into current HDPE products Plastic paint containers Recycled plastic lumber Playgrounds Packaging

29 Applications: Paint/PMMA Appliance housings Electronic housings Replacement for current materials ABS PC/ABS blends PP filled fiberglass

30 Thank You Acknowledgements EPA Benjamin Moore Paints RMT Technologies Publications J.K. Lynch, T.J. Nosker, R. Hamill, and R. Lehman, Recycling of Latex Based Paint as Polymer Feedstock Materials ; Proceedings, Society of Plastics Engineers 2006 ANTEC Conference, Charlotte, NC, (2006).

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