Acrylic dispersion-based coating compositions

Abstract

Coating compositions and methods for their preparation are described. The coating compositions can include a first copolymer produced by emulsion polymerization and derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene. The first copolymer can have a Tg from −50° C. to −23° C. and is present in an amount of 10-50% by weight based on the total polymer content. The coating compositions can also include a second copolymer produced by emulsion polymerization and derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene. The second copolymer can have a Tg from −15° C. to 25° C. and is present in an amount of 50-90% by weight based on the total polymer content. Further described herein are dried coatings, methods for coating a substrate, and methods for producing a coating.

Description

BACKGROUND

Desirable properties for coating compositions suitable for use in roofing applications are set, for example, by the American Society for Testing Materials (ASTM). ASTM D 6083-05 specifies that desirable properties of roof coatings include high tensile strength, high elongation, high flexibility, and mandrel bend performance at low temperatures. At the present time, roof coatings that meet these performance properties are typically based on polyurethane, silicone or polyvinyl chloride (PVC) polymers or copolymers. However, these coatings are often solvent borne and expensive. Thus, there is a need in the art to provide coating compositions that are able to achieve and even exceed the desired performance properties set forth in ASTM D 6083-05 at a cost effective level.

SUMMARY

Coating compositions and methods for their preparation are described. The coating compositions comprise a first copolymer and a second copolymer. In some embodiments, the coating compositions can include a first copolymer produced by emulsion polymerization and derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene. The first copolymer can have a Tg from −50° C. to −23° C. and is present in an amount of 10-50% by weight based on the total polymer content. The coating compositions also include a second copolymer produced by emulsion polymerization and derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene. The second copolymer can have a Tg from −15° C. to 25° C. and is present in an amount of 50-90% by weight based on the total polymer content. The coating compositions can further include a filler comprising at least one pigment, a pigment dispersing agent, a thickener, a defoamer, a surfactant, and water. The coating composition can have a viscosity of from 12,000 to 85,000 cps at 25° C., a volume solids of greater than 50%, and a weight solids of greater than 60%. Also, the coating composition, when applied as a film, dried and weathered for 1000 hours, can pass the mandrel bend test set forth in ASTM D 6083-05 at at −26° C. and can optionally have a tensile strength of greater than 300 psi.

The at least one first copolymer can be present in an amount of 20-30% by weight based on the total polymer content. In some examples, the first copolymer has a Tg of from −36° C. to −23° C. The second copolymer can have a Tg of from −12° C. to 0° C. In some examples, at least one of the first copolymer and the second copolymer is a styrene acrylic copolymer. In some examples, the first copolymer and the second copolymer are pure acrylics. The first copolymer and the second copolymer can each be derived from at least one low Tg monomer selected from the group consisting of butyl acrylate and 2-ethylhexyl acrylate. Optionally, at least one of the first copolymer and the second copolymer are further derived from at least one high Tg monomer selected from the group consisting of methyl methacrylate and styrene. At least one of the first copolymer and the second copolymer can be derived from a crosslinkable monomer. The acid monomers in the first copolymer and the second copolymer can each be selected from the group consisting acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, and mixtures thereof. At least one of the first copolymer and the second copolymer can be further derived from (meth)acrylamide.

The coating composition can further include one or more of a biocide, a dispersing agent, and a coalescing agent. In some examples, the coating composition can further include a quick setting additive (e.g., a polyamine such as polyethyleneimine or a derivatized polyamine such as an alkoxylated polyethyleneimine).

In other embodiments, the coating compositions can comprise a composition including a first copolymer and a second copolymer. In these examples, the first copolymer is produced by emulsion polymerization and derived from one or more monomers including one of more of butyl acrylate and 2-ethylhexyl acrylate, one or more acid monomers, a crosslinkable monomer, and optionally styrene or methyl methacrylate. The first copolymer can have a Tg from −36° C. to −23° C. In these examples, the second copolymer is produced by emulsion polymerization and derived from one or more monomers including one of more of butyl acrylate and 2-ethylhexyl acrylate, one or more acid monomers, a crosslinkable monomer, and optionally styrene or methyl methacrylate. The second copolymer can have a Tg from −12° C. to 0° C. The first copolymer and the second copolymer can be dispersed in an aqueous medium.

Also described herein are dried coatings. The dried coatings can be formed by drying a composition as described herein.

Further described herein are methods of coating a substrate. The method can include applying a coating composition as described herein to a surface. In some examples, the surface is a roof surface. In some examples, the surface is a wall.

Methods of producing a coating are also provided herein. The methods include mixing a composition as described herein with a filler comprising at least one pigment, a dispersing agent, a thickener, a defoamer, and a stabilizer.

The details of one or more embodiments are set forth in the description below. Other features, objects, and advantages will be apparent from the description and from the claims.

DETAILED DESCRIPTION

Acrylic dispersion-based coating compositions and methods of their preparation and use are described herein. The coating compositions include a first copolymer and a second copolymer. The first copolymer described herein can be derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene. The second copolymer described herein can be derived from one or more monomers including one or more (meth)acrylates, one or more acid monomers, and optionally styrene.

The one or more (meth)acrylates can include esters of α,β-monoethylenically unsaturated mono- and dicarboxylic acids having 3 to 6 carbon atoms with alkanols having 1 to 12 carbon atoms (e.g., esters of acrylic acid, methacrylic acid, maleic acid, fumaric acid, or itaconic acid, with C1-C12, C1-C8, or C1-C4 alkanols). In some examples, the one or more (meth)acrylates for preparing the first copolymer and/or second copolymer are selected from butyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, and mixtures of these.

