Effect of nano-sized calcium carbonate on cure kinetics and properties of polyester/epoxy blend powder coatings

Today's strict environmental laws pose significant challenges for coating's formulators to look for eco-friendly products. Powder coatings, particularly polyester/epoxy blends have demonstrated their ability as alternatives to traditional solvent-borne coatings. Recently, the use of nanoparticles such as nano-CaCO₃ (nCaCO₃) has been suggested as a beneficial strategy towards powder coating application with improved properties. Here, we study the effect of nCaCO₃ on morphology, cure behavior, adhesion and hardness of polyester/epoxy systems. The nanoparticles shape, size and dispersion state were investigated through X-ray diffraction (XRD), transmission electron microscopy (TEM) and scanning electron microscopy (SEM) methods. Furthermore, isothermal cure characterization of the neat and filled systems was performed using a torque rheometer. The most important finding based on the rheological studies was the catalytic effect of nCaCO₃ on cure reaction of polyester/epoxy, leading to the shorter curing time. Moreover, the kinetic analyses of rheograms revealed a marked decrease in the activation energy of the cure process upon raising nCaCO₃ content. Interestingly, pull-off adhesion and hardness tests showed that the hardness and adhesion strength were dramatically increased by the addition of nCaCO₃ into the polyester/epoxy system compared to pure blend resin. Therefore, considering the strong competition in powder coating market, the use of nCaCO₃ as a commercial and inexpensive nanofiller is necessary not only to reduce the dwell time which has benefits in terms of the energy consumption and economics, but also to improve the performance of final polyester/epoxy coating.