Coating compositions and methods

• US 20060111503A1
• Filed: 11/17/2005
• Published: 05/25/2006
• Est. Priority Date: 11/22/2004
• Status: Active Grant

• Current Assignee: Axalta Coating Systems Ip Co Llc (Axalta Coating Systems Ltd.)
• Original Assignee: Valspar Sourcing, Inc. (Sherwin-Williams Company)
• Inventors: Killilea, T. Howard, Bohannon, James M.
• Granted Patent: US 7,923,513 B2
• Time in Patent Office: Days
• US Class Current: 524/501
• CPC Class Codes: C08G 18/694 containing carboxylic ester groups
• CPC Class Codes: C08G 18/706 the liquid medium being water
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C09D 133/02 Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C09D 133/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C09D 135/06 Copolymers with vinyl aromatic monomers
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09D 5/024 characterised by the additives
• CPC Class Codes: C09J 175/04 Polyurethanes

Abstract

The present invention provides coating compositions that include substantially non-irritating ethylenically unsaturated compounds and have one or more of the following properties: high performance, low VOC levels, substantially no formaldehyde content, and low irritation levels.

Claims

1. A coating composition comprising:

a polymer component comprising a latex polymer;

a substantially non-irritating ethylenically unsaturated compound; and

water;

wherein the substantially non-irritating ethylenically unsaturated compound;

has a molecular weight of at least 350 grams/mole,

is substantially free of ethylene oxide moieties, propylene oxide moieties, and primary hydroxyl functionality,

has an average ethylenically unsaturated functionality of at least 3.0, and

has a viscosity at 25°

C. of no greater than 2,000 cps.

2. The coating composition of claim 1 wherein the latex polymer is prepared via chain-growth polymerization.

3. The coating composition of claim 1 wherein the latex polymer is prepared from ethylenically unsaturated monomers.

4. The coating composition of claim 3 wherein the ethylenically unsaturated monomers are selected from the group consisting of acrylic acid, methacrylic acid, methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, 2-ethylhexyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxybutyl acrylate, hydroxybutyl methacrylate, glycidyl methacrylate, 4-hydroxybutyl acrylate glycidylether, acrylamide, methylacrylamide, styrene, α

-methyl styrene, vinyl toluene, vinyl acetate, vinyl propionate, allyl methacrylate, and mixtures thereof.

5. The coating composition of claim 3 wherein the ethylenically unsaturated monomers comprise styrene.

6. The coating composition of claim 5 wherein the level of styrene is no greater than 75 wt-%, based on the total weight of the latex polymer composition.

7. The coating composition of claim 5 wherein the level of styrene is no less than 10 wt-%, based on the total weight of the latex polymer composition.

8. The coating composition of claim 1 wherein the polymer component further comprises a water-dispersible polymer.

9. The coating composition of claim 8 wherein the water-dispersible polymer is selected from the group consisting of polyurethanes, epoxies, polyamides, chlorinated polyolefins, acrylics, oil-modified polymers, polyesters, and mixtures or copolymers thereof.

10. The coating composition of claim 9 wherein the water-dispersible polymer is a water-dispersible polyurethane.

11. The coating composition of claim 1 wherein the ethylenically unsaturated compound comprises (meth)acrylate functionality, vinyl ether functionality, (meth)allyl ether functionality, or mixtures thereof.

12. The coating composition of claim 11 wherein the ethylenically unsaturated compound comprises (meth)acrylate functionality.

13. The coating composition of claim 12 wherein the (meth)acrylate-functional compound is selected from the group consisting of di-(trimethylolpropane tetraacrylate), di-(trimethylolpropane tetramethacrylate), and combinations thereof.

14. The coating composition of claim 1 further comprising a free-radical initiator.

15. The coating composition of claim 14 wherein the free-radical initiator comprises a photoinitiator, a thermal initiator, a catalyst for auto-oxidative cure, or combinations thereof.

16. The coating composition of claim 15 wherein the free radical initiator is a photoinitiator.

17. The coating composition of claim 16 wherein the photoinitiator comprises benzophenone, 4-methylbenzophenone, benzoyl benzoate, phenylacetophenones, 2,2-dimethoxy-2-phenylacetophenone, alpha.,.alpha.-diethoxyacetophenone, hydroxycyclo-hexylphenylketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, bis-(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentyl phosphine oxide, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2,4,6-trimethylbenzoyl-diphenylphosphine oxide, or combinations thereof.