The one or more acid monomers can include α,β-monoethylenically unsaturated mono- and dicarboxylic acids (e.g., acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, crotonic acid, dimethacrylic acid, ethylacrylic acid, allylacetic acid, vinylacetic acid, mesaconic acid, methylenemalonic acid, or citraconic acid). In some examples, the one or more acid monomers for preparing the first copolymer and/or second copolymer are selected from the group consisting acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, and mixtures of these.

Optionally, the first copolymer and the second copolymer are each derived from at least one low glass transition temperature (Tg) monomer. As used herein, a low Tg monomer refers to a monomer having a Tg value of less than −40° C. for the corresponding homopolymer. Examples of suitable low Tg monomers include butyl acrylate (Tg value of −43° C.) and 2-ethylhexyl acrylate (Tg value of −58° C.).

Optionally, the first copolymer and the second copolymer are each derived from at least one high Tg monomer. As used herein, a high Tg monomer refers to a monomer having a Tg value of greater than 40° C. for the corresponding homopolymer. Examples of suitable high Tg monomers include methyl methacrylate (Tg value of 105° C.) and styrene (Tg value of 100° C.).

In some embodiments, at least one of the first copolymer and the second copolymer is further derived from an acrylamides or an alkyl-substituted acrylamide. Suitable examples include N-tert-butylacrylamide and N-methyl(meth)acrylamide. In some embodiments, at least one of the first copolymer and the second copolymer is further derived from (meth)acrylamide.

Optionally, at least one of the first copolymer and the second copolymer is derived from a crosslinkable monomer. For example, the crosslinkable monomer can include diacetone acrylamide (DAAM) or a self-crosslinking monomer such as a monomer comprising 1,3-diketo groups (e.g., acetoacetoxyethyl(meth)acrylate) or a silane crosslinker. Examples of suitable silane crosslinkers include 3-methacryloxypropyl trimethoxysilane, 3-mercaptopropyl trimethoxysilane, vinyltriethoxysilane, and polyvinyl-siloxane oligomers such as DYNASYLAN 6490, a polyvinyl siloxane oligomer derived from vinyltrimethoxysilane, and DYNASYLAN 6498, a polyvinyl siloxane oligomer derived from vinyltriethoxysilane, both commercially available from Evonik Degussa GmbH (Essen, Germany) The polyvinyl siloxane oligomer can have the following structure:

wherein n is an integer from 1 to 50 (e.g., 10). Crosslinkable monomers as described herein can further include monomers such as divinylbenzene; 1,4-butanediol diacrylate; methacrylic acid anhydride; and monomers containing urea groups (e.g., ureidoethyl(meth)acrylate, acrylamidoglycolic acid, and methacrylamidoglycolate methyl ether. Additional examples of crosslinkable monomers include N-alkylolamides of α,β-monoethylenically unsaturated carboxylic acids having 3 to 10 carbon atoms and esters thereof with alcohols having 1 to 4 carbon atoms (e.g., N-methylolacrylamide and N-methylolmethacrylamide); glyoxal based crosslinkers; monomers containing two vinyl radicals; monomers containing two vinylidene radicals; and monomers containing two alkenyl radicals. Exemplary crosslinkable monomers include diesters or triesters of dihydric and trihydric alcohols with α,β-monoethylenically unsaturated monocarboxylic acids (e.g., di(meth)acrylates, tri(meth)acrylates), of which in turn acrylic acid and methacrylic acid can be employed. Examples of such monomers containing two non-conjugated ethylenically unsaturated double bonds are alkylene glycol diacrylates and dimethacrylates, such as ethylene glycol diacrylate, 1,3-butylene glycol diacrylate, 1,4-butylene glycol diacrylate and propylene glycol diacrylate, vinyl methacrylate, vinyl acrylate, allyl methacrylate, allyl acrylate, diallyl maleate, diallyl fumarate and methylenebisacrylamide. In some examples, the first copolymer and/or the second copolymer can include from 0 to 5% by weight of one or more crosslinkable monomers.

The first copolymer and/or second copolymer can further include additional monomers. Further examples of additional monomers include vinylaromatics such as α- and p-methylstyrene, α-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene, and vinyltoluene; conjugated dienes (e.g., isoprene); anhydrides of α,β-monoethylenically unsaturated mono- and dicarboxylic acids (e.g., maleic anhydride, itaconic anhydride, and methylmalonic anhydride); (meth)acrylonitrile; vinyl and vinylidene halides (e.g., vinyl chloride and vinylidene chloride); vinyl esters of C1-C18 mono- or dicarboxylic acids (e.g., vinyl acetate, vinyl propionate, vinyl n-butyrate, vinyl laurate and vinyl stearate); C1-C4 hydroxyalkyl esters of C3-C6 mono- or dicarboxylic acids, especially of acrylic acid, methacrylic acid or maleic acid, or their derivatives alkoxylated with from 2 to 50 moles of ethylene oxide, propylene oxide, butylene oxide or mixtures thereof, or esters of these acids with C1-C18 alcohols alkoxylated with from 2 to 50 mol of ethylene oxide, propylene oxide, butylene oxide or mixtures thereof (e.g., hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate, and methylpolyglycol acrylate); and monomers containing glycidyl groups (e.g., glycidyl methacrylate).

