COATING SYSTEMS FOR CEMENT COMPOSITE ARTICLES

• US 20080008895A1
• Filed: 07/09/2007
• Published: 01/10/2008
• Est. Priority Date: 07/07/2006
• Status: Active Grant

• Current Assignee: Axalta Coating Systems Ip Co Llc (Axalta Coating Systems Ltd.)
• Original Assignee: Valspar Sourcing, Inc. (Sherwin-Williams Company)
• Inventors: Garner, Archie, Killilea, T., Hartinger, Dan, Brandenburger, Larry, Evanson, Kevin, Cavallin, Carl
• Granted Patent: US 8,932,718 B2
• Time in Patent Office: Days
• US Class Current: 428/500
• 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

The present invention provides a coating composition, a method of coating a substrate, and a coated substrate (e.g., a coated cement fiberboard article). In preferred embodiments the coating composition includes one or more latex polymers and an aliphatic epoxy resin system. The coating composition can include one or more coating compositions that may be applied in one or more layers. A coated article comprising a cement fiberboard substrate and a coating system applied to the substrate is also provided. The article includes a first coating system applied to the substrate, wherein the first coating system includes an aliphatic epoxy resin system having an aqueous dispersion of polymer particles, optionally a silicate additive, and optionally one or more olefinic compounds and initiator for same. The first coating system preferably includes one or more coating compositions that may be applied in one or more layers. In a preferred embodiment, the first coating system is applied to all the surfaces of the substrate (e.g., the front side, back side and edges of a board). The coated substrate may then be coated with other optional coatings, e.g., decorative or protective topcoats.

Claims

1. A coating composition comprising:

one or more latex polymers;

an aliphatic epoxy resin system having an oxirane functional component that is distinct from the one or more latex polymers;

wherein the oxirane functional component in the aliphatic epoxy resin system has an epoxy equivalent weight less than 1000; and

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

2. The coating composition of claim 1, wherein the latex polymer has a Tg of between 5 and 70°

C.

3. The coating composition of claim 2, wherein the latex polymer has a Tg of between 15 and 60°

C.

4. The coating composition of claim 1, wherein the latex polymer is a multistage latex.

5. The coating composition of claim 1, wherein the latex polymer comprises one or more epoxy functional groups.

6. The coating composition of claim 5, wherein at least one of the latex polymers comprises glycidyl methacrylate, glycidyl acrylate, 4-hydroxybutyl acrylate glycidylether, and combinations thereof.

7. The coating composition of claim 1, wherein the minimum film forming temperature of the blend of the one or more latex polymers with the oxirane functional component of the aliphatic epoxy resin system is less than about 20°

C.

8. The coating composition of claim 1, wherein the latex polymer comprises acetoacetoxy-functionality.

9. The coating composition of claim 1, wherein the latex polymer comprises one or more amine groups.

10. The coating composition of claim 1, wherein the coating composition 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 mixtures thereof.

11. The coating composition of claim 1, wherein the oxirane functional component is the reaction product of an oxirane precursor molecule with an alcohol containing material or a carboxylic acid containing material.

12. The coating composition of claim 11, wherein at least a portion of the alcohol containing material is ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methyl-1,3-propanediol, neopentyl glycol, 2,2-butylethyl propanediol, hexanediol, diethylene glycol, dipropylene glycol, polyethylene glycols, polypropylene glycols, cyclohexane dimethylol, 2,2,3-trimethylpentanediol, trimethyol propane, ethoxylated trimethyol propane, propoxylated trimethyol propane, glycerine, propoxylated glycerine, pentaerythritol, ethoxylated pentaerythritol, propoxylated pentaerythritol, dipentaerythritol, tripentaerythritol, ethoxylated and propoxylated di-pentaerythritol, ethoxylated and propoxylated tri-pentaerythritol, ditrimethylolpropane, hydroxypivalyl hydroxypivalate, hydrogenated bisphenol A, ethoxylated and propoxylated hydrogenated bisphenol A, isosorbide, or mixtures thereof.