18. The coating composition of claim 1 wherein the ethylenically unsaturated compound is present in an amount of 5 wt-% to 40 wt-%, based on the total weight of the ethylenically unsaturated compound and the polymer component.

19. The coating composition of claim 18 wherein the ethylenically unsaturated compound is present in an amount of no greater than 30 wt-%, based on the total weight of the ethylenically unsaturated compound and the polymer component.

20. The coating composition of claim 19 wherein the ethylenically unsaturated compound is present in an amount of at least 7.5 wt-%, based on the total weight of the ethylenically unsaturated compound and the polymer component.

21. The coating composition of claim 1 wherein the ethylenically unsaturated compound has a molecular weight of 350 grams/mole to 1000 grams/mole.

22. The coating composition of claim 1 comprising no more than 7 wt-% volatile organic compounds, based on the total weight of the composition.

24. A method of coating comprising applying the coating composition of claim 1 to a substrate and allowing the coating composition to harden.

25. A method of coating comprising applying the coating composition of claim 1 to a cement-containing substrate and allowing the coating composition to harden.

28. A coating preparable by the method of claim 24.

23. A coating composition comprising:

a polymer component comprising a latex polymer and a water-dispersible polymer;

a substantially non-irritating ethylenically unsaturated compound; and

water;

wherein the substantially non-irritating ethylenically unsaturated compound;

has a molecular weight of at least 350 grams/mole,

is substantially free of ethylene oxide moieties, propylene oxide moieties, and primary hydroxyl functionality,

has an average ethylenically unsaturated functionality of at least 3.0, and

has a viscosity at 25°

C. of no greater than 2,000 cps.

26. A method of coating comprising applying the coating composition of claim 23 to a substrate and allowing the coating composition to harden.

27. A method of coating comprising applying the coating composition of claim 23 to a cement-containing substrate and allowing the coating composition to harden.

29. A coating preparable by the method of claim 26.

30. A method of preparing a coating composition, the method comprising:

mixing water, a polymer component comprising a latex polymer, and a substantially non-irritating ethylenically unsaturated compound, wherein the ethylenically unsaturated compound;

has a molecular weight of at least 350 grams/mole,

is substantially free of ethylene oxide moieties, propylene oxide moieties, and primary hydroxyl functionality,

has an average ethylenically unsaturated functionality of at least 3.0, and

has a viscosity at 25°

C. of no greater than 2,000 cps.

31. A coating composition prepared by the process of claim 30 wherein the polymer component further comprises a water-dispersible polymer.

32. A method of preparing a coating composition, the method comprising:

mixing water, a surfactant, and a substantially non-irritating ethylenically unsaturated compound, wherein the ethylenically unsaturated compound;

has a molecular weight of at least 350 grams/mole,

is substantially free of ethylene oxide moieties, propylene oxide moieties, and primary hydroxyl functionality,

has an average ethylenically unsaturated functionality of at least 3.0, and

has a viscosity at 25°

C. of no greater than 2,000 cps; and

blending this mixture with a latex polymer and water.

33. A coating composition prepared by the process of claim 32.

34. A method of preparing a coating composition, the method comprising:

providing a first mixture comprising a water-dispersible polymer and a substantially non-irritating ethylenically unsaturated compound, wherein the ethylenically unsaturated compound;

has a molecular weight of at least 350 grams/mole,

is substantially free of ethylene oxide moieties, propylene oxide moieties, and primary hydroxyl functionality,

has an average ethylenically unsaturated functionality of at least 3.0, and

has a viscosity at 25°

C. of no greater than 2,000 cps;

providing a second mixture comprising water and a latex polymer; and

combining the first and second mixtures to form the coating composition.

35. The method of claim 34 wherein combining the first and second mixtures comprises dispersing the first mixture in the second mixture.

36. The method of claim 35 wherein the water-dispersible polymer is a water-dispersible polyurethane polymer.

37. The method of claim 36 further comprising chain extending the water-dispersible polyurethane polymer after dispersing the first mixture in the second mixture.

38. The method of claim 34 wherein the water-dispersible polymer is a water-dispersible polyurethane polymer.

39. The method of claim 38 wherein the water-dispersible polyurethane polymer is rendered water dispersible by anionic stabilization of either an acid or a base.

40. The method of claim 38 further comprising chain extending the water-dispersible polyurethane polymer after combining the first and second mixtures.