JP6868187B2 - Coating composition for building materials and base material for building materials to be coated - Google Patents

Description

This application relates to coatings for building materials. More specifically, the particular embodiments described herein relate to coatings that are effective in providing a substrate to be coated with a water vapor permeance value that varies with relative humidity (RH).

The building material can include a film or surface material attached to the building material to provide the desired physical properties. The membrane or surface material typically comprises petroleum products, and as a result,
Significant volatile organic compounds (VOCs) can be gassed during preparation and / or material use.

Currently available products have a poor ability to maintain the desired water vapor permeance at low relative humidity. Furthermore, current coating formulations cannot be used with porous substrates such as porous non-woven fabrics. Therefore, to provide a new coating composition that can be used on a wide variety of different substrates, such as porous substrates, especially porous non-woven substrates, while providing the desired water vapor permeance, especially at low relative humidity. Innovative solutions are needed.

Specific embodiments are described with reference to the accompanying drawings. The drawings are as follows.
FIG. 1 shows a substrate to be coated according to an embodiment of the present disclosure. FIG. 2 shows a substrate to be coated according to an embodiment of the present disclosure, in which the coating penetrates the substrate to a specific depth. FIG. 3 shows a graph of viscosity measurement of Example 3.

Given the advantages of the present disclosure, certain dimensions or features in the drawings may be magnified, deformed, or shown in another non-conventional or non-proportional way, thereby giving the user. It will be appreciated by those skilled in the art that drawings in an easy-to-understand format may be provided. Where dimensions or values are specified in the description below, the dimensions or values are provided solely for explanatory purposes. References to the anterior, posterior, upper and lower parts are provided for illustrative purposes only and are not limiting.

Generally, the present disclosure relates to a coating composition for a building material base material and a base material to be coated which can selectively delay the condensation of water vapor depending on the humidity when cured. These concepts will be better understood by considering the previous description.

The coating composition can generally include a hydrophobic component and a hydrophilic component.

In certain embodiments, the hydrophobic component can include a water-insoluble polymer.

In certain embodiments, the water-insoluble polymer can be given to the coating composition as an aqueous dispersion in which the water-insoluble polymer is dispersed in water.

In a further specific embodiment, the hydrophobic component can include latex. For example, latex can include latex of styrene butadiene, styrene acrylic, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof. In a further specific embodiment, the hydrophobic component can include styrene-butadiene latex.

In certain embodiments, the hydrophobic component can be explained by its% carboxylation. % Carboxylation means the weight percent of the carboxylic acid monomer in the polymer backbone. Thus, in certain embodiments, the hydrophobic component can have essentially 0%, about 0.1% or more, about 0.5% or more, or even about 1% or more% carboxylation. In a further embodiment, the hydrophobic component can have about 20% or less, about 15% or less, about 10% or less, about 5% or less, or even about 3% or less% carboxylation. In addition, the hydrophobic component is in the range of any of the minimum and maximum values given above, eg 0% -20%, 0.1% -15%, 0.5% -10%, or even 1. % ~ 8
It can have% carboxylation in the range of%. In a further specific embodiment, the hydrophobic component can have about 0%% carboxylation, in which case the hydrophobic component is essentially free of carboxylic acid monomers in the polymer backbone.

The particular advantages of% carboxylation described above have been shown to be advantageous in obtaining excellent permeances in response to relative humidity in combination with hydrophobic components. Although not desired to be bound by theory, it is believed that with latex, high levels of carboxylation tend to result in too high a water vapor permeance at moderate relative humidity.

In certain embodiments, the hydrophobic component can be explained by its glass transition temperature (Tg). As used herein, the glass transition temperature (Tg) of the hydrophobic component
) Is measured according to differential scanning calorimetry or dynamic mechanical analysis. Thus, in certain embodiments, the hydrophobic component is about -50 ° C or higher, about -40 ° C or higher, or even about -3.
It can have a glass transition temperature (Tg) of 0 ° C. or higher. In a further embodiment, the hydrophobic component is about 35 ° C. or lower, about 25 ° C. or lower, about 25 ° C. or lower, or even about 15 ° C.
It can have the following glass transition temperature (Tg). Further, the hydrophobic component has a glass transition temperature in the range of either the minimum value or the maximum value given above, for example, in the range of -30 to 25 ° C, -30 to 15 ° C, or even -30 to 0 ° C. Can have.

