UV curing…

More than a Solventless Technology

UV curing opens the door to significant savings by delivering:
• Shorter production times
• Improved product quality
• Lower energy costs
• Lower capital costs versus thermal cure
• Lower maintenance costs
• Lower labor costs
• Shorter startup time
• Equipment space savings
• Environmental responsibility
Initially, environmental responsibility was the main attraction: a solventless
technology that greatly reduced VOC emissions. Today the focus is on
performance and economy. In the following pages, we describe UV curing—
what it is and how it works—and the many benefits it offers. We’ll also deal
with the special features and performance of UV cationic cycloaliphatic
epoxide systems that provide further enhancements. And, finally, there is a
complete guide to formulating with these materials.
Contents

UV-Cure Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
The UV-Curing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
UV Chemistries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Benefits of UV Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Advantages of CYRACURE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Formulation Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cationic UV Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Rigid Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Flexible Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Laminating Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CYRACURE Cycloaliphatic Epoxide Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Chemical Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Typical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Formulating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
UV Light Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
General Formulating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Modifying Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
General-Purpose Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Starting Point Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Test Formulations for Tin-Free Steel and Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Overprint Varnishes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Base Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Barrier Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Flexo Inks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Laminating Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Electronic Encapsulant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Reactive Diluent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Product Stewardship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Note: Throughout this booklet reference is made to two photoinitiators, UVI-6992 and UVI-6976. While
they are chemically the same as UVI-6990 and UVI-6974, respectively, they are produced by a slightly
different and lower-cost process. This lower-cost process allows lower pricing on UVI-6992 and UVI-6976
than UVI-6990 and UVI-6974, respectively. Contact your Dow Sales Representative for pricing information.
UVI-6990 and UVI-6974 remain commercially available.
1
 UV-Cure Technology
Ultraviolet light (UV) curing represents a
major advance in the development of the
polymers, coatings and inks industries. Years
ago, coating and ink technology was limited to
air-dry ambient-cure systems. The advent of
baked systems using lacquers and thermoset
resins greatly enhanced the performance and
cost effectiveness of coatings and inks.
The UV-Curing Process
In UV curing, high-intensity ultraviolet
light, rather than thermal energy, is used to
cure the resin in the coating or ink. Because
cure is accomplished almost instantaneously,
the equipment used is smaller, less expensive,
and requires less space than the ovens used in
thermal cure systems.
The resins themselves are different from
those used in thermal systems, containing
virtually no solvents, but still formulated to be
compatible with widely practiced application
methods such as spray, roll coat, litho, screen,
flexo, and even gravure. A wide range of film
thicknesses can be applied — down to a few
microns.
The coatings are formulated with special
oligomers, monomers and resins and contain
photoinitiators. These materials are responsive
to UV light, which initiates the crosslinking of
the coating or ink. Many of the other formulat-
ing tools that are available to the coating or ink
chemist are used in UV curing.
2
The UV-curing process provides another
means of crosslinking and hence another level
of improvement in this progression. UV was
once viewed only as a low-VOC solution to air
pollution problems. Today, thousands of end
users have proven that UV curing offers far
more than VOC elimination.
All sorts of substrates are coated and
printed via UV curing. These include metal,
paper, glass, wood and numerous plastic
substrates. Systems can be formulated to meet
a wide and ever-expanding range of end-use
requirements.
UV curing is quick because thermal
activity is not critical. There are no solvents
or water to be evaporated or disposed of, and
there is no heating of the coating or substrate
to effect cure. UV light simply passes into the
coating and it cures. And UV light is inherently
more efficient at delivering energy to a surface
than hot air convection.
While this booklet will make frequent
references to coatings and inks (sometimes
interchangeably), the UV-curing process
can also be used for other technologies
requiring thermoset resin systems such as stereo
lithography.
UV Chemistries
In addition to process and equipment
advantages, an important contributor to the
success and growth of UV curing is the range
of performance requirements that can be met.
This application’s latitude comes from the
chemistries used, which are characterized by
the crosslinking method employed.
The products featured in this booklet cure
cationically, wherein the photoinitiator gener-
ates a proton on exposure to UV light. This
cation causes cycloaliphatic epoxide molecules
to crosslink quickly with each other, with
hydroxyl compounds and with vinyl ether com-
pounds. Cationically cured UV systems are
usually formulated with members of these
classes of compounds.
Benefits of UV Curing
Formulation Advantages
of UV Cure
UV-curing formulations provide the
following benefits:
• Fast cure response
• Good chemical resistance
• Excellent gloss
• Good color stability
• Good weathering characteristics
• Broad formulating latitude
An alternative, and somewhat older,
UV technology is referred to as “free radical
polymerization.” A chemical species known
as a free radical is generated and initiates the
crosslinking of acrylate compounds, unsaturated
polyesters and styrene or others.
Either crosslinking method involves certain
characteristics that affect the performance and
utility of the coating. Additionally, the specific
materials used to formulate the coating or ink
will affect its performance. A consequence of
this latitude is that UV systems can be formulated
to meet a variety of requirements including
viscosity, hardness and flexibility.
Low VOC
Because UV coatings contain no solvents,
they release virtually zero VOC. Although
photoinitiators may have some solvent and the
formulations do contain some volatiles, weight
loss of the applied film upon cure is usually in
the 1-3% range versus 70% and higher for low
solids and even waterborne systems.
Low VOC is certainly the most talked
about aspect of UV curing but not always
the most important. Product performance and
cost effectiveness are usually what leads to
the decision to use UV. Low VOC is only one
of a number of advantages that fabricators and
converters discover upon a serious analysis
of UV curing.
3
 Formaldehyde- and HAPS-Free
Some coating systems use Hazardous Air
Pollutants (HAPS) as solvents or generate
formaldehyde upon cure. These compounds
are receiving more attention and regulation for
their impact on the environment. UV systems
generate no formaldehyde or Hazardous Air
Pollutants. As with VOC, this is an important
feature, but just one of many.
Low Energy Consumption
Because UV is more efficient than
convection, the energy used in curing is
reduced relative to baked systems. The amount
of electrical energy consumed by the lamps
in UV ovens is often the same as that used for
blowers and other electrical devices on gas-fired
ovens, leaving the cost of gas as the savings.
Instant Cure
The nature of the process and the
materials permit cure to occur very rapidly.
In most manufacturing processes, line speed
is important. UV users suffer no efficiency
loss and frequently increase productivity.
Pot Life
Because the coatings and inks do not
contain volatiles, evaporation of the coating
on the equipment does not occur. This provides
increased stability on the press and simplifies
cleanup of the equipment at shutdown. The
net result is less waste and reduced downtime
for flexo printing.

Low Capital and Operating Costs

The high energy efficiency of UV translates
to smaller equipment, requiring less floor space
and lower operating costs. Many UV users
report lower maintenance expense as well. In
some installations, UV is used with baked
processes to effect an inexpensive expansion of
coating capacity, while staying under permitted
VOC requirements.
Total operating costs are also favorable
for UV. However, the cost components differ.
Partly offsetting lower energy and capital costs
are the higher costs of UV raw materials, which
contain no inexpensive water or solvent. Even
the “applied solids” raw materials cost will likely
be higher than baked coating. Nevertheless,
total coating cost is usually lower.

