Patent Application
20190040270
Hydrophobic substituted alcohols are employed in coatings to provide surface effects to various articles.
Fluorinated polymer compositions are used in the preparation of a wide variety of surface treatment materials to provide surface effects to substrates. Many such compositions are fluorinated acrylate polymers or copolymers which contain predominantly eight or more carbons in the perfluoroalkyl chain to provide the desired properties. Honda, et al., in Macromolecules, 2005, 38, 5699-5705 teach that for perfluoroalkyl chains of greater than 8 carbons, orientation of the perfluoroalkyl groups, designated Rf groups, is maintained in a parallel configuration while for such chains having 6 or less carbons, reorientation occurs. This reorientation is recited to decrease surface properties such as contact angle. Thus, polymers containing shorter perfluoroalkyl chains or having no fluorine content have traditionally exhibited lower performance. Non-fluorinated copolymers are known to provide water repellency and optionally stain release to textiles, but are less effective than the fluorinated counterparts. Fluoroadditives have also been used to improve cleanability of paints, including latex paints, which generally have poor stain and soil resistance.
U.S. Pat. No. 7,820,745 discloses aqueous water- and oil-repellent compositions containing a fluorinated copolymer in aqueous medium and a sorbitan ester used in small amounts to act as a surfactant.
The need exists for non-fluorinated or partially fluorinated compositions that provide surface effects to treated substrates, with performance results comparable to fluorinated treating agents. Also desirable is a non-fluorinated composition that can be bio-based derived. The present invention meets these needs.
The present invention relates to a coated article comprising a partial or complete durable coating on the surface of an article, wherein the coating comprises a coating base and 0.1 to 5% by weight of a hydrophobic compound, based on the total solids weight of the coating, selected from a cyclic or acyclic alcohol which is substituted with at least one —R1, —C(O)R1, —(CH2CH2O)n(CH(CH3)CH2O)mR2, —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1, or mixtures thereof; where the cyclic or acyclic alcohol is selected from a pentaerythritol, saccharide, reduced sugar, aminosaccharide, citric acid, aldonic acid, or aldonic acid lactone; wherein each n is independently 0 to 20; each m is independently 0 to 20; m+n is greater than 0; each R1 is independently a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; each R2 is independently —H, a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; and the coating has a thickness of at least 0.1 mils.
The present invention further comprises a method of imparting a surface effect to an article comprising contacting a the surface of the article with a durable coating to form a partially or completely coated article, wherein the coating comprises a coating base and 0.1 to 5% by weight of a hydrophobic compound, based on the total solids weight of the coating, selected from a cyclic or acyclic alcohol which is substituted with at least one —R1, —C(O)R1, —(CH2CH2O)n(CH(CH3)CH2O)mR2, —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1, or mixtures thereof; where the cyclic or acyclic alcohol is selected from a pentaerythritol, saccharide, reduced sugar, aminosaccharide, citric acid, aldonic acid, or aldonic acid lactone; wherein each n is independently 0 to 20; each m is independently 0 to 20; m+n is greater than 0; each R1 is independently a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; each R2 is independently —H, a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; and the coating has a thickness of at least 0.1 mils.
Trademarks are indicated herein by capitalization.
The present invention provides coated articles having improved water repellency, oil or stain repellency, and/or other hydrophobic surface effects. The treated articles provide enhanced performance and durability compared to traditional non-fluorinated commercially available treatment agents. The coating materials of the present invention can be derived from bio-sourced materials. The coatings formed are durable, by which is meant that the coatings are lasting films that are not readily removed by water or cleaning agents. In one aspect, the coatings are not soluble or dispersable in water or cleaning agents once they are dry, and in another aspect, the coatings withstand multiple cleanings without loss of performance.
The present invention relates to a coated article comprising a partial or complete durable coating on the surface of an article, wherein the coating comprises a coating base and 0.1 to 5% by weight of a hydrophobic compound, based on the total solids weight of the coating, selected from a cyclic or acyclic alcohol which is substituted with at least one —R1, —C(O)R1, —(CH2CH2O)n(CH(CH3)CH2O)mR2, —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1, or mixtures thereof; where the cyclic or acyclic alcohol is selected from a pentaerythritol, saccharide, reduced sugar, aminosaccharide, citric acid, aldonic acid, or aldonic acid lactone; wherein each n is independently 0 to 20; each m is independently 0 to 20; m+n is greater than 0; each R1 is independently a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; each R2 is independently —H, a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; and the coating has a thickness of at least 0.1 mils. The —(CH2CH2O)— represents oxyethylene groups (EO) and —(CH(CH3)CH2O)— represents oxypropylene groups (PO). These compounds can contain only EO groups, only PO groups, or mixtures thereof. These compounds can also be present as a tri-block copolymer designated PEG-PPG-PEG (polyethylene glycol-polypropylene glycol-polyethylene glycol), for example. In one embodiment, n+m is 1 to 20; in another embodiment, n+m is 1 to 15; and in a third embodiment, n+m is 1 to 12.