In certain embodiments, the hydrophobic component is about 15% by weight or more, about 25% by weight or more, about 35% by weight or more, or even more, based on the total dry weight of the hydrophobic and hydrophilic components of the barrier layer. It can be present in the composition or in the barrier layer in an amount of about 45% by weight or more. In a further embodiment, the hydrophobic component is about 99% by weight or less, about 98% by weight or less, or even about 97% by weight or less, based on the total dry weight of the hydrophobic and hydrophilic components of the barrier layer. It can be present in the composition or in the barrier layer in quantity. Further, the hydrophobic component is 15-99% by weight, 25-98, based on the range of either the minimum value or the maximum value given above, for example, the total dry weight of the hydrophobic component and the hydrophilic component of the barrier layer. It can have a content in the composition or in the barrier layer in the range of% by weight, or even 35-97% by weight.

As mentioned above, in certain embodiments, the composition can include hydrophilic components in addition to hydrophobic components. Hydrophilic components can play a role in absorbing moisture and increasing the permeance of the composition at high relative humidity.

In certain embodiments, the hydrophilic component can include a polymer that is water soluble without cross-linking.

In certain embodiments, the hydrophilic components are polyvinyl alcohol (PVOH), poly (vinylpyrrolidone), starch, cellulose, polyacrylate, polyacrylic acid, hypercarboxylated latex, amine, polyethylene oxide, vinyl ether, high. Hydrolyzed polymers (eg, hydrolyzed maleic anhydride), polysaccharides, or combinations thereof can be included. In a further specific embodiment, the hydrophilic component can include polyvinyl alcohol (PVOH) or sodium polyacrylate.

In certain embodiments, the composition can contain more than one hydrophilic component. For example, as discussed in more detail below, the composition may include a hydrophilic filler in place of or in addition to the above-mentioned selection of hydrophilic components such as PVOH. In certain embodiments, the hydrophilic filler can be an inorganic hydrophilic filler such as kaolin.

In certain embodiments, the hydrophilic component can be explained by its% water absorption. As used herein,% water absorption is measured by weight measurement, which is well understood in the art. The percentage of water absorption increases the permeance relationship to relative humidity, but if the percentage of water absorption is too high, the hydrophilic components tend to dissolve and can destabilize the membrane.

In certain embodiments, the hydrophilic component is about 0.5% or more, about 2% or more, about 5% or more, or even about 7% or more when measured at 100% relative humidity and 23 ° C. Polymers with percent water absorption can be included. In a further embodiment, the hydrophilic component comprises a polymer having a percent water absorption of about 20% or less, about 15% or less, or even about 10% or less when measured at 100% relative humidity and 25 ° C. be able to. In addition, the hydrophilic component is in the range of either the minimum value or the maximum value given above, for example about 0.5.
It can have percent water absorption in the range of% to about 20%, or even about 7% to about 10%.

In certain embodiments, the hydrophilic component can be described by its molecular weight. By using a high molecular weight material that is soluble only at high temperatures, it is possible to prevent the hydrophilic components from dissolving at low temperatures.

In certain embodiments, the hydrophilic component can have a weight average molecular weight of about 50,000 or more. In a further embodiment, the hydrophilic component can have a molecular weight of about 300,000 or less. Further, the hydrophilic component can have a molecular weight in the range of any of the minimum and maximum values given above, for example in the range of 50,000 to 300,000.