Further examples of additional monomers or co-monomers that can be used include linear 1-olefins, branched-chain 1-olefins or cyclic olefins (e.g., ethene, propene, butene, isobutene, pentene, cyclopentene, hexene, and cyclohexene); vinyl and allyl alkyl ethers having 1 to 40 carbon atoms in the alkyl radical, wherein the alkyl radical can possibly carry further substituents such as a hydroxyl group, an amino or dialkylamino group, or one or more alkoxylated groups (e.g., methyl vinyl ether, ethyl vinyl ether, propyl vinyl ether, isobutyl vinyl ether, 2-ethylhexyl vinyl ether, vinyl cyclohexyl ether, vinyl 4-hydroxybutyl ether, decyl vinyl ether, dodecyl vinyl ether, octadecyl vinyl ether, 2-(diethylamino)ethyl vinyl ether, 2-(di-n-butylamino)ethyl vinyl ether, methyldiglycol vinyl ether, and the corresponding allyl ethers); sulfo-functional monomers (e.g., allylsulfonic acid, methallylsulfonic acid, styrenesulfonate, vinylsulfonic acid, allyloxybenzenesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, and their corresponding alkali metal or ammonium salts, sulfopropyl acrylate and sulfopropyl methacrylate); phosphorus-containing monomers (e.g., dihydrogen phosphate esters of alcohols in which the alcohol contains a polymerizable vinyl or olefenic group, allyl phosphate, phosphoalkyl(meth)acrylates such as 2-phosphoethyl(meth)acrylate (PEM), 2-phosphopropyl(meth)acrylate, 3-phosphopropyl(meth)acrylate, and phosphobutyl(meth)acrylate, 3-phospho-2-hydroxypropyl(meth)acrylate, mono- or di-phosphates of bis(hydroxymethyl) fumarate or itaconate; phosphates of hydroxyalkyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate, 3-hydroxypropyl(meth)acrylate, ethylene oxide condensates of (meth)acrylates, H₂C═C(CH₃)COO(CH₂CH₂O)_nP(O)(OH)₂, and analogous propylene and butylene oxide condensates, where n is an amount of 1 to 50, phosphoalkyl crotonates, phosphoalkyl maleates, phosphoalkyl fumarates, phosphodialkyl(meth)acrylates, phosphodialkyl crotonates, vinyl phosphonic acid, allyl phosphonic acid, 2-acrylamido-2methylpropanephosphinic acid, α-phosphonostyrene, 2-methylacrylamido-2-methylpropanephosphinic acid, (hydroxy)phosphinylalkyl(meth)acrylates, (hydroxy)phosphinylmethyl methacrylate, and combinations thereof); alkylaminoalkyl(meth)acrylates or alkylaminoalkyl(meth)acrylamides or quaternization products thereof (e.g., 2-(N,N-dimethylamino)ethyl(meth)acrylate, 3-(N,N-dimethylamino)propyl(meth)acrylate, 2-(N,N,N-trimethylammonium)ethyl(meth)acrylate chloride, 2-dimethylaminoethyl(meth)acrylamide, 3-dimethylaminopropyl(meth)acrylamide, and 3-trimethylammoniumpropyl(meth)acrylamide chloride); allyl esters of C1-C30 monocarboxylic acids; N-vinyl compounds (e.g., N-vinylformamide, N-vinyl-N-methylformamide, N-vinylpyrrolidone, N-vinylimidazole, 1-vinyl-2-methylimidazole, 1-vinyl-2-methylimidazoline, N-vinylcaprolactam, vinylcarbazole, 2-vinylpyridine, and 4-vinylpyridine).

The first copolymer and the second copolymer can independently be pure acrylics, styrene acrylics, or vinyl acrylics. In some embodiments, the first copolymer is a styrene acrylic copolymer (i.e., the first copolymer is a styrene acrylic copolymer, the second copolymer is a styrene acrylic copolymer, or both the first copolymer and the second copolymer are styrene acrylic copolymers). In other embodiments, at least one of the first copolymer and the second copolymer is a pure acrylic (i.e., the first copolymer is a pure acrylic, the second copolymer is a pure acrylic, or both the first copolymer and second copolymer are pure acrylics).

The first copolymer and the second copolymer can be prepared by polymerizing the monomers using free-radical emulsion polymerization. The monomers for the first copolymer and the second copolymer can be prepared as aqueous dispersions. The emulsion polymerization temperature is generally from 30° C. to 95° C. or from 75° C. to 90° C. The polymerization medium can include water alone or a mixture of water and water-miscible liquids, such as methanol. In some embodiments, water is used alone. The emulsion polymerization can be carried out either as a batch, semi-batch, or continuous process. Typically, a semi-batch process is used. In some embodiments, a portion of the monomers can be heated to the polymerization temperature and partially polymerized, and the remainder of the polymerization batch can be subsequently fed to the polymerization zone continuously, in steps or with superposition of a concentration gradient.