4
Advantages of CYRACURE Products
The coatings and inks industries have a
proven track record of developing and modify-
ing various resins, solvents and other materials
to be formulated into products that meet the
needs of their customers’ industries. Differing
resin systems are available for all types of coat-
ings technologies, and several of these have
been modified for use in acrylate-based UV
systems. Formulation work frequently involves
combining several materials to balance the
end-use performance with needed processing
characteristics.
The outstanding performance of
TM
CYRACURE cycloaliphatic epoxide resins
makes them suitable for a variety of end uses
otherwise served by many resins. Their low
viscosity gives the formulator broad latitude in
meeting end-use processing needs. This combi-
nation of end-use properties and formulating
latitude makes CYRACURE resins and diluents
important contributors to the advancement of
UV-curable coatings and inks technology.
Many acrylate UV oligomers have a high
viscosity. Coatings manufacturers deal with
this by diluting the oligomers with acrylate
monomers to reach application viscosities.
Another approach is to heat the formulated
coating prior to application. CYRACURE
UVR-6110 resin can be used by itself or in
combination with numerous modifiers to
achieve desired results.
When combined with an onium salt
photoinitiator and cured alone, CYRACURE
UVR-6110 resin yields clear, glossy coatings
that are hard and somewhat brittle. Although
such coatings have merit in certain applications,
many uses require a certain degree of coating
flexibility. For this reason, CYRACURE UVR-
TM
6110 resin is designed for use with TONE 0301,
0305 and 0310 polyols. When a specific lower
system viscosity is required for certain applica-
tion characteristics, CYRACURE diluents are
available. Combining these products with
CYRACURE UVR-6110 resin provides good
control over viscosity and flexibility.
Alcohols, glycols and glycol ethers can
also be used as additives to UV-cure systems
based on CYRACURE resins to decrease
viscosity and improve flexibility.

Formulation Advantages
Formulations based on CYRACURE
resins and diluents provide the following
specific benefits:
• Very low shrinkage
• Excellent adhesion to a wide variety
of substrates
• Cure is not inhibited by oxygen
• Low potential for skin and eye irritation
or sensitization
• Excellent combinations of hardness
and flexibility
• Ease of handling — all products are
low-viscosity liquids and readily
miscible with each other
• Excellent electrical properties
• Enhanced barrier properties
5
 Cationic UV Cure
The excellent performance of the UV-curing process is further enhanced by the use of cationic
systems based on cycloaliphatic epoxides:

Features Benefits
Low Shrinkage (3-5%) Adhesion, Gloss, Retortable, Pasteurizable
Cycloaliphatic Backbone Toughness, Formable, Abrasion Resistance
Low Viscosity Low VOC
Low Odor Good Work Environment
Low Draize Scores Good Work Environment
Stable Resins & Photoinitiators One-Pack Stability
Cycloaliphatic Epoxide Fast Cure

Cycloaliphatic epoxides rapidly polymerize

in the presence of strong cationic initiators.
Stable onium salt photoinitiators that undergo
photolysis in the presence of ultraviolet light
to form a highly efficient cationic species have
been developed. These photoinitiators can
be combined with cycloaliphatic epoxides to
provide coatings systems that are storage-stable
until activated with UV light. Systems containing
these photoinitiators have been shown to be
stable for more than two years when not exposed
to ultraviolet light.

6
Applications
UV-cured coating systems based on
CYRACURE cycloaliphatic epoxide are useful
in a variety of applications, including:
• Can-End Varnishes
• Cap and Closure Varnishes
• White Base Coat
• Aerosol Can Coatings
• Can Coatings
• General Line Coatings
• Paper Coatings
• Coatings and Inks for Polyethylene,
Oriented Polypropylene, Polyester,
Polyvinylchloride, Polystyrene
• Plastic Tube Varnishes
• Flexo Inks
• Stereolithography
• Ink Jet Inks
• Screen Inks
• Laminating Adhesives
• DVD Adhesives
• Electrical/Electronic Coatings
and Sealants
Rigid Packaging
Cationic, UV-curable formulations contain-
ing CYRACURE cycloaliphatic epoxides and
TONE caprolactone polyols yield superior
overprint varnishes (OPVs) on aluminum and
steel substrates for rigid packaging. Retortable
and pasteurizable, the cured films exhibit
noteworthy adhesion, flexibility and protective
properties. These coating systems are particular-
ly valuable where higher production rates and
lower VOCs are required.
When cured and processed at conditions
used during the production of two- and
three-piece steel food cans and two-piece
aluminum beer and beverage cans, these
UV-curable cationic overprint varnishes offer
a number of advantages to formulators and
end-users:
Coating Formulations
• Low viscosity
• Fast-cure
• Little or no odor
• Low VOC
• Low irritation potential
Cured Films
• Excellent flexibility
• Highly resistant to blistering and blush
• Odorless after UV cure
• Glossy and hard
• Excellent abrasion resistance
• Resistant to chemicals
• Retortable on steel food can ends
• Pasteurizable on aluminum beer and
beverage can ends and bodies
• Low migration
Flexible Packaging
UV-curable cationics currently find use as
overprint varnishes on plastic tubes, films,
paper, and flexo inks. They are also beginning
to win acceptance in laminating adhesives and
wide-web flexographic printing. Cationic lami-
nating adhesives can be specially formulated for
UV curing before nipping for adhering opaque
substrates.
These systems offer a particularly
important advantage to flexible packaging: the
ability to adhere to a wide variety of substrates.
Coatings can be formulated to provide excellent
adhesion to PET (Mylar and Melinex films),
OPP and PE, HDPE and PP, polystyrene and
PVC. Printers also benefit from the high cure
rate that speeds up production. CYRACURE
UVR-6105 resin and UVR-6000 diluent are
particularly well-suited to flexible packaging
applications since they are low odor, low
viscosity and fast curing.
7
 Coating, Ink and Laminating Laminating Adhesives
Adhesive Formulations
Cationic UV cure of epoxides results in
• Stable
low shrinkage and good adhesion to plastics.
• Low viscosity Exposing a cationic adhesive to UV light
• Fast-cure causes the photoinitiator to release an acid that
• Little or no odor catalyzes epoxide polymerization. The acid
• Low VOC remains active after UV curing, which allows
• Universal adhesion cure to continue after UV exposure; this is
referred to as “dark cure”. The dark-cure property
• Low irritation potential
can be used to UV-cure cationic adhesives just
before nipping the laminate; the adhesive prop-
Cured Coatings, Inks and erties develop after laminating. An advantage is
Laminating Adhesives that UV-opaque substrates, such as polyester,
• Excellent adhesion to polymer films metallized film and foil, can be laminated using
• Excellent flexibility the dark-cure property. Adding a polyurethane
• Odorless after UV cure resin or polyether polyol to a cationic UV
• Glossy and hard adhesive increases the tack and slightly retards
• Excellent abrasion resistance the cure, which in turn increases the adhesive
“open time,” allowing more latitude in the time
• Resistant to chemicals
between curing and laminating. Cationic UV
laminating adhesives that are cured before
Advantages of UV Flexo nipping have peel strength values as high as
• Improved dot gain 1.3 lb/in. within 30 minutes after UV curing
• Less press down time and 2.5 lb/in. 24 hours later.
• Stable inks will not dry on press
• Low VOC Advantages of Cationic
UV Laminating Adhesives
Advantages of Cationic UV Flexo Inks • Adhere to a wide variety of plastic films
• Universality, adhere to a wide variety • Excellent adhesive strength
of plastic films • Can be cured before nipping which
• Low odor allows opaque substrates to be
• Low migration laminated using UV
• Fast cure
• Product can be processed shortly
after laminating
• Low-viscosity formulations can
be applied near room temperature
• Low VOC
• Low odor
• Contain no isocyanates
• Low-cost processing equipment

8
CYRACURE Cycloaliphatic Epoxide Products
Dow offers a complete line of products for
use in formulating UV-curable cycloaliphatic
epoxide coatings systems: CYRACURE resins,
diluents, and photoinitiators. TONE
capralactone polyols are useful modifiers. By
adjusting the proportions of these ingredients in
the formulation, systems can be created with
properties to satisfy a wide range of end-use
applications.