As used herein, the term “coating base” is a composition that is applied to a substrate for the purpose of creating a lasting film on the substrate surface. Such coating bases include compositions with polymer resins, such as architectural coatings, clear coats, and floor finishes. Architectural coatings may have a dry film thickness of greater than 3 mils. Depending on the system (epoxy, acrylic, latex, urethane, polyurethane, etc.) and the number of coats (including primer, body, and top coat), the final dry film thickness can be much greater, sometimes greater than 30 mils, for protection in industrial applications. In one aspect, the coating has a dry film thickness of at least 0.3 mils.
The hydrophobic compound may be a multi-ester alcohol having at least two hydrophobic substitutions, which originates from a polyol or polycarboxylic acid compound. Examples of suitable polyols include but are not limited to cyclic or acyclic sugar alcohols, or pentaerythritols including dipentaerythritol. Suitable polycarboxylic acid compounds include citric acid. The cyclic or acyclic sugar alcohol is selected from a saccharide, reduced sugar, aminosaccharide, aldonic acid, or aldonic acid lactone. Mixtures of these compounds may also be used. The hydrophobic compounds are substituted with at least one —R1; —C(O)R1; —(CH2CH2O)n(CH(CH3)CH2O)mR2; —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; or mixtures thereof. Such a substitution lends hydrophobic character to the monomer, and to the polymer molecules. In one embodiment, the hydrophobic compound is substituted with at least two —R1; —C(O)R1; —(CH2CH2O)n(CH(CH3)CH2O)mR2; —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; or mixtures thereof; and in another embodiment, it is substituted with at least three —R1; —C(O)R1; —(CH2CH2O)n(CH(CH3)CH2O)mR2; —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; or mixtures thereof.
These substituted compounds can be made by the reaction of a sugar alcohol with at least one fatty acid or alkoxylated fatty acid, such as by esterification of a fatty acid; or by esterification of a polycarboxylic acid with a long-chain alcohol. Examples of such sugar alcohols include but are not limited to aldoses and ketoses such as those compounds derived from tetroses, pentoses, hexoses, and heptoses. Specific examples include glucose, 1,4-anhydro-D-glucitol, 2,5-anhydro-D-mannitol, 2,5-anhydro-L-iditol, isosorbide, sorbitan, glyceraldehyde, erythrose, arabinose, ribose, arabinose, allose, altrose, mannose, xylose, lyxose, gulose, glactose, talose, fructose, ribulose, mannoheptulose, sedohelptulose, threose, erythritol, threitol, glucopyranose, mannopyranose, talopyranose, allopyranose, altropyranose, idopyranose, gulopyranose, glucitol, mannitol, erythritol, sorbitol, arabitol, xylitol, ribitol, galactitol, fucitol, iditol, inositol, pentaerythritol, dipentaerythritol, volemitol, gluconic acid, glyceric acid, xylonic acid, galactaric acid, ascorbic acid, citric acid, gluconic acid lactone, glyceric acid lactone, xylonic acid lactone, glucosamine, galactosamine, or mixtures thereof.
Suitable fatty acids include, but are not limited to, caprylic acid, capric acid, lauric acid, mysteric acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, palmitoleic acid, lineolic acid, oleic acid, erucic acid, alkoxylated versions of these acids, and mixtures thereof. In one embodiment, R1 is a linear or branched alkyl group having 11 to 29 carbons, and in another embodiment, R1 is a linear or branched alkyl group having 17 to 21 carbons. In one embodiment, R2 is a linear or branched alkyl group having 12 to 30 carbons, in another embodiment, R2 is a linear or branched alkyl group having 18 to 30 carbons, and in another embodiment, R2 is a linear or branched alkyl group having 18 to 22 carbons. In one embodiment, the fatty acid substitution of the cyclic or acyclic sugar alcohols has a melting point of at least −59° C. In another embodiment, the fatty acid substitution of the cyclic or acyclic sugar alcohols has a melting point of at least 0° C., and in a third embodiment, the fatty acid substitution of the cyclic or acyclic sugar alcohols has a melting point of at least 40° C.
In one embodiment, the hydrophobic compound is selected from Formulas (Ia), (Ib), or (Ic):
wherein each R is independently —H; —R1; —C(O)R1; —(CH2CH2O)n(CH(CH3)CH2O)mR2; or
—(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; each n is independently 0 to 20;
each m is independently 0 to 20; m+n is greater than 0; r is 1 to 3; a is 0 or 1; p is independently 0 to 2; provided that a is 0 when r is 3; each R1 is independently a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; each R2 is independently —H, or a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; provided when Formula (Ia) is chosen, then at least one R is —H and at least one R is a —R1; —C(O)R1; —(CH2CH2O)n(CH(CH3)CH2O)mR2;
or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; each R4 is independently —H, a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond, or combinations thereof;
—(CH2CH2O)n(CH(CH3)CH2O)mR2; or
—(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; provided when Formula (Ib) is chosen, then at least one R or R4 is —H; and at least one R or R4 is a linear or branched alkyl group optionally comprising at least 1 unsaturated bond, or combinations thereof; —(CH2CH2O)n(CH(CH3)CH2O)mR2;
or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1; and each R19 is —H, —C(O)R1, or —CH2C[CH2OR]3, provided when Formula (Ic) is chosen, then at least one R19 or R is —H; and at least one R19 or R is —C(O)R1, —(CH2CH2O)n(CH(CH3)CH2O)mR2; or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1.
