Progress in waterborne polymer dispersions for coating applications: commercialized systems and new trends

The environmental impact and safety of products have become increasingly prominent in recent years, with stringent legislation expected to persist. Polymeric coatings are pervasive in modern life, serving to impart desirable properties and protection to a wide range of surfaces. Traditionally dispersed in volatile organic solvents harmful to the environment and workers, modern coatings are shifting towards waterborne, minimizing harmful environmental emissions. Waterborne coatings have seen substantial commercial uptake in large sectors such as architectural and automotive coatings. Nevertheless, their performance still lags behind conventional systems, and, currently, some products lack commercially viable waterborne alternatives. This review focuses on the current state of commercialized waterborne polymer systems, scrutinizing their performance, composition, and market penetration. Additionally, it explores future trends aimed at addressing existing challenges and pioneering novel coating technologies, with an emphasis on achieving fully sustainable systems.