The free-radical emulsion polymerization can be carried out in the presence of a free-radical polymerization initiator. The free-radical polymerization initiators that can be used in the process are all those which are capable of initiating a free-radical aqueous emulsion polymerization including alkali metal peroxydisulfates and H₂O₂, or azo compounds. Combined systems can also be used comprising at least one organic reducing agent and at least one peroxide and/or hydroperoxide, e.g., tert-butyl hydroperoxide and the sodium metal salt of hydroxymethanesulfinic acid or hydrogen peroxide and ascorbic acid. Combined systems can also be used additionally containing a small amount of a metal compound which is soluble in the polymerization medium and whose metallic component can exist in more than one oxidation state, e.g., ascorbic acid/iron(II) sulfate/hydrogen peroxide, where ascorbic acid can be replaced by the sodium metal salt of hydroxymethanesulfinic acid, sodium sulfite, sodium hydrogen sulfite or sodium metal bisulfite and hydrogen peroxide can be replaced by tert-butyl hydroperoxide or alkali metal peroxydisulfates and/or ammonium peroxydisulfates. In the combined systems, the carbohydrate derived compound can also be used as the reducing component. In general, the amount of free-radical initiator systems employed can be from 0.1 to 2%, based on the total amount of the monomers to be polymerized. In some embodiments, the initiators are ammonium and/or alkali metal peroxydisulfates (e.g., sodium persulfate), alone or as a constituent of combined systems. The manner in which the free-radical initiator system is added to the polymerization reactor during the free-radical aqueous emulsion polymerization is not critical. It can either all be introduced into the polymerization reactor at the beginning, or added continuously or stepwise as it is consumed during the free-radical aqueous emulsion polymerization. In detail, this depends in a manner known to an average person skilled in the art both from the chemical nature of the initiator system and on the polymerization temperature. In some embodiments, some is introduced at the beginning and the remainder is added to the polymerization zone as it is consumed. It is also possible to carry out the free-radical aqueous emulsion polymerization under superatmospheric or reduced pressure.

The first or second copolymer can each independently be produced by single stage polymerization or multiple stage polymerization. In some embodiments, the first copolymer and the second copolymer are each copolymerized separately to produce a first dispersion including a plurality of polymer particles including the first copolymer and a second dispersion comprising a plurality of polymer particles including the second copolymer. The first and second dispersions can then be combined to provide a dispersion including the first and second copolymers. In some embodiments, the first copolymer and the second copolymer are provided in the same polymer particle by using multiple stage polymerization such that one of the first copolymer and second copolymer can be present as a first stage copolymer (e.g., as a core in a core/shell polymer particle) and one of the first copolymer and second copolymer can be present as a second stage copolymer (e.g., as a shell in a core/shell polymer particle).

One or more surfactants can be included in the aqueous dispersions to improve certain properties of the dispersions, including particle stability. For example, sodium laureth sulfate and alkylbenzene sulfonic acid or sulfonate surfactants could be used. Examples of commercially available surfactants include Calfoam® ES-303, a sodium laureth sulfate, and Calfax® DB-45, a sodium dodecyl diphenyl oxide disulfonate, both available from Pilot Chemical Company (Cincinnati, Ohio). In general, the amount of surfactants employed can be from 0.01 to 5%, based on the total amount of the monomers to be polymerized.

Small amounts (e.g., from 0.01 to 2% by weight based on the total monomer weight) of molecular weight regulators, such as a mercaptan, can optionally be used. Such substances are preferably added to the polymerization zone in a mixture with the monomers to be polymerized and are considered part of the total amount of unsaturated monomers used in the copolymers.

The first copolymer can have a Tg value of less than −20° C. as measured by differential scanning calorimetry (DSC) by measuring the midpoint temperature using ASTM D 3418-08. For example, the Tg of the first copolymer can be from −50° C. to −23° C., −40° C. to −25° C., or −33° C. to −26° C. In some examples, the Tg of the first copolymer is from −36° C. to −23° C. The second copolymer can have a Tg value of greater than −15° C. For example, the Tg of the second copolymer can be from −12° C. to 25° C., −9° C. to 5° C., or −5° C. to 0° C. In some examples, the Tg of the first copolymer is from −12° C. to 0° C.

The first copolymer can be present in the coating composition in an amount of 10-50% by weight based on the total polymer content. For example, the first copolymer can be present in the coating composition in an amount of 15-35% or 20-30% by weight based on the polymer content. The second copolymer can be present in the coating composition in an amount of 50-90% by weight based on the total polymer content. For example, the second copolymer can be present in the coating composition in an amount of 65-85% or 70-80% by weight based on the total polymer content.

In some embodiments, the first copolymer and the second copolymer can be dispersed in an aqueous medium to form an aqueous dispersion. The aqueous dispersion can be used to form the coating composition. The coating composition can further include at least one filler such as a pigment or extender. The term “pigment” as used herein includes compounds that provide color or opacity to the coating composition. Examples of suitable pigments include metal oxides, such as titanium dioxide, zinc oxide, iron oxide, or combinations thereof. The at least one pigment can be selected from the group consisting of TiO₂ (in both anastase and rutile forms), clay (aluminum silicate), CaCO₃ (in both ground and precipitated forms), aluminum oxide, silicon dioxide, magnesium oxide, talc (magnesium silicate), barytes (barium sulfate), zinc oxide, zinc sulfite, sodium oxide, potassium oxide and mixtures thereof. Examples of commercially titanium dioxide pigments are KRONOS® 2101, KRONOS® 2310, available from Kronos WorldWide, Inc., TI-PURE® R-900, available from DuPont, or TIONA® AT1 commercially available from Millenium Inorganic Chemicals. Titanium dioxide is also available in concentrated dispersion form. An example of a titanium dioxide dispersion is KRONOS® 4311, also available from Kronos WorldWide, Inc. Suitable pigment blends of metal oxides are sold under the marks Minex® (oxides of silicon, aluminum, sodium and potassium commercially available from Unimin Specialty Minerals), Celite® (aluminum oxide and silicon dioxide commercially available from Celite Company), and Atomite® (commercially available from Imerys Performance Minerals). Exemplary fillers also include clays such as attapulgite clays and kaolin clays including those sold under the Attagel® and Ansilex® marks (commercially available from BASF Corporation). Additional fillers include nepheline syenite, (25% nepheline, 55% sodium feldspar, and 20% potassium feldspar), feldspar (an aluminosilicate), diatomaceous earth, calcined diatomaceous earth, talc (hydrated magnesium silicate), aluminosilicates, silica (silicon dioxide), alumina (aluminum oxide), mica (hydrous aluminum potassium silicate), pyrophyllite (aluminum silicate hydroxide), perlite, baryte (barium sulfate), Wollastonite (calcium metasilicate), and combinations thereof. More preferably, the at least one filler includes TiO₂, CaCO₃, and/or a clay.