Where the hydrophobic compound is Formula (Ia), any suitable substituted reduced sugar alcohol may be employed, including esters of 1,4-sorbitan, esters of 2,5-sorbitan, and esters of 3,6-sorbitan. In one embodiment, the hydrophobic compound is selected from Formula (a) to be Formula (Ia′):
wherein R is further limited to —H; —R1; or —C(O)R1 and at least one R is —C(O)R1 or R1. Compounds used to form residues of Formula (Ia′), having at least one of R is —H and at least one R is selected from —C(O)R1, are commonly known as alkyl sorbitans. These sorbitans can be mono-substituted, di-substituted, or tri-substituted with —C(O)R1. It is known that commercially available sorbitans, such as SPAN, contain a mixture of the various sorbitans ranging from where each R is H (un-substituted), and sorbitans where each R is —C(O)R1 (fully substituted); wherein R1 is a linear or branched alkyl group having 5 to 29 carbons; and mixtures of various substitutions thereof. The commercially available sorbitans may also include amounts of sorbitol, isosorbide, or other intermediates or byproducts.
In one embodiment, at least one R is —C(O)R1, and R1 is a linear branched alkyl group having 5 to 29 carbons. In another embodiment, R1 is a linear or branched alkyl group having 7 to 21 carbons, and in a third embodiment, R1 is a linear or branched alkyl group having 11 to 21 carbons. Preferred compounds used to form these residues include mono-, di-, and tri-substituted sorbitans derived from caprylic acid, capric acid, lauric acid, mysteric acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, and mixtures thereof. Particularly preferred compounds include mono-, di-, and tri-substituted sorbitan stearates or sorbitan behenins.
Optionally, R1 is a linear or branched alkyl group having 5 to 29 carbons comprising at least 1 unsaturated bond. Examples of compounds of Formula (Ia) wherein at least one R is selected from —C(O)R1; and R1 contains least 1 unsaturated bond, include, but are not limited to, sorbitan trioleate (i.e., wherein R1 is —C7H14CH═CHC8H17). Other examples but are not limited to include mono-, di-, and tri-substituted sorbitans derived from palmitoleic acid, lineolic acid, arachidonic acid, and erucic acid.
In one embodiment, a compound of Formula (Ia) is employed, wherein at least one R is independently —(CH2CH2O)n(CH(CH3)CH2O)mR2 or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1. Compounds of Formula (Ia), wherein at least one R is —(CH2CH2O)n(CH(CH3)CH2O)mR2 or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1, wherein each m is independently 0 to 20, each n is independently 0 to 20, and n+m is greater than 0 are known as polysorbates and are commercially available under the tradename TWEEN. These polysorbates can be mono-substituted, di-substituted, or tri-substituted with alkyl groups R1 or R2. It is known that commercially available polysorbates, contain a mixture of the various polysorbates ranging from where each R2 is H (unsubstituted), and polysorbates where each R1 is a linear or branched alkyl group having 5 to 29 carbons (fully substituted); and mixtures of various substitutions thereof. Examples of compounds of Formula (Ia) include polysorbates such as polysorbate tristearate and polysorbate monostearate. Examples of compounds of Formula (Ia) wherein m+n is greater than 0, and wherein R1 comprises at least 1 unsaturated bond, but not limited to, polysorbate trioleate (wherein R1 is C7H14CH═CHC8H17) and are sold commercially under the name Polysorbate 80. Reagents may include mixtures of compounds having various values for R, R1, and R2, and may also include mixtures of compounds where R1 comprises at least one unsaturated bond with compounds where R1 is fully saturated.
Compounds of Formula (Ib) are known as alkyl citrates. These citrates can be present as a mono-substituted, di-substituted, or tri-substituted with alkyl groups. It is known that commercially available citrates contain a mixture of the various citrates as well as citric acids from where R and each R4 is —H, ranging to citrates where each R4 is a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; and mixtures of various substitutions thereof. Mixtures of citrates having various values for R1, R2, and R4 may be used, and may also include mixtures of compounds where R1 comprises at least one unsaturated bond with compounds where R1 is fully saturated. Alkyl citrates are also commercially available wherein m+n is greater than 0, R4 is —(CH2CH2O)n(CH(CH3)CH2O)mR2; or —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1 and are present in the various substitutions from wherein R and each R2 is H to wherein each R1 and/or R2 is a linear or branched alkyl group having 5 to 30 carbons optionally comprising at least 1 unsaturated bond. Examples of compounds of Formula (Ib) include, but are not limited to, trialkyl citrates.