CYRACURE
Products Description Function
Resins
UVR-6105 Distilled base epoxide resin Contributes primary film properties
UVR-6107 Low-viscosity base epoxide resin Contributes primary film properties
UVR-6110 Base epoxide resin Contributes primary film properties
UVR-6128 Flexible epoxide resin Contributes primary film properties
Diluents
UVR-6000 Oxetane diluent Viscosity reducer
UVR-6100 Cycloaliphatic epoxide diluent Viscosity reducer
UVR-6216 Linear aliphatic diluent Viscosity reducer
Photoinitiators
UVI-6976 Arylsulfonium salts For fastest cure speeds and/or thick or
pigmented films
UVI-6992 Arylsulfonium salts For most thin film (<1 mil) applications

TONE Polyols
0200 Series Difunctional Flexibilizer
0300 Series Trifunctional Flexibilizer, crosslinker

9
 Chemical Structures
CYRACURE Resins

UVR-6105, UVR-6107 and UVR-6110 UVR-6128

O O
O
O O O O
O
O
O
3,4-Epoxycyclohexylmethyl- Bis-(3,4-epoxycyclohexylmethyl) Adipate
3,4-epoxycyclohexane Carboxylate

CYRACURE Photoinitiators

UVI-6976 UVI-6992

SbF6- + S S PF6- + S S

SbF6- + S S S + SbF6- PF6- + S S S + PF6-

Mixed Arylsulfonium Hexafluoroantimonate Salts Mixed Arylsulfonium Hexafluorophosphate Salts

10
Typical Properties
Table 1 • Typical Properties of CYRACURE Resins†
Product UVR-6105 UVR-6107 UVR-6110 UVR-6128
Chemical Name 3,4-Epoxycyclohexylmethyl- Bis-(3,4-epoxycyclo-
3,4-Epoxycyclohexane Carboxylate hexylmethyl) Adipate
Epoxide Equivalent Weight 130-135 131-140 131-143 190-210
Viscosity at 25˚C, cP 220-250 250-350 350-450 550-750
Specific Gravity at 20/20˚C 1.16 1.168 1.173 1.149
Vapor Pressure at 20˚C, mm Hg <0.01 Nil Nil Nil
Color, Pt-Co <50 <50 <50 <100
Primary Irritation Index
Skin, Draize Value (0-8) 1.6 1.35 1.35 0.25
Eye, Draize Value (0-110) 8.0 7.5 7.5 4.0
†The physical property data listed here are considered to be typical properties, not specifications.

Table 2 • Typical Properties of CYRACURE Diluents†

Product UVR-6000 UVR-6100 UVR-6216
Chemical Name 3-Ethyl-3-hydroxy- Mixed Cycloaliphatic 1,2-Epoxyhexa-
methyl-oxetane Epoxides decane
Equivalent Weight c. 116 130-140 240-280
Viscosity at 25˚C, cP c. 22 85-115 <15
Specific Gravity at 20/20˚C 1.04 1.1395 0.844
Vapor Pressure at 20˚C, mm Hg — 0.59 <0.01
Color, Pt-Co — <100 <50
Primary Irritation Index
Skin, Draize Value (0-8) — 0.9 3.8
Eye, Draize Value (0-110) — 1.0 4.0
†The physical property data listed here are considered to be typical properties, not specifications.

11
 Table 3 • Typical Properties of CYRACURE Photoinitiators†
Product UVI-6976 UVI-6992
Chemical Name Mixed Arylsulfonium Mixed Arylsulfonium
Hexafluoroantimonate Salts Hexafluorophosphate Salts
Description Cationic Photoinitiator Cationic Photoinitiator
Antimonate Salt Phosphate Salt
Faster curing than UVI-6992
Viscosity at 25˚C, cP 75 75
Specific Gravity at 25/25˚C 1.39 1.32
Vapor Pressure at 20˚C, mm Hg <0.03 <0.03
Color, Gardner Scale 5 5
†The physical property data listed here are considered to be typical properties, not specifications.

Table 4 • Typical Properties of TONE Caprolactone Polyol

Flexibilizers and Crosslinkers†
Product 0301 0305 0310
Chemical Name ε-Caprolactone Triol ε-Caprolactone Triol ε-Caprolactone Triol
Description Flexibilizer and Crosslinker
Viscosity at 25˚C, cP 2250 2050 2700
Hydroxyl Equivalent Weight 98–103 174–188 289–312
Specific Gravity at 40˚C 1.08 1.08 1.08
Vapor Pressure at 20˚C, mm Hg <0.01 <0.01 <0.01
Pour Point, ˚C <0 15–20 27–32
Color, Pt-Co 100 max 100 max 100 max
Primary Irritation Index
Skin, Draize Value (0-8) 0.5 — —
Eye, Draize Value (0-110) 7.2 — —
†The physical property data listed here are considered to be typical properties, not specifications.