Generally, the mean particle sizes of the filler ranges from about 0.01 to about 50 microns. For example, the TiO₂ particles used in the aqueous coating composition typically have a mean particle size of from about 0.15 to about 0.40 microns. The filler can be added to the aqueous coating composition as a powder or in slurry form. The filler is preferably present in the aqueous coating composition in an amount from about 5 to about 50 percent by weight, more preferably from about 10 to about 40 percent by weight (i.e. the weight percentage of the filler based on the total weight of the coating composition).

Examples of suitable pigment dispersing agents are polyacid dispersants and hydrophobic copolymer dispersants. Polyacid dispersants are typically polycarboxylic acids, such as polyacrylic acid or polymethacrylic acid, which are partially or completely in the form of their ammonium, alkali metal, alkaline earth metal, ammonium, or lower alkyl quaternary ammonium salts. Hydrophobic copolymer dispersants include copolymers of acrylic acid, methacrylic acid, or maleic acid with hydrophobic monomers. In certain embodiments, the composition includes a polyacrylic acid-type dispersing agent, such as Pigment Disperser N, commercially available from BASF SE.

Examples of suitable thickeners include hydrophobically modified ethylene oxide urethane (HEUR) polymers, hydrophobically modified alkali soluble emulsion (HASE) polymers, hydrophobically modified hydroxyethyl celluloses (HMHECs), hydrophobically modified polyacrylamide, and combinations thereof. HEUR polymers are linear reaction products of diisocyanates with polyethylene oxide end-capped with hydrophobic hydrocarbon groups. HASE polymers are homopolymers of (meth)acrylic acid, or copolymers of (meth)acrylic acid, (meth)acrylate esters, or maleic acid modified with hydrophobic vinyl monomers. HMHECs include hydroxyethyl cellulose modified with hydrophobic alkyl chains. Hydrophobically modified polyacrylamides include copolymers of acrylamide with acrylamide modified with hydrophobic alkyl chains (N-alkyl acrylamide). In certain embodiments, the coating composition includes a hydrophobically modified hydroxyethyl cellulose thickener.

Defoamers serve to minimize frothing during mixing and/or application of the coating composition. Suitable defoamers include organic defoamers such as mineral oils, silicone oils, and silica-based defoamers. Exemplary silicone oils include polysiloxanes, polydimethylsiloxanes, polyether modified polysiloxanes, and combinations thereof. Exemplary defoamers include BYK®-035, available from BYK USA Inc., the TEGO® series of defoamers, available from Evonik Industries, the DREWPLUS® series of defoamers, available from Ashland Inc., and FOAMASTER® NXZ, available from BASF Corporation.

Suitable surfactants include nonionic surfactants and anionic surfactants. Examples of nonionic surfactants are alkylphenoxy polyethoxyethanols having alkyl groups of about 7 to about 18 carbon atoms, and having from about 6 to about 60 oxyethylene units; ethylene oxide derivatives of long chain carboxylic acids; analogous ethylene oxide condensates of long chain alcohols, and combinations thereof. Exemplary anionic surfactants include ammonium, alkali metal, alkaline earth metal, and lower alkyl quaternary ammonium salts of sulfosuccinates, higher fatty alcohol sulfates, aryl sulfonates, alkyl sulfonates, alkylaryl sulfonates, and combinations thereof. In certain embodiments, the composition comprises a nonionic alkylpolyethylene glycol surfactant, such as LUTENSOL® TDA 8 or LUTENSOL® AT-18, commercially available from BASF SE. In certain embodiments, the composition comprises an anionic alkyl ether sulfate surfactant, such as DISPONIL® FES 77, commercially available from BASF SE. In certain embodiments, the composition comprises an anionic diphenyl oxide disulfonate surfactant, such as CALFAX® DB-45, commercially available from Pilot Chemical.

Optionally, the coating compositions can further include quick setting additives. Exemplary quick setting additives suitable for use in the coating compositions described herein includes polyamines (i.e., polymers formed from either an amine-group containing monomer or an imine monomer as polymerized units such as aminoalkyl vinyl ether or sulfides; acrylamide or acrylic esters, such as dimethylaminoethyl(meth)acrylate; N-(meth)acryloxyalkyl-oxazolidines such as poly(oxazolidinylethyl methacrylate), N-(meth)acryloxyalkyltetrahydro-1,3-oxazines, and monomers that readily generate amines by hydrolysis). Suitable polyamines can include, for example, poly(oxazolidinylethyl methacrylate), poly(vinylamine), or polyalkyleneimine (e.g., polyethyleneimine). In some embodiments, the quick setting additive is a derivatized polyamine such as an alkoxylated polyalkyleneimine (e.g., ethoxylated polyethyleneimine). Suitable derivatized polyamines are described in U.S. Application Ser. No. 61/714,497, filed Oct. 16, 2012, which is incorporated by reference herein in its entirety.