In certain embodiments, the hydrophilic component is about 0.1% by weight or more, about 0.5% by weight or more, or even about 1% by weight or more, based on the total dry weight of the hydrophobic and hydrophilic components. Can be present in the composition or in the barrier layer in an amount of. In a further embodiment,
The hydrophilic component is about 40% by weight or less based on the total dry weight of the hydrophobic component and the hydrophilic component.
Present in composition or barrier layer in an amount of about 30% by weight or less, about 25% by weight or less, about 20% by weight or less, about 15% by weight or less, about 10% by weight or less, or even about 8% by weight or less. can do. In addition, the hydrophilic component is in the range of either the minimum value or the maximum value given above,
For example, it may be present in the composition or in the barrier layer in an amount ranging from 0.1 to 35% by weight, or even 1 to 15% by weight, based on the total dry weight of the hydrophobic and hydrophilic components. it can.

In certain embodiments, the composition is optionally an inorganic filler, viscosity modifier, pigment, dye,
Further can include desired additive components such as UV absorbers, lubricants, surfactants, biocides, defoamers, defoamers, or combinations thereof.

In certain embodiments, the composition can include a filler. In a further specific embodiment, the composition can have a filler content of approximately less than or equal to the limit pigment volume concentration of the filler. For example, the limit pigment volume concentration of the filler is a concentration at which the binder does not completely occupy the voids between the pigment particles at a concentration higher than that concentration. For example, the critical pigment volume concentration can be measured by oil absorption of the pigment. CPVC can vary from 20 to 68% by volume, but its value is generally around 50-55%.

In certain embodiments, the filler can include clay, montmorillonite, calcium carbonate, barium sulfate, bentonite, muscovite, illite, cookstone, kaolinite, chlorite, or other filler material. The filler may include an inorganic material, an organic material, or a combination thereof. Specific fillers are kaolin clay, CaCO ₃ , CaSO ₄ , B
It can include aSO ₄ , silica, talc, carbon black, diatomaceous earth, alumina, titanium, or a combination thereof. In some preferred embodiments, a filler having a plate-like form, such as kaolin clay, can increase the slope of the permeance relationship to relative humidity. This is due to the increased twist of the film, which allows the coating to be applied thinner, allowing the coating to have excellent properties. In some examples, the filler may provide reinforcement of the cured coating, may provide flame retardancy with the cured coating, or may improve the physical properties of the cured composition (eg,). It may provide other desired characteristics (eg, increase the overall viscosity of the composition), as compared to the coefficient of linear thermal expansion (CLTE) of the curing composition without filler). May be allowed to promote a more uniform coating on the substrate). An example of a commercially available filler is Sou.
tern Clay Products, Inc. Bentonite available from
e (registered trademark), Cloisite (registered trademark), Nanofil (registered trademark), Nan
Examples include, but are not limited to, othix® and Permont® fillers.

In certain embodiments, the filler can be present in the composition in the range of 0-85% by weight, based on the total dry weight of the composition or barrier layer.

In certain examples, the dispersion can include one or more killing agents. The killing agent can be effective in blocking or preventing the growth of organisms on the coating and / or substrate surface. In some embodiments, the killing agent can be effective as a fungicide, such as a fungicide, to prevent the growth of mold or other fungi on the surface of the substrate. In other embodiments, the killing agent can be effective in preventing the growth of bacteria, mosses, algae, or other organisms on the surface of the substrate. If a killing agent is present, it may be present in an amount effective to prevent or prevent the growth of the organism.

In some embodiments, the dispersion can include a stain resistant additive. In some embodiments, the stain resistant additive can act to reduce or prevent the material from being absorbed during the coating, generally from the penetration of materials other than water and gas. Can help seal. For example, stain resistant additives
It can impart oil resistance or oil repellency to prevent non-polar chemicals from being trapped in the coating. Contamination resistant additives may suppress fading of the coating when exposed to heat, ultraviolet light or other energy forms. Examples of stain resistant additives are those commercially available, for example from 3M (eg SRC-220, PM-5000, PM-1680, PM-4).
800) and those commercially available from AkzoNobel (eg, Elotex® stain resistant additives).