12
Formulating Guidelines
Introduction
Cationically UV-cured coatings have
become an important part of the overall
UV-cure market. The growing use of cationic
chemistry results from the unique properties
that are inherent in ring-opening polymeriza-
tion, particularly improvements in adhesion
and other properties over free radical UV-cure
coatings. However, cationic chemistry and
formulating skills are less widely understood
than the older free radical-based systems.
The following sections provide a wide range of
general formulating guidelines and techniques
to help the chemist develop the balance of
properties needed for a particular application.
Materials that will cure by a cationic mech-
anism include epoxides, vinyl ethers and other
electron-rich vinyl compounds, and alcohols in
combination with epoxides. Cycloaliphatic
epoxides cure cationically more rapidly than
glycidyl epoxides. Alcohols and polyols co-react
with epoxides by acting as chain transfer agents,
generally improving cure speed.
Coatings based on CYRACURE resins can
be applied by many methods to a great many
substrates. Metals, plastics, wood, glass, paper
and ceramic have been successfully coated.
Coatings based on CYRACURE resins can be
formulated to give a wide range of properties,
including excellent hardness, adhesion, impact
resistance, chemical resistance, stain resistance,
abrasion resistance and cure speed. These
coatings can also be formulated over a broad
range of viscosities by utilizing reactive diluents
or solvents, or by emulsifying them with water.
Low VOCs can therefore be achieved.
In many applications, UV-curable coatings
outperform free radical-curable coatings. They
can also outperform many traditional heat-
curing or ambient two-pack systems. The wide
variety of available components allows the
formulator to achieve a broad range of
performance characteristics.
Although UV-curing of epoxies through a
cationic mechanism has been a commercial
success for many years, many formulators are
more familiar with the free-radical curing
mechanism used with acrylate systems.
Therefore, it may be helpful to point out some
of the formulating and process parameters that
are specific to cationic UV curing.
Base Contamination
Amines or other basic materials, including
certain pigments, tend to deactivate the cationic
catalyst, resulting in poor cure response.
Additives must be selected to avoid this type
of contamination. Equipment that has been
used to process amine-containing acrylates or
water-borne products may be contaminated
and need to be thoroughly cleaned. Bases such
as amine synergists, ammonia, rhodamine
pigments and urethane acrylates in the cationic
formulation or in the substrate to which the
cationic formulation will be applied have a
negative effect on cure. Base contamination
may be manifested by poor adhesion or
micro-wrinkling or both.
Atmospheric Inhibition
The cationic cure mechanism is unaffected
by oxygen. The use of CYRACURE resins does
not require an inert atmosphere to achieve
optimum cure response. However, cationic cure
is negatively affected by high ambient humidity.
Using no polyol in the cationic composition
helps overcome some of the high humidity cure
problem. At 87 percent relative humidity, dry
air purge increased surface cure speed by about
50 percent. The use of infrared preheaters is
also effective in improving cure speed.
Thermal Energy
Heat will increase cure speed. This can
be accomplished in several ways: by using a
UV source that generates heat, by warming the
formulation or substrate before application, or
by use of infrared radiation following UV expo-
sure. In many cases, a “heat bump” by infrared
radiation or a conventional thermal oven after
UV exposure will improve cure speed and water
resistance of the coating or adhesive. Flame
treatment of the substrate can also significantly
improve adhesion.
13
 Figure 1 •
UV Activation of Photoinitiator
- UV Light
Ar+MF6 H+MF6- (Superacid)
Ar = Mixed Arylsulfonium Cation
M = P for UVI-6992 and Sb for UVI-6976
UV Light Source
The UV light emitted by high-intensity
UV bulbs activates the photoinitiator (Figure 1).
In any UV-cure system, it is critical for the
photoinitiator to be capable of absorbing light at
the wavelengths emitted by the UV bulb. This
can be determined by comparing the photoini-
tiator UV absorption spectrum and the bulb
UV emission spectrum. CYRACURE UVI-6992
and UVI-6976 photoinitiators are activated by
standard mercury-filled UV bulbs because they
efficiently absorb some of the major emission
bands of the standard bulbs (Figure 2). A
number of commercial “doped” bulbs can also
be used with the UVIs. This may be useful for
curing pigmented or thick formulations.
The emission spectrum of the xenon
chloride-filled UV bulb (e.g., 308 Excimer,
Fusion UV Systems, Inc.) offers better overlap
with the UVI absorption spectrum (Figure 3).
The improved match provides faster cure of
clear, yellow and red flexographic inks. For
example, clear coatings cured 20% to 40% faster
using the xenon chloride bulb compared to a
standard mercury bulb. Significant increases
in the degree of epoxide conversion were also
measured by DSC for coatings cured using the
xenon chloride bulb. The improved overlap
results in more acid catalyst being generated at
the same line speed and lamp power compared
to mercury bulbs.
14
Chemistry
A typical cationic starting point formula-
tion consists of cycloaliphatic epoxide and
cationic photoinitiator. Other ingredients such
as polyols and other epoxides can be added to
modify properties. An understanding of the
cure chemistry helps in formulating better prod-
ucts and avoiding problems. Upon exposure to
UV light, the cationic photoinitiator generates a
superacid (Figure 1). This superacid is a catalyst
for rapid cationic polymerization of epoxides
(Figure 4) and for reaction of epoxides with
hydroxyls (Figure 5). Rapid cure is one of the
advantages of cycloaliphatic epoxides.
Cationic polymerization is an ionic process
involving highly reactive, positively charged
polymerizing centers. Free-radical polymeriza-
tion of acrylates involves unpaired electrons
and, therefore, uncharged polymerizing centers.
Cationic cure is not inhibited by oxygen but is
inhibited by bases, because it involves positively
charged species and not unpaired electrons.
Cationic cure rate is proportional to the
concentration of acid catalyst, which in turn
is proportional to the cationic photoinitiator
concentration. Cationic cure rate is also
proportional to acid strength. For example,
CYRACURE UVI-6976 photoinitiator results in
faster cure than CYRACURE UVI-6992
photoinitiator because CYRACURE UVI-6976
photoinitiator generates a stronger acid.
Cationic compositions are typically formu-
lated to cure to a hard, non-tacky state during
UV curing. However, properties in areas
exposed to UV light continue to develop after
UV exposure, a phenomenon typically referred
to as “dark cure”. The acid catalyst generated
from the photoinitiator continues to be active
after UV curing, and so conversion of reactants
and crosslinking continues. Properties can
develop up to 24 hours or more after
UV curing.
Figure 2 • Overlap of UVI Absorption Spectrum
and Standard Mercury UV Bulb Emission Spectrum

Hg Lamp Emission
UVI Absorption

200 250 300 350 400

Wavelength (nm)

Another important technical advantage The ratio of epoxide equivalents to hydroxyl

of cationic UV cure compositions is excellent equivalents (the R value) is an important factor
adhesion. The superior adhesion is attributed affecting properties when formulating with
to the low shrinkage that occurs during cure polyols. Compositions with lower R value (more
due to the ring-opening epoxide polymerization hydroxyl equivalents) are typically more flexible
(Figures 4 & 5). Shrinkage of cationic composi- and softer. The R value should generally be kept
tions during cure is typically about five percent above about 1.5 to obtain hard, tack-free coatings.
or less. By comparison, shrinkage of acrylate Experimental designs have shown that reactant
compositions may exceed 10 to 15 percent. Low (epoxide and polyol) equivalent weight also has
shrinkage minimizes internal stress, which has an important influence on coating properties.
been blamed in part for poor adhesion. Another Increasing reactant equivalent weight makes
benefit of low shrinkage is reduced tendency for compositions more flexible, extensible and
flexible substrates to curl during cure. softer; decreasing reactant equivalent weight
Other ingredients can be added to cationic increases hardness and cure rate.
UV-curable compositions to meet specific appli-
cation requirements. A variety of other epoxides
can be blended with cycloaliphatic epoxides to
modify viscosity, hardness, flexibility, cure rate,
adhesion and other properties. Surfactants and
waxes can be used to improve substrate wetting
and surface slip. Polyol additions increase
flexibility and increase depth of cure of thick
coatings (>1 mil).

15
 Figure 3 • Improved Overlap for Improved Performance: UVI Absorption
Spectrum and Xenon Chloride UV Bulb Emission Spectrum

Xenon Chloride
Lamp Emission
UVI Absorption

200 250 300 350 400

Wavelength (nm)

16
Figure 4 • Activated-Polymer Mechanism of Epoxide Polymerization

O O
– +
O HPF6 O
O O PF6 H O O

– O O
R + HO
PF6
O H– O O O O O
+
O
–
PF6
R

O + PF –
R HO O 6 O OH
O O
O
O+
–
PF6 O O O O
R
O O

O O
O
R= O O

17
 Figure 5 • Activated-Monomer Mechanism of Epoxide Polymerization

O O
–+
O HPF6 O
O O PF6 H O O

– O O
PF6 + HO
R’-OH H– O O O – O O
PF6 H +
O
R’

O O
HO HO
– O O O O
PF6 H + HPF6 +
O O
R’ R’

R’
O
O O
O
O-R’’
O
Where R’- = H-, alkyl, or
O
O
O
HO O
O

18
General Formulating
Guidelines
Resin Selection
• Blend epoxide(s) and photoinitiator(s) to
achieve desired properties. Good starting points
are blends of CYRACURE UVR-6110 and
UVR-6128 resins, and 4 wt % CYRACURE
UVI-6992 photoinitiator.
• If formulating with polyols, good
starting points are blends of CYRACURE
UVR-6110 resin, polyol(s), and 4 wt %
CYRACURE UVI-6992 photoinitiator.
Keep R between 1.5 and 10, for good
coating physical properties, where:
Photoinitiator Selection
• Start formulating with either 4 wt %
CYRACURE UVI-6992 photoinitiator or 2 wt %
CYRACURE UVI-6976 photoinitiator, which
is twice as efficient.
• Blends of the photoinitiators may also
be used to maximize cure rate and minimize
cost. A good starting point is 2 parts CYRACURE
UVI-6992 photoinitiator and 1 part CYRACURE
UVI-6976 photoinitiator.
• The selection of the photoinitiator can
affect the cure rate and adhesion of a cured
formulation. Table 5 provides an initial
selection guide.
• UV-absorption spectra of CYRACURE
photoinitiators are shown in Figure 2.