Other suitable additives that can optionally be incorporated into the composition include coalescing agents (coalescents), pH modifying agents, biocides, co-solvents and plasticizers, crosslinking agents, dispersing agents, rheology modifiers, wetting and spreading agents, leveling agents, conductivity additives, adhesion promoters, anti-blocking agents, anti-cratering agents and anti-crawling agents, anti-freezing agents, corrosion inhibitors, anti-static agents, flame retardants and intumescent additives, dyes, optical brighteners and fluorescent additives, UV absorbers and light stabilizers, chelating agents, cleanability additives, flatting agents, flocculants, humectants, insecticides, lubricants, odorants, oils, waxes and slip aids, soil repellants, stain resisting agents, and combinations thereof.

Suitable coalescents, which aid in film formation during drying, include ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol monoethyl ether acetate, ethylene glycol monobutyl ether acetate, diethylene glycol monobutyl ether, diethylene glycol monoethyl ether acetate, dipropylene glycol monomethyl ether, 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, and combinations thereof.

Examples of suitable pH modifying agents include bases such as sodium hydroxide, potassium hydroxide, amino alcohols, monoethanolamine (MEA), diethanolamine (DEA), 2-(2-aminoethoxyl)ethanol, diisopropanolamine (DIPA), 1-amino-2-propanol (AMP), ammonia, and combinations thereof.

Suitable biocides can be incorporated to inhibit the growth of bacteria and other microbes in the coating composition during storage. Exemplary biocides include 2-[(hydroxymethyl)amino]ethanol, 2-[(hydroxymethyl)amino]2-methyl-1-propanol, o-phenylphenol, sodium salt, 1,2-benzisothiazolin-3-one, 2-methyl-4-isothiazolin-3-one (MIT), 5-chloro2-methyland-4-isothiazolin-3-one (CIT), 2-octyl-4-isothiazolin-3-one (OTT), 4,5-dichloro-2-n-octyl-3-isothiazolone, as well as acceptable salts and combinations thereof. Suitable biocides also include biocides that inhibit the growth of mold, mildew, and spores thereof in the coating. Examples of mildewcides include 2-(thiocyanomethylthio)benzothiazole, 3-iodo-2-propynyl butyl carbamate, 2,4,5,6-tetrachloroisophthalonitrile, 2-(4-thiazolyl)benzimidazole, 2-N-octyl4-isothiazolin-3-one, diiodomethyl p-tolyl sulfone, as well as acceptable salts and combinations thereof. In certain embodiments, the coating composition contains 1,2-benzisothiazolin-3-one or a salt thereof. Biocides of this type include PROXEL® BD20, commercially available from Arch Chemicals, Inc. The biocide can alternatively be applied as a film to the coating and a commercially available film-forming biocide is Zinc Omadine® commercially available from Arch Chemicals, Inc.

Exemplary co-solvents and humectants include ethylene glycol, propylene glycol, diethylene glycol, and combinations thereof.

Exemplary crosslinking agents include dihydrazides (e.g., dihydrazides of adipic acid, succinic acid, oxalic acid, glutamic acid, or sebastic acid). The dihydrazides can be used, for example, to crosslink diacetone acrylamide or other crosslinkable monomers.

A coating composition can be produced by combining the components as described herein. The resulting coating compositions can have a viscosity of from 12,000 to 85,000 cps at 25° C. For example, the coating compositions can have a viscosity of from 15,000 to 80,000 cps, 20,000 to 75,000 cps, 25,000 to 70,000 cps, 30,000 to 65,000 cps, 35,000 to 60,000 cps, or 40,000 to 55,000 cps at 25° C.

The volume solids percentage of the coating composition can be greater than 50%. For example, the volume solids percentage of the coating composition can be greater than 55%, greater than 60%, greater than 65%, greater than 70%, or greater than 75%.

Optionally, the weight solids percentage of the coating composition can be greater than 60%. For example, the weight solids percentage can be greater than 65%, greater than 70%, greater than 75%, or greater than 80%.

In some embodiments, the coating composition can include the following components (based on total weight of the coating composition): water 6.8-17.2% by weight, propylene glycol 0.5-2.5% by weight, pigment dispersing agent 0.4-0.85% by weight, copolymer dispersion (at 55-65% by weight copolymer) 37.8-41.3% by weight, plasticizer 0-1.0% by weight, defoamer 0.3-1.4% by weight, non-ionic surfactant 0-0.1% by weight, thickener 0.1-0.4% by weight, titanium dioxide 3.0-11.2% by weight, zinc oxide 0-3.4% by weight, calcium carbonate 27.7-33.7% by weight, talc or kaolin 0-18.3% by weight, biocide 0.1-0.3% by weight, and ammonia 0.1-0.3% by weight.

The coating composition can be applied to a substrate (e.g., as a film) and allowed to dry to form a dried coating. Generally, coatings are formed by applying a coating composition described herein to a surface, and allowing the coating to dry to form a dried coating. In some embodiments, the surface can be a substantially horizontal surface such as a roof surface. In some embodiments, the surface can be a substantially vertical surface such as a wall. Optionally, the coating composition can be applied to floors to provide moisture control to provide crack-bridging properties.

The coating composition can be applied to a surface by any suitable coating technique, including spraying, rolling, brushing, or spreading. Coating compositions can be applied in a single coat, or in multiple sequential coats (e.g., in two coats or in three coats) as required for a particular application. Generally, the coating composition is allowed to dry under ambient conditions. However, in certain embodiments, the coating composition can be dried, for example, by heating and/or by circulating air over the coating.

The coating can be co-applied with a setting accelerator to decrease the setting time of the coating on a surface. Suitable setting accelerators include compounds, such as acids, which consume the volatile base and decrease coating setting time. For example, the setting accelerator can be a dilute acid, such as acetic acid or citric acid. Setting accelerators can be applied to a surface prior to coating application, applied simultaneously with the coating composition, or applied to the coating after it has been applied to a surface but prior to drying.

