COATING SYSTEM FOR CEMENT COMPOSITE ARTICLES

• US 20070259166A1
• Filed: 01/30/2007
• Published: 11/08/2007
• Est. Priority Date: 01/31/2006
• 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., Evanson, Kevin, DeChaine, Daniel, Carlson, Stephen
• Granted Patent: US 8,293,361 B2
• Time in Patent Office: Days
• US Class Current: 428/294.700
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0046 added as monomers or as oligomers
• CPC Class Codes: C04B 2111/29 Frost-thaw resistance
• 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 41/502 Water
• CPC Class Codes: C04B 41/5089 Silica sols, alkyl, ammonium or alkali metal silicate cements
• 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 41/63 Macromolecular compounds
• CPC Class Codes: C04B 41/71 at least one coating being an organic material
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31815 Of bituminous or tarry residue
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers

Abstract

A coated article which includes a cement fiberboard substrate and a radiation-curable coating system applied to the substrate. The coating system includes a latex polymer, one or more olefinic compounds and water, and may be provided in the form of one or more coating compositions that may be applied in one or more layers, wherein each of the coating compositions is preferably an aqueous composition, or can be mixed with another composition (e.g., on the substrate) to form an aqueous composition.

Claims

1. A coated article, comprising:

a cement fiberboard substrate; and

a radiation-curable coating system applied to the substrate;

wherein the coating system comprises;

an aqueous latex polymer; and

one or more olefinic compounds; and

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

2. The article of claim 1, wherein the coating system further comprises a UV photoinitiator system.

3. The article of claim 1, wherein the latex polymer is stabilized with an alkali-soluble polymer.

4. The article of claim 1, wherein the coating system further comprises a water-dispersible polymer.

5. The article of claim 1, wherein the latex polymer is functionalized so that it may participate in radiation curing.

6. The article of claim 1, wherein the coating system comprises a first composition that includes one or more olefinic compounds and a second composition that includes a latex polymer and water and wherein the coating system is cured using radiation.

7. The article of claim 6, wherein the one or more olefinic compounds comprise a (meth)acrylate, vinyl, vinyl ether, allyl ether, vinyl ester, unsaturated oil, unsaturated fatty acid, or combination thereof.

8. The article of claim 7, wherein the one or more olefinic compounds comprise isobornyl (meth)acrylate, isodecyl (meth)acrylate, phenoxyethyl (meth)acrylate, trimethylolpropane tri(meth)acrylate, alkoxylated cyclohexane dimethanol di(meth)acrylate, trimethylolpropane ethoxylate tri(meth)acrylate, dipropylene glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate, hexanediol di(meth)acrylate, tetrahydrofurfuryl (meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, di-(trimethyolpropane tetra(meth)acrylate), propoxylated glycerol tri(meth)acrylate, beta-carboxyethyl (meth)acrylate, bisphenol A ethoxylate di(meth)acrylate, ethoxylated neopentyl glycol di(meth)acrylate, propoxylated neopentyl glycol di(meth)acrylate, di-(trimethyolpropane tetra (meth)acrylate) or combination thereof.

9. The article of claim 8, wherein the one or more olefinic compounds comprise trimethylolpropane tri(meth)acrylate, bisphenol A ethoxylate di(meth)acrylate, propoxylated glycerol tri(meth)acrylate, trimethylolpropane ethoxylate tri(meth)acrylate, di-(trimethyolpropane tetra(meth)acrylate), or combination thereof.

10. The article of claim 6, wherein the one or more olefinic compounds comprise a monomer.

11. The article of claim 6, wherein the one or more olefinic compounds comprise an oligomer.

12. The article of claim 1, wherein at least one of the coating compositions is UV curable.

13. The article of claim 1, wherein at least one of the coating compositions is electron beam curable.

14. The article of claim 1, wherein the latex polymer is derived from at least one (meth)acrylate monomer.

15. The article of claim 1, wherein the latex polymer is derived from at least one styrene monomer.

16. The article of claim 1, wherein the latex polymer is derived from vinyl acetate.

17. The article of claim 1, wherein the latex polymer is derived from a vinyl ester of a saturated monocarboxylic acid containing about 5 to about 10 carbon atoms.

18. The article of claim 1, wherein the latex polymer is derived from acetoacetyl ethyl methacrylate.

19. The article of claim 1, wherein the latex polymer is radiation curable.

20. The article of claim 1, wherein the latex polymer is substantially free of radiation curable moieties.

21. The article of claim 1, wherein the coating system further comprises a water-soluble silicate salt.

22. The article of claim 21, wherein the coating composition comprises potassium silicate.

23. The article of claim 1, wherein a topcoat is applied over the coating system.

24. The article of claim 1, wherein the cement fiberboard substrate is in the form of a siding product.

25. The article of claim 1, wherein the coated article when radiation cured can withstand at least 30 freeze-thaw cycles.

26. The article of claim 25, wherein the coated article when radiation cured can withstand at least 75 freeze-thaw cycles.

27. The article of claim 26, wherein the coated article when radiation cured can withstand at least 175 freeze-thaw cycles.

28. The article of claim 1, wherein the coating system has a VOC of less than about 5% based on the total weight of the coating system.

29. The article of claim 1, wherein the coating system has a VOC of less than about 2% based on the total weight of the coating system.

30. The article of claim 1, wherein the coating system has a VOC of less than about 0.5% based on the total weight of the coating system.

32. A method for making a coated article, which method comprises:

providing a cement fiberboard substrate;

coating at least a portion of the substrate with a radiation-curable coating system of claim 1;

and

radiation-curing the coating.

33. A method according to claim 32 comprising coating the substrate with a first coating composition comprising the one or more olefinic compounds followed by a second coating composition comprising the aqueous dispersion of polymer particles.

34. A coated article prepared according to the method of claim 32.

31. A coated article, comprising:

a cement fiberboard substrate; and

a radiation-curable coating system applied to the substrate;

wherein the coating system comprises;

an aqueous dispersion of polymer particles wherein the dispersion comprises a latex polymer dispersion and a polyurethane dispersion; and

one or more olefinic compounds;

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

wherein at least one of the one or more coating compositions is an aqueous composition.