To describe the composition as a whole, the composition can have a specific weight% ratio of the hydrophobic component to the hydrophilic component. For example, in certain embodiments, the volume% ratio of the hydrophobic component to the hydrophilic component can be about 3: 1 or greater, about 10: 1 or greater, or even about 30: 1 or greater. In a further embodiment, the volume% ratio of the hydrophobic component to the hydrophilic component can be about 200: 1 or less, or even about 100: 1 or less. Further, the volume% ratio of the hydrophobic component to the hydrophilic component can be within any of the minimum and maximum values given above, for example in the range of about 2: 1 to about 200: 1. ..

The composition can also have the desired viscosity. For example, in certain embodiments, the composition can have a viscosity of about 1000 cps or higher at a ^{shear rate of 1s-1 and a temperature of 21 ° C.} In a further embodiment, the composition has a shear rate of 1000s ^-1.
And at a temperature of 21 ° C., it can have a viscosity of about 1000 cps or less. further,
The composition can have a viscosity of about 5000 cps or more at a shear rate of 1 s- ¹ and a temperature of 21 ° C. and about 1000 cp at a shear rate of 1000 s- ¹ and a temperature of 21 ° C.
It can have a viscosity of s or less.

The composition can also be described by its properties after curing. As used herein, the cured composition refers to a barrier layer. In certain embodiments, the barrier layer can have a particular coating weight. For example, the barrier layer is about 10 gsm or more, about 20 gsm.
It can have a coating weight of more than, or even more, about 40 gsm or more. In a further embodiment, the barrier layer can have a coating weight of about 120 gsm or less. In addition, the barrier layer is a range of either the minimum or maximum values given above,
It can have a coating weight ranging from, for example, about 10 gsm to about 120 gsm, or even from about 40 gsm to about 100 gsm.

When the composition is applied and cured, the composition can have a variable moisture permeability depending on the relative humidity. As discussed herein, moisture permeability can be measured at a temperature of 21 ° C. at selected average relative humidity (RH) values according to ASTM E96. Moisture permeability is a measure of the amount of water vapor that can pass through a material. When used to describe the properties of the cured composition
Moisture permeability is the weight of the composition coated on a point-bonded polypropylene non-woven fabric base material 7
It is coated with 5 gsm, the composition is cured and measured. In this way, the variable moisture permeability is
It can be standardized to a specific substrate for comparison and evaluation. Then the moisture permeability, ASTM
Measured at a temperature of 21 ° C. at different relative humidity according to E96. Thus, in certain embodiments, the composition can be adapted so that the composition has a variable moisture permeability depending on the relative humidity after the composition has been applied onto the substrate and cured.

In certain embodiments, the composition can exhibit desirable moisture permeation at low relative humidity, medium relative humidity, and high relative humidity.

For example, in certain embodiments, the composition is 1 palm (pe) at a 25% average Rhesus factor.
rm) It can have the following moisture permeability.

In a further embodiment, the composition has a perm of 5 palms at a 45% average Rhesus factor.
) Or less, or even 2.5 palm (perm) or less.
In certain embodiments, the composition is 2.5 palm (per) at a 45% average Rhesus factor.
m) It can have the following moisture permeability.

In a further embodiment, the composition is 6 palms (per) at a 75% average RH.
It can have a moisture permeability in the range of m) to 12 palms.

In a further embodiment, the composition is about 12 palms (p) at 95% average Rhes.
More than erm, about 15 palms (perm) or more, or even about 20 palms (perm)
) Can have the above moisture permeability. In certain embodiments, the composition can have a moisture permeability of about 20 palms or higher at a 95% average Rhesus factor.

The coating composition can further have various combinations of moisture permeation at different relative humidity given above.

For example, in certain embodiments, the composition is about 1 palm (p) at a 25% average Rhesus factor.
It can have a moisture permeability of erm) or less; and a moisture permeability of about 20 palms or more at a 95% average RH.

In a further embodiment, the composition is about 1 palm (per) at a 25% average RH.
Moisture permeability of m) or less; moisture permeability of about 20 palms (perm) or more at 95% average RH; 5 palms (perm) or less at 45% average RH, or even 2.5 palms (p).
erm) It can have the following moisture permeability.