Compounds of Formula (Ic) are known as pentaerythriol esters. These pentaerythriol esters can be present as a mono-substituted, di-substituted, or tri-substituted with alkyl groups. Preferred compounds used to form X of Formula (Ic) are dipentaerythriol esters, where R19 is —CH2C[CH2OR]3. It is known that commercially available pentaerythriol esters contain a mixture of the various pentaerythriol esters where R19 and each R is —H, ranging to pentaerythriol esters where each R is —C(O)R1, and R1 is a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; and mixtures of various substitutions thereof. The pentaerythriol esters also may contain compounds with mixtures of different chain lengths for R, or mixtures of compounds where R1 comprises at least one unsaturated bond with compounds where R1 is fully saturated.
Compounds of Formulas (Ia), (Ib), and (Ic) can all be bio-based derived. By “bio-based derived”, it is meant that at least 10% of the material can be produced from non-crude oil sources, such as plants, other vegetation, and tallow. In one embodiment, the hydrophobic compound is from about 10% to 100% bio-based derived. In one embodiment, hydrophobic compound is from about 35% to 100% bio-based derived. In another embodiment, hydrophobic compound is from about 50% to 100% bio-based derived. In one embodiment, hydrophobic compound is from about 75% to 100% bio-based derived. In one embodiment, hydrophobic compound is 100% bio-based derived. The average OH value of the hydrophobic compounds can range from just greater than 0 to about 230. In one embodiment, the average OH value is from about 10 to about 175, and in another embodiment, the average OH value is from about 25 to about 140.
The coating on the article surface comprises 0.1 to 5% by weight of the hydrophobic compound, based on the total solids weight of the coating. In a second aspect, the coating on the article surface comprises 0.2 to 5% by weight of the hydrophobic compound; and in a third aspect, 0.25 to 2% by weight of the hydrophobic compound based on the total solids weight of the coating. The term “solids weight of the coating”, is used to mean the sum of the coating components that would remain once the aqueous, solvent, or other liquid components evaporated. In other words, it is the sum of the non-aqueous, non-solvent, and non-volatile components of the coating. The coating may further comprise aqueous or organic solvents, polymer resins, coating bases that contain polymer resins, pigments, functional additives, surfactants, and hydrophobic surface effect agents.
When the coating is in the form of a paint, stain, or sealer, the coating further comprises a coating base. In one embodiment, the the coating base is selected from the group consisting of an acrylic polymer, epoxy polymer, vinyl polymer, and polyurethane polymer in the form of an interior house paint, exterior house paint, stain, or clear coating. Such paints, usually comprising a polymer resin, a liquid carrier, and functional additives, are readily available in the marketplace under a number of major brands. Such coatings may be unpigmented or may be pigmented with compounds including but not limited to titanium dioxide.
In another embodiment, the coating base is a floor finish, polishing agent, or floor polish. Floor waxes, polishes, or finishes are generally water-based or solvent-based polymer emulsions. Commercially available floor finish compositions typically are aqueous emulsion-based polymer compositions comprising one or more organic solvents, plasticizers, coating aides, anti-foaming agents, surfactants, polymer emulsions, metal complexing agents, and waxes. The particle size range and solids content of the polymer are usually controlled to control the product viscosity, film hardness and resistance to deterioration. Polymers containing polar groups function to enhance solubility and may also act as wetting or leveling agents providing good optical properties such a high gloss and distinctness of reflected image.
In one embodiment, the coating base is a clearcoat. Such clearcoat compositions, which can be used to coat metal substrates, contain a polymer composition such as an epoxy polymer resin composition. One type of epoxy resin composition is described in US2015/0344748. Such compositions may be fluorinated or nonfluorinated, and may contain one or more curing agents, fillers, lubricants, anti-dripping agents, flame retardant agents, mold release agents, nucleating agents, colorants, UV stabilizers, solvents, or catalysts.
Preferred polymers for use in floor finishes include acrylic polymers, polymers derived from cyclic ethers, and polymers derived from vinyl substituted aromatics. Polyesters, polyamides, polyurethanes and polysiloxanes are also used in floor finishes. The waxes or mixtures of waxes that are used in floor finishes include waxes of a vegetable, animal, synthetic, and/or mineral origin. Representative waxes include, for example, carnuba, candelilla, lanolin, stearin, beeswax, oxidized polyethylene wax, polyethylene emulsions, polypropylene, copolymers of ethylene and acrylic esters, hydrogenerated coconut oil or soybean oil, and the mineral waxes such as paraffin or ceresin. The waxes typically range from 0 to about 15 weight percent and preferably from about 2 to about 10 weight percent based on the weight of the finish composition.
When the coating composition is a floor finish, floor wax, or floor polish, the hydrophobic compounds of the present invention are effectively introduced to the coating composition by thoroughly stirring it in at room or ambient temperature. More elaborate mixing can be employed such as using a mechanical shaker or providing heat or other methods.
