Coating systems for cement composite articles
First Claim
Patent Images
1. A method for preparing an aqueous film-forming curable coating composition comprising:
- mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and
providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin;
wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and
the coating composition contains about 5 to about 60 wt. % solids based on the total weight of non-volatile components in the coating composition and contains at least about 2 wt. % and less than about 40 wt. % aliphatic epoxy resin based upon total solids in the coating composition.
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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.
236 Citations
29 Claims
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1. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and
the coating composition contains about 5 to about 60 wt. % solids based on the total weight of non-volatile components in the coating composition and contains at least about 2 wt. % and less than about 40 wt. % aliphatic epoxy resin based upon total solids in the coating composition. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one er-mere aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and
wherein the at least one latex polymer comprises acetoacetoxy-functionality.
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19. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and
wherein the first or second component further comprises a water-soluble silicate salt. - View Dependent Claims (20)
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21. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and
wherein the first or second component further comprises one or more olefinic compounds and the coating composition is radiation curable.
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22. A method for preparing an aqueous low-VOC film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein the at least one latex polymer is selected from the group consisting of single-phase latex polymers having a Tg of at least 5°
C. and multi-stage latex polymers having a hard segment with a Tg between 30 and 70°
C. and a soft segment with a Tg between 0 and 25°
C.;wherein a mixture of the first and second components provides the aqueous low-VOC film-forming curable coating composition; and wherein the coating composition;
has a VOC content of less than about 5%, based on the total weight of the coating composition;
does not contain a volatile reactive coalescing agent;
contains about 5 to about 60 wt. % solids based on the total weight of non-volatile components in the coating composition; and
contains at least about 2 wt. % and less than about 40 wt. % aliphatic epoxy resin based upon total solids in the coating composition.
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23. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and further comprising mixing the first and second components to form the aqueous film-forming curable coating composition, and applying the coating composition onto a substrate, wherein the substrate comprises cement.
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24. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and further comprising mixing the first and second components to form the aqueous film-forming curable coating composition, and applying the coating composition onto a substrate, wherein the substrate comprises cement fiberboard.
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25. A method for preparing an aqueous film-forming curable coating composition comprising:
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mixing at least one latex polymer and at least one aliphatic epoxy resin having an epoxy equivalent weight less than 1000 and being distinct from the at least one latex polymer to provide an aqueous first component; and providing a second component having reactive groups that can react with the at least one aliphatic epoxy resin; wherein a mixture of the first and second components provides the aqueous film-forming curable coating composition; and further comprising (i), (ii), or (iii);
(i) applying a latex-containing primer onto a substrate before applying the coating composition onto the substrate, (ii) applying a latex-containing topcoat after applying the coating composition onto a substrate, and (iii) both (i) and (ii). - View Dependent Claims (26, 27, 28, 29)
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Specification