In a further embodiment, the composition is about 1 palm (per) at a 25% average RH.
Moisture permeability of m) or less; moisture permeability of about 20 palms (perm) or more at 95% average RH; 5 palms (perm) or less at 45% average RH, or even 2.5 palms (p).
Moisture permeability below erm; 6 palms to 12 palms at 75% average RH (erm)
It can have a moisture permeability in the range of perm).

It should be understood that the combinations of moisture permeability at different relative humidity described above are exemplary combinations and that all possible combinations of moisture permeability in the compositions described above are within the scope of the present disclosure.

If the coating exhibits the above-mentioned moisture permeability at different RH values, the change in moisture permeability with increasing humidity is linear or non-linear in the logarithmic plot of permeance to relative humidity as described herein. Further note that it may be.

Another aspect of the present disclosure relates to a substrate to be coated. For example, the above composition can be coated on a substrate and cured. A particular advantage of certain embodiments of the present disclosure is the ability of the above compositions to be used with relatively porous substrates. For example, the properties of certain embodiments of the compositions described herein can completely fill the voids in the porous substrate, thereby providing a coating that is effective in delaying the condensation of water vapor. Other compositions that may provide variable moisture permeability depending on the humidity may not be usable on relatively porous substrates. The reason is that due to the low viscosity of the coating liquid, the composition will "strike through" the substrate, resulting in a discontinuous and useless coating. We have surprisingly discovered the ability to synergistically combine effective viscosities with variable moisture permeability, allowing them to be used on relatively porous substrates. However, it should be understood that the particular embodiment is not limited to a relatively porous substrate, as the composition itself has also been found to have apparently superior variability in moisture permeability. There is.

In certain examples, the aqueous dispersions described herein may be used, for example, in kraft paper, spunbonded or pointbonded non-woven fabrics, oriented strand boards, or used as backing materials for glass fiber insulation. As a coating for house wrap
Alternatively, a cured coating can be provided on a building substrate such as other materials such as gypsum that can be used to seal the exterior surface of the building. With reference to FIG. 1, article 100 is shown to include a substrate 110 and a coating 120 placed on it. The exact thickness of the substrate 110 and the coating 120 can vary, but in most cases the thickness of the substrate 110 will be substantially greater than the thickness of the coating 120. The thickness of the coating 120 is shown to be substantially the same in the planar direction of the substrate 110, but such uniformity is not required. In particular, the thickness need not be uniform in each region of the substrate 110, as long as the thickness of the coating 120 is effective in providing the variable moisture permeability values described herein.

In certain embodiments, the substrate 110 can be any suitable substrate commonly used in the construction industry. For example, buildings usually have some sort of insulation in the hollow of walls, floors and / or ceilings. This insulation is often a glass fiber insulation that contains a vapor condensation retarder and can prevent moisture from entering the adiabatic cavity. A common vapor setting retarder is kraft paper coated with asphalt. The kraft paper itself has a high percentage of moisture permeation. When used with asphalt coatings and / or asphalt adhesives, kraft paper can serve as a suitable vapor setting retarder.
When the water content in the hollow wall is reduced, deterioration of the building material can be prevented, and the decrease in thermal conductivity in the hollow wall can be prevented, which can further help reduce the energy cost. In some examples, the substrate 110 may be kraft paper that can be attached to a larger building substrate, such as glass fiber insulation, using an adhesive or other suitable adhesive means. .. The exact weight of kraft paper can vary, but exemplary weights include, but are not limited to, about 25 to about 75 pounds per 1000 square feet, for example about 39 pounds. In some examples, the substrate 110 is a cloth.
In some examples, the cloth can be a woven or non-woven fabric. In other examples, the coating can be applied directly to drywall or other materials commonly used to finish the interior of a building. For example, coating the gypsum board with a coating,
A gypsum wallboard with variable moisture permeability can be provided. Similarly, wooden siding, wooden planks, plywood, fiberboard, or other materials used to finish the outer, inner, outer or inner ceilings are coated with the coatings described herein. , Can provide variable moisture permeability. Further building substrates that can be coated using this coating will be readily selected by one of ordinary skill in the art given the advantages of the present disclosure.