In one embodiment, the hydrophobic compound is combined with a surface effect agent to extend or improve the performance of the surface effect agent. In this case, the hydrophobic surface effect agents may be used from about 5:95 to 95:5 in one aspect; from about 10:90 to 90:10 in a second aspect; and from about 20:80 to 80:20 in a third aspect, based on the total solids weight of the coating. Hydrophobic surface effect agents provide surface effects such as moisture control, strength, anti-slip, anti-static, anti-snag, anti-pill, stain repellency, stain release, soil repellency, soil release, water repellency, oil repellency, odor control, antimicrobial, sun protection, anti-blocking, cleanability, dust resistance, leveling, corrosion resistance, acid resistance, anti-fog, or anti-ice, and similar effects. Such materials can be in the form of hydrophobic non-fluorinated cationic acrylic polymers, hydrophobic non-fluorinated anionic acrylic polymers, hydrophobic non-fluorinated nonionic acrylic polymers, partially fluorinated urethanes, hydrophobic non-fluorinated urethanes, cationic partially fluorinated acrylic polymers or copolymers, nonionic partially fluorinated acrylic polymers or copolymers, partially fluorinated acrylamide polymers or copolymers, fluorinated phosphates, fluorinated ethoxylates, fluorinated or non-fluorinated organosilanes, silicones, waxes, including parafins, and mixtures thereof. Some stain release and soil release agents are hydrophilic and include compounds such as polymethyl acrylates or hydrophilic urethanes. These compounds may also be used as surface effect agents and combined with the hydrophobic compounds, from about 5:95 to 95:5 in one aspect; from about 10:90 to 90:10 in a second aspect; and from about 20:80 to 80:20 in a third aspect, based on the total solids weight of the coating.
Superior properties, along with desirable properties of low yellowing and good durability, are imparted to articles by the combination of the hydrophobic compounds to hydrophobic surface effect agents before application to the articles. These combined blends are applied to the articles in the form of a dispersion in water or other solvent either before, after or during the application of other treatment chemicals.
Of particular interest are fluorinated polymers useful as hydrophobic surface effect agents to provide repellency properties to the surface of treated substrates. These include fluorochemical compounds or polymers containing one or more fluoroaliphatic groups (designated here as Rf groups) which are fluorinated, stable, inert, and non-polar, preferably saturated, monovalent, and both oleophobic and hydrophobic. The Rf groups contain at least 3 carbon atoms, preferably 3 to 20 carbon atoms, more preferably 4 to 12 carbon atoms, and most preferably about 4 to about 6 carbon atoms. The Rf groups may contain straight or branched chain or cyclic fluorinated alkylene groups or combinations thereof. The terminal portion of the Rf groups is preferably a perfluorinated aliphatic group of the formula CnF2n+1 wherein n is from about 3 to about 20. Examples of fluorinated polymer treating agents are CAPSTONE and ZONYL available from The Chemours Company, Wilmington, Del.; ASAHI GARD from Asahi Glass Company, Ltd., Tokyo, Japan; UNIDYNE from Daikin America, Inc., Orangeburg, N.Y.; SCOTCHGARD from 3M Company, St. Paul, Minn.; and NANO TEX from Nanotex, Emeryville, Calif.
Examples of such fluorinated polymers include Rf-containing polyurethanes and poly(meth)acrylates. Especially preferred are copolymers of fluorochemical (meth)acrylate monomers with a co-polymerizable monovinyl compound or a conjugated diene. The co-polymerizable monovinyl compounds include alkyl (meth)acrylates, vinyl esters of aliphatic acids, styrene and alkyl styrene, vinyl halides, vinylidene halides, alkyl esters, vinyl alkyl ketones, and acrylamides. The conjugated dienes are preferably 1,3-butadienes. Representative compounds within the preceding classes include the methyl, propyl, butyl, 2-hydroxypropyl, 2-hydroxyethyl, isoamyl, 2-ethylhexyl, octyl, decyl, lauryl, cetyl, and octadecyl acrylates and methacrylates; vinyl acetate, vinyl propionate, vinyl caprylate, vinyl laurate, vinyl stearate, styrene, alpha methyl styrene, p-methylstyene, vinyl fluoride, vinyl chloride, vinyl bromide, vinylidene fluoride, vinylidene chloride, allyl heptanoate, allyl acetate, allyl caprylate, allyl caproate, vinyl methyl ketone, vinyl ethyl ketone, 1,3-butadiene, 2-chloro-1,3-butadiene, 2,3-dichloro-1,3-butadiene, isoprene, N-methylolacrylamide, N-methylolmethacrylamide, glycidyl acrylate, glycidyl methacrylate, amine-terminated (meth)acrylates, and polyoxy(meth)acrylates.
Hydrophobic non-fluorinated acrylic polymers include copolymers of monovinyl compounds, including alkyl (meth)acrylates, vinyl esters of aliphatic acids, styrene and alkyl styrene, vinyl halides, vinylidene halides, alkyl esters, vinyl alkyl ketones, and acrylamides. The conjugated dienes are preferably 1,3-butadienes. Representative compounds within the preceding classes include the methyl, propyl, butyl, 2-hydroxypropyl, 2-hydroxyethyl, isoamyl, 2-ethylhexyl, octyl, decyl, lauryl, cetyl, and octadecyl acrylates and methacrylates; vinyl acetate, vinyl propionate, vinyl caprylate, vinyl laurate, vinyl stearate, styrene, alpha methyl styrene, p-methylstyene, vinyl fluoride, vinyl chloride, vinyl bromide, vinylidene fluoride, vinylidene chloride, allyl heptanoate, allyl acetate, allyl caprylate, allyl caproate, vinyl methyl ketone, vinyl ethyl ketone, 1,3-butadiene, 2-chloro-1,3-butadiene, 2,3-dichloro-1,3-butadiene, isoprene, N-methylolacrylamide, N-methylolmethacrylamide, glycidyl acrylate, glycidyl methacrylate, amine-terminated (meth)acrylates, and polyoxy(meth)acrylates.