R = Epoxide Equivalents
Hydroxyl Equivalents
R = g Epoxides/Epoxide Equivalent Wt
g Polyol/Hydroxyl Equivalent Wt
Components to Avoid
• DO NOT USE BASIC OR ALKALINE
MATERIALS, SUCH AS ORGANIC AMINES OR
BASIC PIGMENTS. Basic or alkaline materials
will neutralize the protons generated from
photolysis of the initiator and the cure will
be dramatically slowed or stopped.

Table 5 • Selection Guide for CYRACURE Photoinitiator

Application Selection Factors
Photoinitiator Heat in Curing Metal Plastic Overprint Inks
(Suggested Use Level) Process Substrate Substrate Varnish
CYRACURE UVI-6992 ✓ ✓ ✓ ✓
(4 wt %) Not prone Better
to yellow adhesion
CYRACURE UVI-6976 ✓ ✓ ✓
(2 wt %) Faster cure

19
 Modifying Formulations
Formulation properties can be modified by the proper choice of ingredients and curing techniques:
CURE RATE • Increase Cure Rate by using:
CYRACURE UVR-6105
CYRACURE UVR-6100
Limonene dioxide
More photoinitiator
CYRACURE UVI-6974 in place of CYRACURE UVI-6992
Infrared lamp preheaters
• Increase Cure Rate When Formulating With Polyols by using:
An R value between 3 and 10 for thin coatings (0.1–0.5 mil)
An R value between 1.5 and 3 for thick coatings (>1 mil)
Low equivalent weight triol (e.g., TONE 0301 polyol; Fomrez 1066-560,
Witco/Crompton; or VORANOL* 234-630 polyol
Up to 5% ethylene glycol
Infrared lamp preheater or a dry air blanket, if relative humidity is above 70%

VISCOSITY • Decrease Viscosity by using:

CYRACURE UVR-6000
CYRACURE UVR-6100
CYRACURE UVR-6105
CYRACURE UVR-6107
Limonene dioxide
Monoepoxide (e.g., UVR-6216 or Vikolox 14, Atofina)
Vinyl ether
• Decrease Viscosity When Formulating With Polyols by using:
Low-viscosity glycol (diethylene, triethylene, dipropylene, or tripropylene glycol)
Polyether polyol
TONE 0201 polyol
• Increase Viscosity by using:
Solution Vinyl Resin (e.g., UCAR™ VAGF or VYHH)
Cellulose acetate butyrate resin (e.g., CAB-551-0.2, Eastman Chemical)
Epoxy novolac resin
Bisphenol A epoxy resin
Epoxidized polybutadiene (e.g., Poly bd 605, Atofina)
CYRACURE UVR-6128
• Increase Viscosity When Formulating With Polyols by using:
High-viscosity polyol (e.g., Desmophen 800, Bayer)

FLEXIBILITY • Increase Flexibility by using:

Epoxidized oil (e.g., FLEXOL™ LOE or EPO plasticizers)
CYRACURE UVR-6128
CYRACURE UVR-6000
Solution Vinyl Resin (e.g., UCAR VAGF, VROH and VYHH)
Monoepoxide (e.g., CYRACURE UVR-6216 or Vikolox 14, Atofina)
Post-bake (5–10 min at 120°C)
• Increase Flexibility When Formulating With Polyols by using:
More polyol
Higher equivalent weight polyol

20
* Trademark of The Dow Chemical Company
HARDNESS • Increase Hardness by using:
Epoxy novolac resin
Lower equivalent weight epoxide (e.g., CYRACURE UVR-6105
or limonene dioxide)
Less reactive diluent
Post-bake (5–10 min at 120°C)
• Increase Hardness When Formulating With Polyols by using:
Less polyol
Lower equivalent weight polyol

TOUGHNESS • Increase Toughness by:

Applying the coating at lower film thickness
Using CYRACURE UVR-6128
Using tough polyols (e.g. Desophen 800, Bayer)
Post baking

CHEMICAL • Increase Chemical and Stain Resistance by using:

AND STAIN Epoxy novolac resin
RESISTANCE Lower equivalent weight epoxide (e.g., CYRACURE UVR-6105
or limonene dioxide)
Less reactive diluent
Post-bake (5–10 min at 120°C)
• Increase Chemical and Stain Resistance When Formulating With Polyols
by using:
Less polyol
Higher equivalent weight polyol

ADHESION • Increase Adhesion by using:

Higher equivalent weight epoxide
Post-bake (5–10 min at 120°C)
CYRACURE UVI-6992 instead of CYRACURE UVI-6976
Silane adhesion promoter (e.g., Silwet A-186 or A-187,
OSi Specialties/Crompton) on metal or silica-containing substrates,
such as glass or clay-filled paper
• Increase Adhesion When Formulating With Polyols by using:
More polyol
Higher equivalent weight polyol

COST • Lower Cost by using:

Lowest initiator levels possible
CYRACURE UVI-6992 or blends to minimize the amount
of CYRACURE UVI-6976
Epoxidized oil (e.g., FLEXOL LOE or EPO plasticizers) or castor oil
Bisphenol A epoxy resin
Infrared lamp preheater to minimize photoinitiator level
Low-cost acrylates in cationic-acrylate “hybrid” systems
• Lower Cost When Formulating With Polyols by using:
Inexpensive polyol or glycol

21
 General-Purpose Formulations
The following formulations highlight the effects of polyol type, R value, and equivalent weights
on coating properties, as discussed in the previous section.

Wt Percent
Ingredients A B C D E F
CYRACURE UVR-6110 Resin 70.4 81.0 46.1 62.2 72.3 82.3
TONE 0301 Polyol 25.1 14.5 — — — —
TONE 0310 Polyol — — 49.4 33.3 — —
VORANOL 234-630 Polyether Polyol — — — — 23.2 13.2
CYRACURE UVI-6976 Photoinitiator 4.0 4.0 4.0 4.0 4.0 4.0
Silicone Surfactant(1) 0.5 0.5 0.5 0.5 0.5 0.5
SUPPLIER:
(1) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton).

Table 6 • Effect of Polyol and R Value on Properties of General-Purpose Formulations†

Coating Properties
R Value 2 4 2 4 2 4
Brookfield Viscosity at 25°C, cP 480 430 770 600 390 410

Film Properties(1) at 1.0 mil (25 µm)

Cure Rate, fpm (m/min.)
Surface(2) 410 (125) >900 (>270) 170 (50) 650 (200) 200 (60) 400 (120)
Through (3) 260 (80) 100 (30) 60 (20) 50 (15) 210 (65) 150 (45)
Pencil Hardness 2H 2H 2B F H H
MEK Rubs
15 min after UV exposure 200 200 100 200 >200 >200
24 hours after UV exposure >200 >200 100 200 >200 >200
Impact Resistance, in-lb
Forward 30 25 120 90 55 35
Reverse 0 0 75 30 10 0
Crosshatch Adhesion, % 100 35 100 65 75 65

Film Properties(1) at 0.25 mil (6 µm)

Surface-Cure Rate(2), fpm (m/min.) 520 (160) >900 (>270) 15 (5) 320 (100) 120 (35) 230 (70)
Pencil Hardness 2H 2H F H 2H 3H
MEK Rubs 24 hours after UV exposure 200 >200 20 190 200 >200
Impact Resistance, in-lb
Forward 60 30 150 120 80 40
Reverse 4 4 75 40 40 0
Crosshatch Adhesion, % 100 95 100 95 100 70

(1) Properties were measured 24 hours after UV exposure, except as noted. Cure Unit: Linde PS-2000; UV Lamps: 2 X 400 W/in.
(2 X 160 W/cm); Belt Speed: 50 fpm (15 m/min.); Relative Humidity: 30 to 40%; Substrate: Bonderite 1000.
(2) Surface-cure was determined by lightly touching the coating with a cotton ball immediately after UV exposure.
The coating was considered cured if the fibers did not stick to it. Cure conditions as described in (1) above.
(3) Through-cure was determined by scraping the coating with a wooden tongue depressor immediately after UV exposure. The coating
was considered cured if it did not peel around the edges of the tongue depressor. Cure conditions as described in (1) above.
† The physical property data listed here are considered to be typical properties, not specifications.

