COATING SYSTEMS FOR CEMENT COMPOSITE ARTICLES

• US 20150104583A1
• Filed: 12/16/2014
• Published: 04/16/2015
• 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 W., Killilea, T. Howard, Cavallin, Carl Lewis, Peterson, Todd A., Evanson, Kevin W., Hartinger, Dan, Brandenburger, Larry B.
• Granted Patent: US 9,593,051 B2
• Time in Patent Office: Days
• US Class Current: 427/532
• 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 method for preparing a coating composition comprising:

mixing one or more latex polymers and one or more aliphatic epoxy resins 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;

wherein a mixture of the first and second components provides a film-forming curable coating composition.

2. The method of claim 1, wherein the latex polymer has a Tg of at least 5°

C.

3. The method of claim 1, wherein the latex polymer is a multistage latex.

4. The method of claim 3, wherein the multistage latex has a hard segment having a Tg between 30 and 70°

C. and a soft segment having a Tg between 0 and 25°

C.

5. The method of claim 1, wherein the latex polymer comprises acetoacetoxy-functionality.

6. The method of claim 1, wherein the latex polymer further comprises one or more epoxy functional groups.

7. The method of claim 6, wherein the latex polymer can be prepared from glycidyl methacrylate, glycidyl acrylate, 4-hydroxybutyl acrylate glycidylether, or combination thereof.

8. The method of claim 1, wherein the aliphatic epoxy resin is the reaction product of an oxirane precursor molecule with an alcohol containing material, and 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, trimethylol propane, ethoxylated trimethylol propane, propoxylated trimethylol 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 mixture thereof.

9. The method of claim 1, wherein the aliphatic epoxy resin component is the reaction product of an oxirane precursor molecule with a carboxylic acid containing material, and 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 mixture thereof.

10. The method of claim 1, wherein the aliphatic epoxy resin has an epoxy equivalent weight of about 90 to 350.

11. The method of claim 1, wherein the second component comprises an amine.

12. The method of claim 11, wherein the amine comprises an amidoamine, aliphatic amine, cycloaliphatic amine, waterborne amine, water dispersed amine, dicyandiamide, polyoxyalkyleneamine, amino functional phenolic resin, isophorone diamine or piperazine.

13. The method of claim 1, wherein the mixture has a minimum film forming temperature that is lowered by the aliphatic epoxy resin.

14. The method of claim 1, wherein the mixture has a minimum film forming temperature less than about 20°

C.

15. The method of claim 1, wherein the first or second component further comprises a water-soluble silicate salt.

16. The method of claim 15 wherein the silicate salt is potassium silicate, ammonium silicate, sodium silicate, lithium silicate, or mixture thereof.

17. The method of claim 1, wherein the first or second component further comprises one or more pigments.

18. The method of claim 1, wherein the first or second component further comprises one or more olefinic compounds and the mixture is radiation curable.

19. The method of claim 1, further comprising mixing the first and second components to form the mixture and applying the mixture onto a substrate.

20. The method of claim 19, wherein the substrate comprises cement.

21. The method of claim 19, wherein the substrate comprises cement fiberboard.

22. The method of claim 19, wherein the substrate comprises an article having major and minor surfaces and the mixture is applied to at least one major surface of the substrate and up to four minor surfaces of the substrate including edges.

23. The method of claim 19, further comprising applying a latex-containing primer before applying the mixture, (ii) a latex-containing topcoat after applying the mixture, or (iii) both (i) and (ii).

24. The method of claim 23, wherein the latex-containing primer or latex-containing topcoat comprise a functionalized latex polymer, a multistage latex polymer or a functionalized, multistage latex polymer.

25. The method of claim 23, comprising applying an acetoacetoxy-functional latex-containing topcoat.

26. The method of claim 23, comprising applying a latex-containing topcoat after applying the mixture and while the mixture is still wet.

27. The method of claim 23, further comprising radiation-curing the mixture.

28. The method of claim 19, wherein the mixture when cured can withstand at least 30 freeze-thaw cycles.