The coating thickness can vary depending upon the application of the coating. For example, the coating can have a dry thickness of at least 10 mils (e.g., at least 15 mils, at least 20 mils, at least 25 mils, at least 30 mils, or at least 40 mils). In some instances, the coating has a dry thickness of less than 100 mils (e.g., less than 90 mils, less than 80 mils, less than 75 mils, less than 60 mils, less than 50 mils, less than 40 mils, less than 35 mils, or less than 30 mils). In some embodiments, the coating has a dry thickness of between 10 mils and 100 mils. In certain embodiments, the coating has a dry thickness of between 10 mils and 40 mils.

The coating composition can be applied as a film, dried, subjected to an accelerated weathering process to simulate extended field exposure for 1000 hours or more, and then subjected to the mandrel bend test set forth in ASTM D 6083-05 at −26° C. The coating composition described herein when applied as a film, dried and weathered passes the mandrel bend test set forth in ASTM D 6083-05 at −26° C. The dried and weathered coating compositions can have a tensile strength of from 200 psi or greater as set forth in ASTM D 6083-05. For example, the tensile strength of the dried and weathered coating compositions can be 250 psi or greater, 300 psi or greater, 350 psi or greater, or 400 psi or greater. Such dried and weathered coating compositions can also have an elongation at break of greater than 100% (e.g., greater than 200%, greater than 300%, or greater than 400%) as set forth in ASTM D 6083-05.

The examples below are intended to further illustrate certain aspects of the methods and compositions described herein, and are not intended to limit the scope of the claims.

EXAMPLES

Acrylic Copolymer Blends

An aqueous dispersion of acrylic copolymers was prepared by combining two copolymer dispersions, each separately prepared by emulsion polymerization. Exemplary ingredients used to prepare the coating compositions described herein are shown in Table 1.

TABLE 1
	Ex. 1	Ex. 2	Ex. 3	Ex. 4
Ingredients	(wt %)	(wt %)	(wt %)	(wt %)
Water	6.9	6.8	6.8	14.8
Propylene glycol	2.2	2.2	2.2	2.1
Pigment dispersing agent	0.5	0.5	0.5	0.4
Copolymer Dispersion 1	28.5	28.5	28.5	0.0
(Tg = −8° C.)
Defoamer	0.5	0.5	0.5	0.5
Non-ionic surfactant	0.0	0.0	0.0	0.1
Cellulosic thickener	0.0	0.0	0.0	0.1
Titanium oxide	11.2	11.2	7.8	10.2
Zinc oxide	0.0	0.0	3.4	0.0
Calcium carbonate (medium	26.4	21.9	21.9	24.3
particle size)
Calcium carbonate (fine	1.3	5.9	5.9	1.3
particle size)
Calcium carbonate (ultrafine	0.0	7.9	7.9	0.0
particle size)
Uncoated talc	18.3	0.0	0.0	7.5
Biocide	0.2	0.2	0.2	0.2
Copolymer Dispersion 2	12.8	12.8	12.8	37.8
(Tg = −28° C.)
Cellulose thickener	0.3	0.3	0.3	0.3
Ammonia	0.2	0.2	0.2	0.2
Defoamer	0.9	0.9	0.9	0.9
Total	110.2	99.8	99.8	100.7
Approximate Weight % Solids	72	72	72	66

The ingredients were mixed in the order shown in Table 1 until a homogeneous mixture was formed. The viscosities of the resulting mixtures were in the range of 12,000 to 85,000 cps at 25° C. The percentages of PVC in the mixtures were approximately 42%. The volume percentages of solids in the mixtures were approximately 59%.

Performance Properties of Comparative Example 1 and Example 5

Example 5 was prepared using 20 weight percent of D1 and 80 weight percent of D2. D1 is an acrylic copolymer containing diacetone acrylamide and adipic dihydrazide (DAAM/ADDH) room temperature crosslinking package and having a Tg of −28° C. D2 is a styrene-acrylate copolymer containing a silane crosslinker and having a Tg of −8° C. The dispersion was combined with additives listed in Table 1 to form a coating composition. The coating composition was applied as a film, dried, and weathered for 1278 hours. The resulting weathered film had a tensile strength of 390 psi, a 443% elongation at break, and a water absorption of 13.4%. The weathered film also passed the −26° C. mandrel bend test set forth in ASTM D 6083-05. A film prepared from D2 as the only copolymer (Comparative Example 1) and including the same additives in the same amounts as Example 5 failed the mandrel bend test after weathering and under similar conditions.

Example 6 was the same as Example 5 except it used 35 weight percent of D1 and 65 weight percent of D2 as described above. The resulting weathered film had a tensile strength of 354 psi, a 387% elongation at break, and a water absorption of 13.2%. The film of Example 6 also passed the −26° C. mandrel bend test set forth in ASTM D 6083-05.

Example 7 was the same as Example 5 except it used 50 weight percent of D1 and 50 weight percent of D2 as described above. The resulting weathered film had a tensile strength of 344 psi, a 388% elongation at break, and a water absorption of 13.6%. The film of Example 7 also passed the −26° C. mandrel bend test set forth in ASTM D 6083-05.

The compositions, products, and methods of the appended claims are not limited in scope by the specific compositions, products, and methods described herein, which are intended as illustrations of a few aspects of the claims and any compositions, products, and methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the compositions, products, and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative composition materials and method steps disclosed herein are specifically described, other combinations of the composition materials and method steps also are intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated. The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various embodiments, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide for more specific embodiments of the invention and are also disclosed.