22
 The general-purpose formulations that follow are used to demonstrate the effect of diluents on
coating film properties.

Wt Percent
Ingredients A B C D E
CYRACURE UVR-6110 Resin 69.7 36.4 64.7 64.7 64.7
CYRACURE UVR-6100 Resin — 33.3 — — —
Limonene Dioxide(1) — — 5.0 — —
1,2-Epoxytetradecane(2) — — — 5.0 —
Diethylene Glycol — — — — 5.0
TONE 0301 Polyol 25.8 25.8 25.8 25.8 25.8
CYRACURE UVI-6974 Photoinitiator 4.0 4.0 4.0 4.0 4.0
Silicone Surfactant(3) 0.5 0.5 0.5 0.5 0.5
SUPPLIER:
(1) (Atofina) or equivalent.
(2) Vikolox 14 (Atofina) or equivalent.
(3) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton).

Coating Properties
R Value 2 2 2 2 2
Viscosity at 25°C, cP 525 300 400 330 400

Film Properties(1)
Cure Rate, fpm (m/min.)
Surface 430 (130) 400 (120) 450 (135) 400 (120) 350 (105)
Through 260 (80) 230 (70) 260 (80) 230 (70) 260 (80)
Pencil Hardness 2H 2H 3H 2H H
MEK Rubs >150 >150 >150 >150 125
Crosshatch Adhesion, % 100 100 100 100 100
Forward Impact Resistance, in-lb 26 20 28 30 36
(1) Properties were measured 24 hours after UV exposure, except as noted.
Cure Unit: Linde PS-2000; UV Lamps: 2 X 400 W/in. (2 X 160 W/cm); Substrate: Bonderite 1000; 1.0 mil (25 µm)
CYRACURE resin-based coating.

23
 Starting Point Formulations
A variety of starting point formulations
for UV-curable coatings and inks based on
CYRACURE resins, diluents and photoinitiators
are described below.

Test Formulations for Tin-

Free Steel and Aluminum
The cationic overprint varnish (OPV) test
formulations shown below have low viscosities
that make them ideal for roll coating, an
application technique used to apply OPVs to
metal sheet substrates. Achieving low viscosity
without resorting to high-odor monomers is a
technical advantage of cationic chemistry.

Table 7 • UV-Curable, Cationic Test Formulations

Coating Formulation
Ingredients 1 2 3
CYRACURE UVR-6110 Resin 70.9 81.3 83.6
TONE 0301 Polyol 24.6 14.2 9.9
CYRACURE UVI-6992 Photoinitiator 6.0 6.0 6.0
Silicone Surfactant(1) 0.5 0.5 0.5

Coating Properties
Viscosity, at 25˚C, cP 480 410 390

SUPPLIER:
(1) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton) or equivalent.

24
Performance on Tin-Free Steel are known to flexibilize cationically cured
epoxides. The comparison also demonstrates
After post-baking, the cured films on
that the flexibility of cationic coatings can be
can-end tin-free steel showed the following:
varied depending on the relative concentrations
of polyol and epoxide.
Excellent Adhesion: All coating
formulations exhibited excellent adhesion after
Excellent Hardness and Solvent
post-baking (before retort). These UV-curable,
Resistance: The pencil hardness and MEK
cationic coatings showed no loss of adhesion
resistance of these overprint varnishes was
and no blistering or blush after retort.
excellent, providing further evidence of the
usefulness of cationics as protective coatings
High Flexibility: The flexibility of these
for can ends.
coatings, as measured by wedge bend, was very
Flame treatment of tin-free steel and tin
good. A comparison of Formulations 1-3 shows
plate before coating can also significantly
that flexibility increased with increasing polyol
improve adhesion.
concentration. This was expected since polyols

Table 8 • Cured(1) Film Properties(2) on Can-End Tin-Free Steel

Coating Formulation
Properties † 1 2 3
Film Appearance Clear Clear Clear
Adhesion, %
Initial 100 100 100
After Retort(3) 100 100 100
Blistering (after Retort) None None None
Blush (after Retort) None None None
Wedge Bend Failure, mm 49 55 61
Pencil Hardness 5H 6H 7H
MEK Rubs 200+ 200+ 200+
(1) Cure was at 190 fpm (60 m/min.) with 2 X 400 W/in. (2 X 160 W/cm) lamps. UV dose was 300 mJ/cm2.
(2) Coatings were post-baked for 10 min at 400˚F (205°C) prior to physical testing.
(3) Coated panels were autoclaved in distilled water for 60 min at 250˚F (120°C) and 15 psi (1 atm).
† The physical property data listed here are considered to be typical properties, not specifications.

25
 Performance on Aluminum aluminum appeared smooth. The striations on
the can-end aluminum are expected to enhance
On can-end aluminum, the UV-cured
coating adhesion.
cationic coatings also exhibited superior results:
Although these adhesion tests were
conducted on post-baked samples, experience
Excellent Adhesion: All coatings
has shown that post-baking is not necessary
demonstrated excellent adhesion and resistance
to ensure good adhesion of cationic coatings
to blistering and blush—both initially and
to aluminum.
after pasteurization. However, with can-body
aluminum, Formulation 2 blistered slightly after
Fast Surface-Cure Rates: The coatings
pasteurization, suggesting that it is slightly
cured fast and cure rate increased with
more difficult to adhere coatings to can-body
decreasing polyol concentration. Less polyol
aluminum.
typically increases surface-cure rate at moderate
The can-end aluminum appeared striated
and high humidity.
to the unaided eye, whereas the can-body

Table 9 • Cured(1) Film Properties(2) on Can-End Aluminum

Coating Formulation
Properties † 1 2 3
Appearance Clear Clear Clear
Surface-Cure Rate(3), fpm (m/min.) 330 (100) 680 (205) 900+ (270+)
Adhesion, %
Initial 100 100 100
After Pasteurization(4) 100 100 100
Blistering (after Pasteurization) None None None
Blush (after Pasteurization) None None None
Gloss
20˚ 110 110 100
60˚ 140 140 130
85˚ 99 96 99
(1)Cure was at 190 fpm (60 m/min.) with 2 x 400 W/in. (2 X 160 W/cm) lamps. UV dose was 300 mJ/cm2.
(2)Coatings were post-baked for 10 min at 400˚F (205°C) prior to physical testing.
(3)Cure rates conducted using aluminum panels and 1 X 200 W/in. (1 X 80 W/cm) lamp; relative humidity was 25%.
(4)Coated panels were immersed for 30 min in a constant-temperature bath at 180˚F (80°C).
† The physical property data listed here are considered to be typical properties, not specifications.

