Nanoclays are small enough to appear
optically transparent, yet
they have large surface-to-volume and high aspect ratios that can
significantly inhibit water diffusion when incorporated into protective
coatings. Clear coatings, which minimally affect the aesthetics of
metalworks, are commonly applied to outdoor metalworks, such as sculptures,
to prevent and slow corrosion. In recent years, waterborne clear coatings,
rather than solvent-based clear coatings, are increasingly used in
many applications to reduce the quantity of volatile organic components
in the formulation, yet the performance of dry films produced from
waterborne colloidal suspensions is generally poorer. In this work,
we aim to improve the barrier properties of a highly weatherable waterborne
acrylic/polyvinylidene fluoride emulsion by adding a synthetic nanoclay,
Laponite, into the formulation. To improve clay–polymer compatibility,
the clay was covalently modified using an acetoxy or perfluoroalkyl
silane monomer that is reactive with the hydroxyl groups at the edges
of the Laponite platelets. Cation exchange on the clay faces using
phosphorylcholine was conducted to increase the stability in water
and characterized by zeta potential. Resulting changes in barrier
properties of the polymer nanocomposite films were characterized by
gravimetry, colorimetry, and electrochemical impedance spectroscopy.
Surface ablation after accelerated artificial weathering was monitored
by attenuated total internal reflectance Fourier transform infrared
microspectroscopy and Raman microspectroscopy, thin film X-ray diffraction
(TF-XRD) and gloss and thickness
measurements. The composite films showed many improved properties:
reduced water sensitivity and ultraviolet-induced polymer degradation,
which increased the barrier properties and reduced the diffusion constants
over both short- and long-term weathering studies compared with films
without nanoclays. The diffusion constant measured for the highest
performing composite film showed that the performance gap between
relevant water- and solvent-borne coatings used to protect outdoor
metals was narrowed by half.