Hydrophobic non-fluorinated urethanes include, for example, urethanes synthesized by reacting an isocyanate compound with the hydrophobic compounds described above as an alcohol reagent. These compounds are described in US2014/0295724 and US2016/0090508. Hydrophobic non-fluorinated nonionic acrylic polymers include, for example, polymers made by polymerizing or copolymerizing an acrylic ester of the hydrophobic compounds described above. Such compounds are described in US2016/0090686.
The coating composition of the present invention optionally further comprises additional components such as additional treating agents or finishes to achieve additional surface effects, or additives commonly used with such agents or finishes. One or more such treating agents or finishes can be combined with the blended composition and applied to the article. Other additives commonly used with such treating agents or finishes may also be present such as surfactants, pH adjusters, cross linkers, wetting agents, and other additives known by those skilled in the art. Further, other extender compositions are optionally included to obtain a combination of benefits.
The present invention further comprises a method of imparting a surface effect to an article comprising contacting a the surface of the article with a durable coating to form a partially or completely coated article, wherein the coating comprises a coating base and 0.1 to 5% by weight of a hydrophobic compound, based on the total solids weight of the coating, selected from a cyclic or acyclic alcohol which is substituted with at least one —R1, —C(O)R1, —(CH2CH2O)n(CH(CH3)CH2O)mR2, —(CH2CH2O)n(CH(CH3)CH2O)mC(O)R1, or mixtures thereof; where the cyclic or acyclic alcohol is selected from a pentaerythritol, saccharide, reduced sugar, aminosaccharide, citric acid, aldonic acid, or aldonic acid lactone; wherein each n is independently 0 to 20; each m is independently 0 to 20; m+n is greater than 0; each R1 is independently a linear or branched alkyl group having 5 to 29 carbons optionally comprising at least 1 unsaturated bond; each R2 is independently —H, a linear or branched alkyl group having 6 to 30 carbons optionally comprising at least 1 unsaturated bond; and the coating has a thickness of at least 0.1 mils.
The articles may include but are not limited to a unglazed concrete, brick, tile, metal, granite, limestone, marble, grout, mortar, statuary, monument, wood, composite material, terrazzo, gypsum board, wall or ceiling panel, glass, or a combination thereof, or a combination thereof. The contacting step may occur by applying the hydrophobic compound by liquid carrier with the coating base. When applied by liquid carrier, the hydrophobic compound may be in the form of an aqueous solution, aqueous dispersion, organic solvent solution or dispersion, or cosolvent solution or dispersion. The contacting step may occur by any conventional method, including but not limited to spraying, rolling, dip-squeeze, brushing, sprinkling, dripping, powder coating, tumbling, or screen printing.
In one aspect, the method further comprises the step of heating the partially or completely coated article. For example, the hydrophobic agent may be applied, and the treated article may be heated to melt, flow, dry, or otherwise fix the hydrophobic agent onto the article surface. The final coating on the article surface will be a solidified, lasting, permanent coating. In another aspect, the method further comprises the step of solidifying the coating by drying, cooling, or allowing to cool. The liquid carrier may be dried by heating or air drying to allow for evaporation of the liquid carrier, thus leaving a permanent solid coating.
Specifically, the treated articles of the present invention are useful to provide enhanced surface properties, especially durability of oil-, water- and soil-repellency, while reducing or eliminating the amount of fluorinated compounds employed. The repellency property is effective with a variety of other surface effects.
All solvents and reagents, unless otherwise indicated, were purchased from Sigma-Aldrich, St. Louis, Mo., and used directly as supplied. Methyl isobutyl ketone (MIBK) is also available from Sigma-Aldrich, St. Louis, Mo.
Sorbitan tristearate and sorbitan trioleate are commercially available from Croda, East Yorkshire, England, or DuPont Nutrition & Health, Copenhagen, Denmark.
Behenyl 50 and lauryl sorbitan are available from DuPont Nutrition & Health, Copenhagen, Denmark.
CHEMIDEX S is a stearaminopropyl dimethylamine surfactant available from Lubrizol, Wickliffe, Ohio.
ETHAL LA-4 is an ethoxylated emulsifier available from Ethox Chemicals, Greenville, South Carolina.
CAPSTONE FS-81, FS-87, and 1470 are fluorinated cleanability agents or surfactants available from The Chemours Company, Wilmington, Del.
Witco C-6094 and WAQE are available from AkzoNobel, Amsterdam, Netherlands.
The following test methods and materials were used in the examples herein.
