Coating systems for cement composite articles

• US 10,640,427 B2
• Filed: 02/10/2017
• Issued: 05/05/2020
• Est. Priority Date: 07/07/2006
• Status: Active Grant

• Current Assignee: Axalta Coating Systems Ip Co Llc (Axalta Coating Systems Ltd.)
• Original Assignee: Axalta Coating Systems Ip Co Llc (Axalta Coating Systems Ltd.)
• Inventors: Garner, Archie W., Killilea, T. Howard, Cavallin, Carl L., Peterson, Todd A., Evanson, Kevin W., Hartinger, Dan, Brandenburger, Larry B.
• Primary Examiner(s): Feely, Michael J
• Application Number:
  US15/429,396
• Publication Number:
  US 20170226022A1
• Time in Patent Office: 1,180 Days
• Field of Search: 428413, 428414
• CPC Class Codes: B05D 1/36 Successively applying liquids or other fluent materials, e.g. without intermediate treatment
• CPC Class Codes: B05D 3/06 by exposure to radiation B05D3/02 takes precedence ; plasma treatment B05D3/141
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: C04B 14/04 Silica-rich materials; Silicates
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0065 Polymers characterised by their glass transition temperature (Tg)
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/00517 for masonry
• CPC Class Codes: C04B 2111/00568 Multiple coating with same or similar material
• CPC Class Codes: C04B 2111/27 Water resistance, i.e. waterproof or water-repellent materials
• CPC Class Codes: C04B 2111/29 Frost-thaw resistance
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 26/14 Polyepoxides
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 41/0045 Irradiation; Radiation, e.g. with UV or IR C04B41/0036 takes precedence
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4853 : Epoxides
• CPC Class Codes: C04B 41/4884 : Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 41/5024 : Silicates C04B41/5022 takes precedence; silico-fluorides C04B41/5018
• CPC Class Codes: C04B 41/52 : Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/522 : Multiple coatings, for one of the coatings of which at least one alternative is described
• CPC Class Codes: C04B 41/63 : Macromolecular compounds
• CPC Class Codes: C04B 41/71 : at least one coating being an organic material
• CPC Class Codes: C08F 265/04 : on to polymers of esters
• CPC Class Codes: C08F 291/00 : Macromolecular compounds obtained by polymerising monomers on to macromolecular compounds according to more than one of the groups C08F251/00 - C08F289/00
• CPC Class Codes: C08L 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/22 : Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20
• CPC Class Codes: C08L 63/00 : Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C09D 133/068 : containing glycidyl groups
• CPC Class Codes: C09D 133/14 : of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen
• CPC Class Codes: C09D 151/003 : grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds C09D151/04, C09D151/06 take precedence
• CPC Class Codes: C09D 163/00 : Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

A method for making a coating composition by mixing one or more latex polymers and an aliphatic epoxy resin system having an epoxy equivalent weight less than 1000 and being distinct from the one or more latex polymers to provide an aqueous first component, and providing a second component having reactive groups that can react with the one or more epoxy resins. A mixture of the first and second components provides a film-forming curable coating composition that may be used on substrates including cement, cement fiberboard, wood, metal, plastic, ceramic, glass and composites.

Claims

1. A coated article, comprising:

a cement fiberboard substrate; and

a first coating system applied to the substrate, wherein the first coating system comprises;

an aliphatic epoxy resin system comprising one or more latex polymers;

wherein the first coating system includes one or more coating compositions that may be applied in one or more layers;

wherein all surfaces of the substrate are coated with the first coating system at a dry film thickness of about 2 to about 75 microns.

2. The coated article of claim 1, wherein the one or more latex polymers has a Tg of between 5 and 70 °

C.

3. The coated article of claim 1, wherein the one or more latex polymers is a multistage latex.

4. The coated article of claim 1, wherein the one or more latex polymers further comprises one or more epoxy functional groups.

5. The coated article of claim 4, wherein at least one of the one or more latex polymers is prepared from glycidyl methacrylate, glycidyl acrylate, 4-hydroxybutyl acrylate glycidyl ether, or combination thereof.

6. The coated article of claim 1, wherein the one or more latex polymers comprises one or more amine groups.

7. The coated article of claim 1, wherein the first coating system further comprises about 2 to 50 wt. % of a silicate salt;

wherein the silicate salt is potassium silicate, ammonium silicate, sodium silicate, lithium silicate, or mixture thereof.

8. The coated article of claim 7, wherein the substrate has two major surfaces and four edges and is coated on both major surfaces and on the four edges with the first coating system.

9. The coated article of claim 1, wherein the first coating system further comprises one or more olefinic compounds and is radiation curable.

10. The coated article of claim 1, wherein the first coating system is applied to a dry film weight of between about 6 and 60 gm/m².

11. The coated article of claim 1, further comprising a second coating system comprising (i) a latex containing primer, (ii) a latex containing topcoat, or (iii) both.

12. The coated article of claim 11, wherein the second coating system comprises a functionalized latex polymer, a multistage latex polymer or a functionalized, multistage latex polymer.

13. The coated article of claim 12, wherein the second coating system comprises (i) an acetoacetoxy-functional latex containing primer, or (ii) an acetoacetoxy-functional latex containing topcoat, or (iii) both.

14. The coated article of claim 12, wherein the substrate has two major surfaces and four edges and is coated on both major surfaces and on the four edges with the first and second coating systems.

15. The coated article of claim 1, wherein the substrate has two major surfaces and four edges and is coated on both major surfaces and on the four edges with the first coating system at a dry film thickness of 3-30 microns and with a second primer coating at a dry film thickness of 3-20 microns.

16. The coated article of claim 1, wherein the first coating system comprises one or more pigments.

17. The coated article of claim 1, wherein the article can withstand at least 30 freeze-thaw cycles.

18. A coated article, comprising:

a cement fiberboard substrate; and

a first coating system applied to the substrate, wherein the first coating system comprises;

an aliphatic epoxy resin system comprising one or more aqueous dispersions of polymer particles; and

wherein the first coating system includes one or more coating compositions that may be applied in one or more layers;

wherein all surfaces of the substrate are coated with the first coating system at a dry film thickness of about 2 to about 75 microns.

19. The coated article of claim 18, wherein the one or more aqueous dispersions of polymer particles is a polyurethane polymer, a latex polymer, or a mixture of both.

20. The coated article of claim 18, wherein the one or more aqueous dispersions of polymer particles is a polyurethane polymer.