Introduction

Lubrizol Performance Coatings has over 40 years of experience manufacturing specialty waterborne polymers to provide customers with creative, cost-effective solutions to the ever changing and challenging functional and environmental requirements in the global marketplace. Lubrizol meets critical performance needs through state-of-the-art emulsion synthesis capabilities, computerized process controls, statistical modeling, and the ability to utilize virtually thousands of monomer combinations.

Applications

Lubrizol acrylic emulsions are used in a wide range of applications. Carbocure™ acrylic emulsions are designed for high performance paper and nonwoven applications. They are ideally suited for applications where high solvent/oil resistance, high tensile strength, excellent water resistance, and high temperature performance are required. The colloidal stabilization system of Carboset® dispersions enable them to meet the needs of applications extending to graphic arts and inks, paints and coatings, and plastic coatings. Carbotac®emulsions are pressure-sensitive polymers that are designed for adhesive use where consistent performance and ease of compoundability are important. Because of their wide range of end-use properties, Hycar® emulsions are frequently used in nonwoven, textile, and paper saturation applications. A number of acrylic emulsion products have been designed for "green" applications, which require products to be free of specific chemicals of health and environmental concern such as formaldehyde and APE surfactants and to provide low residual volatile organic content (VOC). Hycar acrylic emulsions are used in construction applications where indoor air quality is critical.

Physical and Chemical Properties

Carbocure, Carboset, Carbotac, and Hycar acrylic polymers are made in water producing emulsion products that vary both in the composition and concentration of the polymer. The molecular weights of these polymers typically range from 10,000 to 1,000,000 Daltons. Their physical appearance varies from liquids (Carboset and Carbotac and Hycar emulsions) to pastes (Carbocure emulsions). While these acrylic polymers are not volatile, the manufacturing processes are designed to remove or reduce the levels of many unreacted starting materials. Curing of the final coating or film further reduces levels of volatile components.

Health Effects

The health effects of the starting materials that are used to make Carbocure, Carboset, Carbotac, and Hycar acrylic polymers generally have been well-studied, and their hazards are well-known. Once the starting materials are reacted, the polymers are not bioavailable because their molecular weight is too large for them to be absorbed by the body. Some residual components in the acrylic emulsions, however, are acutely toxic if ingested and/or contain monomers or other substances that can cause skin and eye irritation, sensitization and/or chronic heath effects including cancer from repeated exposure. Biocompatability studies on a number of cured products in an end-use form support their safety for use in medical device applications, such as nonwovens for surgical drapes, where skin contact is intended. Many are composed of ingredients that meet the current requirements of the U.S. FDA, the EU Plastics Directive 2002/72/EC and amendments and other food contact regulations when used in accordance with the requirements and limitations of these regulations.

Environmental Effects

The environmental effects of the starting materials that are used to make Carbocure, Carboset, Carbotac, and Hycar acrylic polymers generally have been well-studied and their hazards are well-known. While they are not expected to be absorbed and cause systemic effects in aquatic organisms, high concentrations of the polymers may cause local effects that impact survival. Also, residual starting materials in some acrylic emulsions are toxic to aquatic organisms and may cause long-term adverse effects in the aquatic environment. In general, these polymers are not expected to be readily biodegradable, although some components are biodegradable, and do not display any potential to bioconcentrate.

Regulatory Information

Coatings that contact food are regulated by the specific country health authority. Many countries have lists of ingredients that are acceptable for use in articles that contact food. For coatings and other ingredients that are used in medical devices, the competent authorities rely on the device manufacturers to ensure that safety of their products and to meet all regulatory requirements. In turn, the device manufacturers rely on their suppliers for biocompatability data and other information to support their safety assessments and regulatory submissions. Although Carbocure, Carboset, Carbotac, and Hycar acrylic polymers are not subject to the European Commission REACH (Registration, Evaluation, Authorisation and Restriction of Chemical substances) regulation, certain starting materials must comply in order for these polymers to be sold. The registration and Chemical Safety Reports for these starting substances either have been completed or will be submitted to the European Chemicals Agency (ECHA) by Lubrizol in accordance with the specified reporting deadlines. As noted in Lubrizol safety data sheets, the polymers have gained acceptance in major industrialized countries through global notifications.

Exposure Potential

Carbocure, Carboset, Carbotac, and Hycar acrylic polymer emulsions are sold to customers who use them in a wide range of coating applications. Based on their physical properties and intended uses, human and environmental exposures may occur. The primary potential route of exposure to the polymer for workers is dermal contact with the exception of spraying applications where inhalation may occur. Workers also may be exposed via inhalation and dermal contact to the residual starting materials during manufacture and processing. The potential for consumer exposure to components of the emulsion and adverse reactions is minimal to nil. Processing of the emulsion during the manufacture of the article reduces the level of volatile components and limits their bioavailability.

Risk Management

Information on the safe handling of these products is provided through material safety data sheets to workers who make the acrylic emulsion products and who use them. These documents provide a broad range of safety information including hazard warnings and recommendations on exposure controls. They note that engineering controls are needed to control exposures and specify what personal protective equipment is needed.

During the manufacture of these products, engineering controls and work practices are used to minimize exposure to aerosols, mist, or vapors and liquid. Good industrial hygiene practices, gloves and eye protection are used to avoid skin and eye contact and the irritating effects of these substances. Spill control procedures are used to avoid release to the environment.

Conclusion

Carbocure, Carboset, Carbotac, and Hycar acrylic polymer emulsions provide creative, cost-effective solutions to the ever changing and challenging functional and environmental requirements in the global marketplace. They are designed for use in applications that include paper, textile and nonwovens, graphic arts and inks, paints and coatings, and plastic coatings, pressure senstive polymers and in "green" applications where certain chemicals of concern cannot be present. The health and environmental effects of the starting materials that are used to make Carbocure, Carboset, Carbotac, and Hycar acrylic polymers generally have been well-studied and their hazards are well-known. Once the starting materials are reacted, the polymers are not bioavailable because their molecular weight is too large for them to be absorbed by the body. Some residual components in the acrylic emulsions, however, can cause human and environmental effects. Processing of the emulsion during the manufacture of the article reduces the level of volatile components and limits their bioavailability. Biocompatability studies on a number of cured products in an end-use form support their safety for use in medical device applications, such as nonwovens for surgical drapes, where skin contact is intended. Many are composed of ingredients that meet the current requirements of the U.S. FDA, the EU Plastics Directive 2002/72/EC and amendments and other food contact regulations when used in accordance with the requirements and limitations of these regulations. The use of engineering controls and personal protective equipment and the implementation of spill prevention procedures are key to risk management.

Carbocure™, Carboset®, Carbotac®, and Hycar® Acrylic Emulsions