Hydrophobic compounds of the present invention are added to selected commercially available interior and exterior latex paints that are, prior to dosing, free of fluoroadditives. The sample is mixed using an overhead Cowles Blade stirrer at 600 rpm for 10 minutes. The mixture is then transferred to a glass bottle, sealed and placed on a roll mill overnight to allow uniform mixing of the fluoropolymer. The samples are then drawn down uniformly on a black Leneta Mylar® card (5.5″×10″) or Aluminium Q-panel (4″×12″) via a BYK-Gardner drawdown apparatus using 5 mL bird-applicator, to yield a wet paint film with a film thickness of 5 mils. The paint films are then allowed to dry at room temperature for 7 days to yield dry paint films with a film thickness of about 2.5 mils.
Water and oil contact angle measurements are used to test for the migration of fluoroadditive to the surface of the paint film. Testing is performed by goniometer on 1 inch strips of Leneta panel coated with dried paint film. A Ramé-Hart Standard Automated Goniometer Model 200 employing DROPimage standard software and equipped with an automated dispensing system, 250 μl syringe, and illuminated specimen stage assembly is used. The goniometer camera is connected through an interface to a computer, allowing the droplet to be visualized on a computer screen. The horizontal axis line and the cross line can both be independently adjusted on the computer screen using the software. Prior to contact angle measurement, the sample is placed on the sample stage and the vertical vernier is adjusted to align the horizontal line (axis) of the eye piece coincident to the horizontal plane of the sample. The horizontal position of the stage relative to the eye piece is positioned so as to view one side of the test fluid droplet interface region at the sample interface.
To determine the contact angle of the test fluid on the sample, approximately one drop of test fluid is dispensed onto the sample using a 30 μL pipette tip and an automated dispensing system to displace a calibrated amount of the test fluid. For oil contact angle measurements, hexadecane is suitably employed, and deionized water is used for water contact angle measurements. Horizontal and cross lines are adjusted via the software in case of the Model 200 after leveling the sample via stage adjustment, and the computer calculates the contact angle based upon modeling the drop appearance. The initial contact angle is the angle determined immediately after dispensing the test fluid to the sample surface. Initial contact angles above 30 degrees are indicators of effective oil repellency.
A modified version of ASTMD3450 is used to determine the oil stain cleanability of painted panels. The test material dosed in interior flat paint is applied to a black Leneta card as described in the application method. The dried samples are cut into a 4″×3″ size for testing. A thin, evenly laid layer of Leneta staining medium (5 wt. % dispersion of Leneta carbon black in Vaseline®) is placed on half of the film, and left for 1 hour. The excess stain is gently scrapped off and wiped with a clean paper towel until no visible stain can be wiped off. The panel is then moved to an Gardco abrasion tester covered with 8 layers of cheese cloth at the washing block. The cheesecloth is moisturized with 10 mL of 1% mild detergent solution in water and performs washability via moving the washing block over the stained panel. After 5 cycles, the panel is rinsed with deionized water and left to dry for 12 hours. The whiteness of the unwashed stained paint and washed stained paint are measured using a Hunter lab colorimeter to obtain L values. Cleanability is calculated as per the equation: Cleanability=(Lwashed paint−Lunwashed stained paint)×10/(Lunstained paint−Lunwashed stained paint). Similarly a cleanability rating for a control sample that is devoid of fluorinated additive is accessed simultaneously. The difference between the cleanability rating of the sample to the control are determined and represented as a cleanability score ΔC. The higher the ΔC the better the performance, suggesting that relatively lower amounts of stain remains on the treated sample compared to control. A negative ΔC indicates that the sample is worse than the control.
Paint was tested without any hydrophobic additive, according to the test methods above.
A 100-g paint sample was blended with 0.59 g of CAPSTONE FS-81 according to the dosing procedure above and tested according to the test methods above.
A 100-g paint sample was blended with 0.1 g of CAPSTONE FS-87 according to the dosing procedure above and tested according to the test methods above.
A 100-g paint sample was blended with 0.13 g of CAPSTONE 1470 according to the dosing procedure above and tested according to the test methods above.
Into a 4-neck round bottom flask equipped with an overhead stirrer, thermocouple and condenser is added sorbitan tristearate (111 g) and 4-methyl-2-pentanone (MIBK, 274 g). The solution is heated to 80° C. An aqueous dispersion is then prepared by adding warm water (512 g), CHEMIDEX S (2.4 g), ETHAL LA-4 (3.2 g) and acetic acid (1.6 g) at 65° C. The mixture is immersion blended (2 min), homogenized at 6000 psi, and the resulting dispersion is distilled under reduced pressure to remove the solvent and yield a non-flammable dispersion at 13.15% solids after cooling and filtering. The product is dosed into paint such that the sorbitan tristearate composes 1% by weight of the sample and tested according to the test methods above.
Example 1 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Into a 4-neck round bottom flask equipped with an overhead stirrer, thermocouple and condenser is added sorbitan tristearate (80 g) and MIBK (200 g). The solution is heated to 70° C. An aqueous dispersion is then prepared by adding warm water (225 g), CHEMIDEX S (1.7 g), ETHAL LA-4 (2.3 g), acetic acid (1.2 g), and dipropylene glycol (19.7 g) at 65° C. The mixture is immersion blended (2 min), homogenized at 6000 psi, and the resulting dispersion is distilled under reduced pressure to remove the solvent and yield a non-flammable dispersion at 10.73% solids after cooling and filtering. The product is dosed into paint such that the sorbitan tristearate composes 1% by weight of the sample and tested according to the test methods above.