13. The coating composition of claim 11, wherein at least a portion of the carboxylic acid containing material is malonic acid, succinic acid, glutaric acid, sebacic acid, fumaric acid, adipic acid, pimelic acid, hexahydrophthalic acid, 1,3- and 1,4 cyclohexanedicarboxylic acid, orthophthalic acid, isophthalic acid, maleic acid, chlorendic acid, glycolic acid, citric acid, trimellitic acid, lactic acid, caprolactone, or mixtures thereof.

14. The coating composition of claim 11, wherein oxirane functional component has an epoxy equivalent weight of about 90 to 350.

15. A coated article comprising one or more layers of the composition of claim 1, and one or more layers of a second coating system comprising a latex polymer.

16. A coated article comprising one or more layers of the composition of claim 1, and one or more layers of a second coating system comprising a functionalized latex polymer, a multistage latex polymer, or a functionalized, multistage latex polymer.

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

18. The method of claim 17, comprising applying the coating composition on at least one major surface and on the four edges of a substrate.

19. A method for preparing the coating composition of claim 1 comprising:

mixing one or more latex polymers with one or more aliphatic epoxy resins to form a first component;

mixing the first component with a second component having reactive groups that can react with the epoxy resin; and

applying the mixed first and second components onto a substrate.

20. 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 having 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.

21. The coated article of claim 20, wherein the latex polymer has a Tg of between 5 and 70°

C.

22. The coated article of claim 20, wherein the latex polymer is a multistage latex.

23. The coated article of claim 20, wherein the latex polymer comprises one or more epoxy functional groups.

24. The coated article of claim 23, wherein at least one of the one or more latex polymers comprises glycidyl methacrylate, glycidyl acrylate, 4-hydroxybutyl acrylate glycidylether, or combinations thereof.

25. The coated article of claim 20, wherein the latex polymer comprises one or more amine groups.

26. The coated article of claim 20, 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 mixtures thereof.

27. The coated article of claim 26, wherein the article is coated on both major surfaces and on the four edges with the first coating system.

28. The coated article of claim 20, wherein the first coating system further comprises one or more olefinic compounds and is radiation curable.

29. The coated article of claim 20, wherein the first coating system is applied to a dry film weight of between about 6 and 60 gm/m².

30. The coated article of claim 20, further comprising a second coating system comprising (i) a latex containing primer, (ii) a latex containing topcoat, or (iii) both.

31. The coated article of claim 30, wherein the second coating system comprises a functionalized latex polymer, a multistage latex polymer or a functionalized, multistage latex polymer.

32. The coated article of claim 31, wherein the second coating system comprises (i) an acetoacetoxy-functional latex containing primer, or (ii) an acetoacetoxy-functional latex containing topcoat, or (iii) both.

33. The coated article of claim 31, wherein the article is coated on both major surfaces and on the four edges with the first and second coating system.

34. The coated article of claim 20, wherein the article has been 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.

35. The coated article of claim 20, wherein the first coating system comprises one or more pigments.

36. The coated article of claim 20, wherein the article can withstand at least 30 freeze-thaw cycles.

37. 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 having 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.

38. The coated article of claim 37, wherein the aqueous dispersion of polymer particles is a polyurethane polymer, a latex polymer, or a mixture of both.

39. The coated article of claim 37, wherein the aqueous dispersion of polymer particles is a polyurethane polymer.

40. A method, comprising the steps of:

providing a cement fiberboard substrate;

applying a first coating system to the substrate;

wherein the first coating system comprises an aliphatic epoxy resin system having one or more aqueous dispersions of polymer particles;

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

allowing the first coating system to harden.

41. The method of claim 40, further comprising the step of:

applying a second coating system to the substrate, wherein the second coating system comprises a latex polymer.

42. The method of claim 41, wherein the latex polymer is a functionalized latex polymer or a multistage latex polymer or a functionalized, multistage latex polymer.

43. The method of claim 41, wherein the first coating system is at least partially dried prior to the application of the second coating system.

44. The method of claim 41, wherein the first coating system is dried prior to the application of the second coating system.

45. The method of claim 41, wherein the second coating system is applied to the first coating system while the first coating system is still wet.

46. The method of claim 41, further comprising the step of exposing one or both of the coating systems to UV light.