Claims

1. A coating composition, comprising a first copolymer and a second copolymer, wherein: the first copolymer is produced by emulsion polymerization and derived from one or more (meth)acrylates, one or more acid monomers, and optionally styrene, said first copolymer having a Tg from −50° C. to −23° C. and being present in an amount of 10-50% by weight based on the combined weight of the first copolymer and the second copolymer;the second copolymer is produced by emulsion polymerization and derived from one or more (meth)acrylates, one or more acid monomers, and optionally styrene, said second copolymer having a Tg from −15° C. to 25° C. and being present in an amount of 50-90% by weight based on the combined weight of the first copolymer and the second copolymer;a defoamer; anda filler comprising at least one pigment, wherein the filler is present in an amount of from 5-50% by weight, based on the coating composition;wherein at least one of the first copolymer and the second copolymer is crosslinked,wherein said coating composition has a viscosity of from 12,000 to 85,000 cps at 25° C., a volume solids of greater than 50%, and a weight solids of greater than 60%,wherein the coating composition when applied as a film, dried and weathered for 1000 hours passes the mandrel bend test at −26° C., has a tensile strength of greater than 300 psi, and an elongation at break of greater than 200% as set forth in ASTM D 6083-05.

2. The coating composition of claim 1, wherein the coating composition when applied as a film, dried and weathered for 1000 hours as described in ASTM D 6083-05 has a tensile strength of greater than 300 psi to 400 psi.

3. The coating composition of claim 1, wherein the at least one first copolymer is present in an amount of 20-30% by weight based on the combined weight of the first copolymer and the second copolymer.

4. The coating composition of claim 1, wherein the first copolymer has a Tg of from −36° C. to −23° C.

5. The coating composition of claim 1, wherein the second copolymer has a Tg of from −12° C. to 0° C.

6. The coating composition of claim 1, wherein at least one of the first copolymer and the second copolymer is a styrene acrylic copolymer.

7. The coating composition of claim 1, wherein the first copolymer and the second copolymer are pure acrylics.

8. The coating composition of claim 1, wherein the first copolymer and the second copolymer are each derived from at least one low Tg monomer selected from the group consisting of butyl acrylate and 2-ethylhexyl acrylate.

9. The coating composition of claim 1, wherein at least one of the first copolymer and the second copolymer are further derived from at least one high Tg monomer selected from the group consisting of methyl methacrylate and styrene.

10. The coating composition of claim 1, wherein at least one of the first copolymer and the second copolymer is derived from a crosslinkable monomer selected from diacetone acrylamide, a 1,3-diketo-containing monomer, or a silane-containing monomer.

11. The coating composition of claim 1, wherein the acid monomers in the first copolymer and the second copolymer are each selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, and mixtures thereof.

12. The coating composition of claim 1, wherein at least one of the first copolymer and the second copolymer is further derived from (meth)acrylamide.

13. The coating composition of claim 1, further comprising a quick setting additive.

14. The coating composition of claim 13, wherein the quick setting additive includes polyethyleneimine.

15. The coating composition of claim 1, further comprising a setting accelerator.

16. The coating composition of claim 1, wherein the filler is present in an amount of from 10-40% by weight, based on the coating composition.

17. The coating composition of claim 1, wherein the filler comprises a pigment selected from metal oxides, clays, calcium carbonate, talc, barytes, feldspar, zinc sulfite, nepheline syenite, mica, pyrophyllite, perlite, wollastonite, or a combination thereof.

18. The coating composition of claim 17, wherein the pigment has a mean particle size of from about 0.01 to about 50 microns.

19. A composition, comprising: a first copolymer produced by emulsion polymerization and derived from one of more of butyl acrylate and 2-ethylhexyl acrylate, one or more acid monomers, a crosslinkable monomer, and optionally styrene or methyl methacrylate, said first copolymer having a Tg from −36° C. to −23° C.;a second copolymer produced by emulsion polymerization and derived from one of more of butyl acrylate and 2-ethylhexyl acrylate, one or more acid monomers, a crosslinkable monomer, and optionally styrene or methyl methacrylate, said second copolymer having a Tg from −12° C. to 0° C., anda filler comprising at least one pigment, wherein the filler is present in an amount of from 5-50% by weight, based on the composition;wherein the composition has a viscosity of from 12,000 to 85,000 cps at 25° C., andwherein the composition when applied as a film, dried and weathered for 1000 hours passes the mandrel bend test at −26° C., has a tensile strength of greater than 300 psi, and an elongation at break of greater than 200% as set forth in ASTM D 6083-05.

20. The composition of claim 19, wherein the first copolymer and the second copolymer are dispersed in an aqueous medium.

21. The composition of claim 20, wherein the filler is present in an amount of from 10-40% by weight, based on the composition.

22. The composition of claim 19, wherein the filler comprises a pigment selected from metal oxides, clays, calcium carbonate, talc, barytes, feldspar, zinc sulfite, nepheline syenite, mica, pyrophyllite, perlite, wollastonite, or a combination thereof.

23. The composition of claim 22, wherein the pigment has a mean particle size of from about 0.01 to about 50 microns.

24. A dried coating, formed by drying the composition of claim 20.

25. A method of coating a substrate, comprising applying the composition of claim 20 to a surface.

26. The method of claim 25, wherein the surface is a roof surface.

27. The method of claim 25, wherein the surface is a wall.

28. The method of claim 25, wherein the method includes brushing, rolling, or spraying.