Example 2 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Example 1 is repeated, except 0.1 g of CAPSTONE FS-87 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Example 1 is repeated, except 0.13 g of CAPSTONE 1470 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Into a 4-neck round bottom flask equipped with an overhead stirrer, thermocouple and condenser was added sorbitan tristearate (60.1 g) and MIBK (150 g). After the solution was heated to 55° C. An aqueous dispersion was then prepared by adding warm water (299 g), Witco C-6094 (7.6 g) and dipropylene glycol (14.8 g) at 65° C. The mixture was immersion blended (2 min), homogenized at 6000 psi, and the resulting dispersion was distilled under reduced pressure to remove the solvent and yield a non-flammable urethane dispersion at 12.56% solids after cooling and filtering. The product is dosed into paint such that the sorbitan tristearate composes 1% by weight of the sample and tested according to the test methods above.
Example 7 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Example 7 is repeated, except 0.1 g of CAPSTONE FS-87 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Example 7 is repeated, except 0.13 g of CAPSTONE 1470 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
A 100-g paint sample was dosed with CAPSTONE FS-81 to form a composition at 0.2% by weight of CAPSTONE FS-81. The dosed paint was tested according to the test methods above.
Example 1 is repeated, using the percentage of sorbitan tristearate shown in Table 2. Examples 12 and 14 also contain 0.59 g of CAPSTONE FS-81 added to the 100-g paint sample. The resulting paints are tested according to the test methods above.
Example 7 is repeated, using the percentage of sorbitan tristearate shown in Table 2. Example 16 and 18 also contain 0.59 g of CAPSTONE FS-81 added to the 100-g paint sample. The resulting paints are tested according to the test methods above.
Into a 4-neck round bottom flask equipped with an overhead stirrer, thermocouple and condenser was added sorbitan tristearate (60.1 g) and MIBK (150 g). The solution was heated to 55° C. An aqueous dispersion was then prepared by adding warm water (383 g), WAQE (11.4 g) and dipropylene glycol (14.8 g) at 65° C. The mixture was immersion blended, homogenized at 6000 psi, and the resulting dispersion was distilled under reduced pressure to remove the solvent and yield a non-flammable urethane dispersion at 12.91% solids after cooling and filtering. The product is dosed into paint such that the sorbitan tristearate composes 1 by weight of the sample and tested according to the test methods above.
Example 19 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
A 4-neck 500 mL round bottom flask was set-up with an additional funnel, thermocouple, mechanical stirrer, nitrogen inlet, condenser, and gas outlet. The flask was charged with Behenyl 50 (30 g) and MIBK (75 g). The mixture was heated to 75° C. and Behenyl 50 dissolved. In a separate flask, hot DI water (280.5 g), WAQE (5.69 g) and dipropylene glycol (7.33 g) were mixed and added to the flask with Behenyl 50. The mixture was stirred for 30 minutes at 75° C. and then homogenized at 6000 psi. The final product was distilled to remove MIBK and filtered through a sock filter to yield a product at 13% solids. The product is dosed into paint such that the Behenyl 50 composes 1% by weight of the sample and tested according to the test methods above.
Example 21 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
A 4-neck round bottom flask was set-up with an additional funnel, thermocouple, mechanical stirrer, nitrogen inlet, condenser, and gas outlet. The flask was charged with lauryl sorbitan (30 g) and MIBK (75 g).
The mixture was heated to 75° C. In a separate flask, hot DI water (280.5 g), WAQE (5.69 g) and dipropylene glycol (7.33 g) were mixed and added to the flask with lauryl sorbitan. The mixture was stirred for 30 minutes at 75° C. and then homogenized at 6000 psi. The final product was distilled to remove MIBK and filtered through a sock filter to yield a product at 20% solids. The product is dosed into paint such that the lauryl sorbitan composes 1% by weight of the sample and tested according to the test methods above.
Example 23 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
Into a 4-neck round bottom flask equipped with an overhead stirrer, thermocouple and condenser was added sorbitan trioleate (60.3 g) and MIBK (150 g). The solution was heated to 55° C. An aqueous dispersion was then prepared by adding warm water (429 g), WAQE (11.4 g) and dipropylene glycol (14.8 g) at 65° C. The mixture was immersion blended (2 min), homogenized at 6000 psi, and the resulting dispersion was distilled under reduced pressure to remove the solvent and yield a non-flammable urethane dispersion at 14.44% solids after cooling and filtering. The product is dosed into paint such that the sorbitan trioleate composes 1% by weight of the sample and tested according to the test methods above.
Example 25 is repeated, except 0.59 g of CAPSTONE FS-81 is added to the 100-g paint sample and mixed according to the dosing procedure above. The resulting paint is tested according to the test methods above.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/054591 | 9/30/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62236349 | Oct 2015 | US |