Table 10 • Effects of Pasteurization on Can-Body Aluminum

Properties(1) Coating Formulation 2
Adhesion, %
Before Pasteurization(2) 100
After Pasteurization 60
Blistering (after Pasteurization) Slight
Blush (after Pasteurization) None
(1) Tests were conducted after the coated panels were post-baked for 2 min at 400˚F (205°C).
(2) Coated panels were immersed for 30 min in a constant-temperature bath at 180˚F (80°C).
26
Overprint Varnishes
Overprint Varnishes for Aluminum, Tin-Free Steel, and Tin Plate
Wt Percent
Ingredients Aluminum Tin-Free Steel Tin Plate
CYRACURE UVR-6110 Resin 74.5 76.9 —
CYRACURE UVR-6105 Resin — — 65.8
Castor Oil 11.0 — —
D.E.N.* 431 Epoxy Novolac Resin — — 10.0
Epoxy Novolac Resin(1) — 7.7 —
Polyester Polyol(2) — 11.3 —
n-Propanol 5.0 — —
TONE 0301 Polyol — — 17.2
CYRACURE UVI-6992 Photoinitiator 6.0 4.0 5.0
Polyethylene Wax(3) 2.0 2.0 —
Teflon Wax(4) 1.0 1.0 —
Silicone Surfactant(5) 0.5 0.5 —
Slip and Mar Resistance Additive(6) — — 2.0
SUPPLIERS:
(1) Epon SU-3 (Shell Chemical Company) or equivalent.
(2) Desmophen 800 (Bayer USA) or equivalent.
(3) S-394-N1 (Shamrock Technologies Inc.) or equivalent.
(4) SST-3 (Shamrock Technologies Inc.) or equivalent.
(5) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton) or equivalent.
(6) Byk 310 (Byk-Chemie, USA) or equivalent.

Coating Properties
R Value 4.6 10.0 2.8
Viscosity at 25°C, cP 150 640 400

Film Properties(1)
Surface-Cure Rate, fpm (m/min.) 900+ (270+) 600 (180) 450 (135)
Pencil Hardness 6H 4H 5H
MEK Rubs >200 >100 >100
Crosshatch Adhesion, % Aluminum 100 100 100
Tin-Free Steel 100 100 —
Tin Plate — — 100
Wedge Bend Failure, mm After Bake 45 28 —
After Retort(2) — 34 —
(1) Properties were measured 24 hours after UV exposure, except for cure rate.
Cure Unit: Linde PS-2000; UV Lamps: 2 X 400 W/in. (2 X 160 W/cm); 0.18 mil (4.5 µm) CYRACURE resin-
based coating.
(2) Retort: 60 min at 250°F (120°C) and 15 psi (1 atm).

27
* Trademark of The Dow Chemical Company
 Overprint Varnishes for Plastic Film and Paper
Wt Percent
Ingredients OPP Paper
CYRACURE UVR-6110 Resin 81.0 —
CYRACURE UVR-6105 Resin — 72.0
Limonene Dioxide(1) 5.0 —
Polyglycidyl Ether of Castor Oil(2) 5.0 —
1,6-Hexanediol Diglycidyl Ether(3) — 13.0
TONE 0301 Polyol 4.0 —
Castor Oil — 8.0
CYRACURE UVI-6992 Photoinitiator 4.0 4.0
Slip and Mar Resistance Additive(4) 1.0 —
Lanolin Oil(5) — 2.0
Slip and Mar Resistance Additive(6) — 1.0
SUPPLIERS:
(1) (Atofina) or equivalent.
(2) Heloxy 505 (Shell Chemical Company) or equivalent.
(3) Eurepox RV-H (Witco GmbH/Crompton) or equivalent.
1,6-Hexanediol Diglycidyl Ether is EINECS registered but not TSCA registered.
(4) DC-57 (Dow Corning Corporation) or equivalent.
TM
(5) LANOGENE (Amerchol Corporation) or equivalent.
(6) Byk 306 (Byk-Chemie, USA) or equivalent.

Coating Properties
Viscosity at 25°C, cP 200 140

Film Properties(1)
Surface-Cure Rate, fpm (m/min.) >800 (>240) >800 (>240)
180 degree Bend Pass Pass
MEK Rubs >100 >100
Cured Coating Odor Very low Very low
Crosshatch Adhesion, % 100 100
Crinkle Test Pass —
(1) Properties were measured 24 hours after UV exposure, except as noted.
Cure Unit: Linde PS-2000; UV Lamps: 2 X 400 W/in. (2 X 160 W/cm).
Substrate: Mobil SPW 120 45-55 Dyne/cm treated OPP and plain paper stock with 0.18 mil (4.5 µm)
CYRACURE resin-based OPV.

28
Base Coat
White Base Coat Formulation
Ingredients Wt Percent
CYRACURE UVR-6128 Resin 15.6
CYRACURE UVR-6110 Resin 10.2
Polyether Polyol(1) 10.6
Titanium Dioxide(2) 49.5
CYRACURE UVI-6992 Photoinitiator 7.4
Isopropylthioxanthone(3) 0.8
n-Propanol 4.3
Silicone Surfactant(4) 0.8
Dispersant(5) 0.8
SUPPLIERS:
(1) Terathane 650 (DuPont) or equivalent.
(2) Ti-Pure R-900 (DuPont) or equivalent.
(3) (Aceto Corp.) or equivalent.
(4) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton) or equivalent.
(5) Byk P-104S (Byk-Chemie) or equivalent.

Base Coat Properties

Viscosity at 25°C, cP 500
Through-Cure Speed, fpm (m/min.) 200 (60)

Barrier Coatings
Test Formulations
The cationic varnish formulations shown These formulations also have low viscosi-
were chosen to illustrate the low gas transmis- ties that make them ideal for roll coating and
sion rates of CYRACURE resin-based coatings. flexo printing. Cationic chemistry provides a
Barrier properties are important for many technical advantage in that low viscosity can
flexible packaging applications. According to be achieved without the use of high-odor
the Wiley Encyclopedia of Packaging Technology, monomers.
a “barrier” polymer is one that has an oxygen
transmission rate of <10 cm3•mil/100 in2/24hr/
atm. Using this definition, the cationic varnish
qualifies as a barrier polymer.

29
 Table 11 • UV-Curable, Cationic Varnish as an Oxygen Barrier
Ingredients Wt Percent
CYRACURE UVR-6110 Resin 89.1
TONE 0301 Polyol 6.4
CYRACURE UVI-6976 Photoinitiator 4.0
Silicone Surfactant (1) 0.5

Coating Properties
Oxygen Transmission Rate, cm3•mil/100 in2/24 hr/atm
0% Humidity
Uncoated Polyethylene, 0.5 mil (12 µm) 550(2)
Coated Polyethylene, 1 mil (25 µm) 9.9(2)
Cationic UV Coating, 0.5 mil (12 µm) 5.0(3)
90% Humidity
Uncoated Polyethylene, 0.5 mil (12 µm) 500(2)
Coated Polyethylene, 1 mil (25 µm) 18(2)
CYRACURE Cationic UV Coating, 0.5 mil (12 µm) 9.4(3)
(1) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton) or equivalent.
(2) Experimental value.
(3) Calculated value.

Table 12 • UV-Curable, Cationic Varnish as a Carbon Dioxide Barrier

Ingredients Wt Percent
CYRACURE UVR-6105 Resin 79.0
TONE 0301 Polyol 10.0
CYRACURE UVR-6216 Diluent 6.5
CYRACURE UVI-6992 Photoinitiator 3.0
CYRACURE UVI-6976 Photoinitiator 1.0

Coating Properties
Carbon Dioxide Transmission Rate, cm3•mil/100 in2/24 hr/atm
Uncoated Polyester(1), 1.0 mil (25 µm) 15.5(2)
Coated Polyester(1), 1.5 mil (38 µm) 8.1(2)
CYRACURE Cationic UV Coating, 0.5 mil (12 µm) 4.1(3)
(1) Mylar A (DuPont) or equivalent.
(2) Experimental value.
(3) Calculated value.

