Coatings from Liquid and Supercritical Carbon Dioxide

This chapter describes several aspects of the use of carbon dioxide as a solvent or cosolvent in coating applications. The primary impetus for using carbon dioxide for this purpose has been the alleviation of volatile emissions and liquid solvent wastes. However, the special physical properties of liquid and supercritical carbon dioxide may offer some processing advantages over conventional organic or aqueous solvents. Liquid carbon dioxide is quite compressible, and a reduction in temperature results not only in a reduction in the operating pressure, but also in a significant increase in the liquid density to values of approximately 0.9 g/cm3. At these high liquid densities, carbon dioxide exhibits improved solvent performance, but with much lower viscosities and interfacial tensions than aqueous or organic liquid solvents. Under supercritical conditions, carbon dioxide also exhibits high densities, low viscosities, and improved solvent power. Low viscosities and interfacial tensions tend to facilitate the transport of the solvents into any crevices or imperfections on the surface to be covered, and this might prove advantageous in the coating of patterned or etched surfaces. Since carbon dioxide dissolves and diffuses easily into many different polymers and organic liquids, it can also be used to reduce the viscosity of coating solutions. Whether in the liquid or the supercritical state, the temperature and pressure of the mixture can be used to control its physical properties in ways that are impossible to achieve with traditional solvents. These distinguishing features have raised the level of industrial interest in carbon dioxide as a solvent for coating applications, beyond those based solely on environmental concerns. In this chapter, we will discuss current applications and research on the use of CO2 as a solvent for coatings. The first section deals with spray coating from supercritical CO2. Subsequent sections deal with the use of liquid coatings, such as spin and free meniscus coatings, and impregnation coatings. Since the start of the 20th century (ca. 1907), atomization has been the basis for conventional spray coating applications (Muirhead, 1974). Typically, atomization is caused by high shear of the coating fluid in air, leading to droplet or particle formation.