30
Table 13 • UV-Curable, Cationic Varnish as Moisture Vapor Barrier
The following starting-point formulations demonstrate the effect of different epoxide coating
materials on coating film properties, particularly moisture vapor transmission rates and cure rate
at high relative humidity.

Wt Percent
Ingredients A B C D E
CYRACURE UVR-6110 Resin 66.9 66.9 66.9 66.9 66.9
CYRACURE UVR-6128 Resin 28.6 — — — —
DER* 330 Diglycidyl Ether of Bisphenol A — 28.6 — — —
Epoxidized Polybutadiene Resin(1) — — 28.6 — —
D.E.N. 431 Epoxy Novolac Resin — — — 28.6 —
TONE 0301 Polyol — — — — 28.6
CYRACURE UVI-6992 Photoinitiator 4.0 4.0 4.0 4.0 4.0
Silicone Surfactant(2) 0.5 0.5 0.5 0.5 0.5
SUPPLIERS:
(1) Poly bd 605 (Atofina) or equivalent.
(2) Silwet L-7604 Silicone Surfactant (OSi Specialties/Crompton) or equivalent.

Film Properties(1)
Surface Cure Rate at 80% RH(2), fpm (m/min) 400 (120) 400 (120) 260 (80) 400 (120) 130 (40)
Moisture Vapor Transmission Rate(3),
g/100 in2/day/mil 1.50 1.10 1.37 1.29 2.65
MEK Rubs(2) 90 110 190 200+ 8

(1) Properties were measured 24 hours after UV exposure, except as noted.

Cure Unit: Linde PS-2000; UV Lamps; 1 X 400 W/in. (1 X 160 W/cm).
(2) Substrate: Laneta paper stock with aluminum coating with 0.18 mil (4.5 µm) CYRACURE resin-based OPV.
(3) Substrate: Plain paper stock with 0.18 mil (4.5 µm) CYRACURE resin-based OPV. Run at 100°F (40°C) and 94% RH.

31
* Trademark of The Dow Chemical Company
 Flexo Inks
A wide variety of pigment colors can be used to formulate cationic inks. Cationic inks have
excellent adhesion to a wide variety of substrates, including steel, aluminum and films. Typically,
cationic inks require more photinitiator than clears because pigments absorb and scatter UV light.
UV-curable, cationic process inks for flexo printing are presented below.

Process Ink Formulations

Wt Percent
Ingredients Cyan Magenta Yellow Black
CYRACURE UVR-6105 Resin 66 66 66 66
Poly bd 605 Resin(1) 12 12 12 12
CYRACURE UVR-6000 Diluent 5 5 5 5
Sunfast Blue 15:3(2) 10 — — —
Sunbrite Rubine 57:(3) — 10 — —
Sunbrite Yellow 12(4) — — 10 —
Printex 35 Carbon Black(5) — — — 10
CYRACURE UVI-6992 Photoinitiator 7 7 7 7
(1) Atofina.
(2) Sun Chemical Code 249-2083 or equivalent.
(3) Sun Chemical Code 219-3707 or equivalent.
(4) Sun Chemical Code 273-3556 or equivalent.
(5) Degussa.

Laminating Adhesives
The table below shows a typical cationic Ingredients
adhesive formulation containing a polyether
CYRACURE UVR-6128 Resin 60
polyol used to slightly retard cure so that the
adhesive could be UV-cured before nipping two VORANOL CP-755 Polyol 36
films together. The graph shows improvement CYRACURE UVI-6992 Photoinitiator 4
of the T-peel strength with time and high adhe- R Value 2
sive T-peel strength values beginning an hour Viscosity at 25°C, cP 380
after nipping. The film began to fail above about
2 lb/in. in the T-peel test using an Instron test
instrument. The adhesive was low viscosity,
which allowed it to be applied at room
temperature, and was low VOC.

32
Table 14 • Time Effect on Cationic Adhesive T-Peel Strength Using PE Film

2.5

2.0
T-Peel Strength, lb/inch

1.5

1.0

0.5

0.0
0.1h 1h 5h 24h
Hours After Laminating

Electronic Encapsulant
Cationic UV formulations can be used for various electronic applications such as
potting/casting and “glob top” encapsulants, which require curing thick sections (>1 mil).
The following suggestions have been useful for curing thick sections:
• CYRACURE UVR-6105 resin because it is highly reactive.
• Low photoinitiator concentration to help allow the UV light to penetrate
into the lower layers.
• UVI-6976 photoinitiator because it generates the strongest acid. Maximum acid strength
is beneficial because the photoinitiator concentration, and therefore the acid concentration,
will be low.
• Relatively long UV cure times (15 to 90 seconds) to allow time for the UV light to penetrate
into the lower layers.
• A hydroxyl-functional material such as CYRACURE UVR-6000 diluent or polyols or both.

A starting-point formulation follows, which uses these suggestions:

Ingredients Wt Percent
CYRACURE UVR-6105 Resin 91
CYRACURE UVR-6000 Diluent 9
CYRACURE UVI-6976 Photoinitiator 0.05 to 0.05
R-Value 10

Higher CYRACURE UVI-6976 photoinitiator concentrations (0.5%) will result in more

yellowing during UV cure than lower concentrations (0.05%). Post-baking will improve
properties such as hardness but might cause yellowing depending on factors such as the time
and temperature of the post-bake and the photoinitiator concentration.
33
 Reactive Diluent
CYRACURE UVR-6000 Diluent Effect on Coating Viscosity
and Cure Rate
CYRACURE UVR-6000 diluent is a low-odor oxetane reactive diluent that has good diluency
and fast cure rate when used with cycloaliphatic epoxides as demonstrated in the following table
and graphs.

Ingredients
CYRACURE UVR-6110 Resin 95.5 85.5 75.5 65.5 55.5
CYRACURE UVR-6000 Diluent 0 10 20 30 40
CYRACURE UVI-6992 Photoinitiator 4 4 4 4 4
Silicone Surfactant (1) 0.5 0.5 0.5 0.5 0.5

Coating Properties
Viscosity at 25°C, cP 520 295 180 120 90
Surface-Cure Rate, feet/min. (m/min.) 425 (130) 425 (130) 620 (190) 560 (170) 390 (120)

(1) Byk 307 (Byk-Chemie) or equivalent.

Table 15 • Effect of CYRACURE UVR-6000 Diluent on Coating Viscosity

700

600
500
Viscosity at 25°C, cP

400

300

200
100

0
0 10 20 30 40
Concentration of CYRACURE UVR-6000 Diluent

34
Table 16 • Effect of CYRACURE UVR-6000 Diluent on Coating Surface-Cure Rate

700 210

600 180
Surface-Cure Rate, feet/minute

Surface-Cure Rate, m/minute

500 150

400 120

300 90

200 60
100 30

0 0
0 10 20 30 40
Concentration of CYRACURE UVR-6000 Diluent

Product Stewardship
The Dow Chemical Company has a
fundamental concern for all who make,
distribute, and use its products, and for the
environment in which we live. This concern is
the basis for Dow Product Stewardship
philosophy by which Dow assesses the health
and environmental information on its products.
Dow’s Product Stewardship program rests with
each and every individual involved with DOW
products — from the initial concept and
research to the manufacture, sale, distribution,
use and disposal of each product.
Dow encourages its customers to review
their applications of DOW products from the
standpoint of human health and environmental
quality. To help ensure that DOW products are
not used in ways for which they are not intended
or tested, Dow personnel will assist customers
in dealing with ecological and product safety
considerations. Your Dow sales representative
can arrange the proper contacts.

35
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37
 The Dow Chemical Company
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Published September 2001.

Printed in the U.S.A. *Trademark of The Dow Chemical Company Form No. 321-00013-0901 AMS