In a further specific embodiment, the substrate can include kraft paper exterior material, scrim, polymer sheet, gypsum wallboard, or a combination thereof. In a further specific embodiment, the substrate can be described as a synthetic substrate. Further, as discussed in more detail below, the substrate can be porosity or include a pore structure such that the coating composition or barrier layer can be placed in the pore structure of the substrate. In a more specific embodiment, the substrate can include a cloth such as a synthetic fiber having a pore structure as described herein.

In certain embodiments, the coating 110 can be placed on the substrate 120 by rolling, thermal spraying, roll coating, or other means capable of placing a layer of aqueous dispersion on the substrate. If desired, an additional coating layer can be added to the cured coating layer to increase the thickness of the coating layer.

In certain embodiments, the substrate can include kraft paper exterior material.

In certain embodiments, the substrate can be a cloth substrate. For example, the cloth substrate can include a woven material and / or a non-woven material. In certain embodiments, the substrate can include non-woven materials. Certain non-woven materials can include spunbonded fabrics or pointbonded fabrics.

In certain examples, the coatings provided herein can be used to provide pre-coated building substrates or allow on-site coating of building substrates. For example, a glass fiber insulation vat with kraft paper can be pre-coated with one or more components and then coated in-situ with additional components to provide an effective final coating. In another example, the coating can be made at the site of manufacture so that the installer does not have to do anything to provide the coating. In other cases, the installer may spray the coating onto the substrate after installation to provide the coating to the installed substrate. In some examples, the substrate may be a porous substrate such as a non-woven substrate.

In certain embodiments, the substrate to be coated can have certain desired properties.

In certain embodiments, the combined thickness of the substrate and the barrier layer can be about 25 microns or more, about 50 microns or more, or even about 100 microns or more. In a further embodiment, the combined thickness of the substrate and the barrier layer can be about 1000 microns or less, about 800 microns or less, or even about 750 microns or less. Further, the combined thickness of the base material and the barrier layer can be within the range of either the minimum value or the maximum value given above, for example, 25 um to 1000 um.

With particular reference to FIG. 2, in certain embodiments, the composition is a relatively porous substrate 11
If 0 coating to cure on the barrier layer 120 are able to penetrate to a desired depth P _D to a substrate, in certain embodiments, it is impossible to strike through the entire substrate. For example, in certain embodiments, the thickness ST of the substrate, as first main surface of the substrate substantially no barrier layer may be greater than P _D. Furthermore, the barrier layer, as shown in FIG. 3, can be from the outermost surface of the barrier layer has a thickness BL _T were measured to a length of the barrier layer penetrates into the substrate.

Thus, in certain embodiments, the barrier layer is at least about 1% and about 5% of the thickness of the substrate.
It can penetrate the substrate by more than, or even about 10% or more. In a further embodiment, the barrier layer can penetrate the substrate by about 95% or less, about 90% or less, or even about 85% or less of the thickness of the substrate.

Further, in certain embodiments, the barrier layer is about 1% or more, about 5% of the thickness of the barrier layer.
Permeation into the substrate by% or more, or even about 10% or more. In a further embodiment, the barrier layer can penetrate the substrate by about 95% or less, about 90% or less, or even about 85% or less of the thickness of the barrier layer.

In other embodiments, the substrate can be completely covered such that continuous layers of the composition are located on both main surfaces of the substrate. For example, _{P D} can be equal to either greater or ST than ST. In addition, the barrier layer can have the desired thickness on both main surfaces of the substrate.

The embodiments of the present disclosure can exhibit variable moisture permeation that varies with relative humidity, which is very advantageous. Similar to the above discussion of the composition, the article to be coated containing the substrate and the composition can exhibit desirable moisture permeation at low relative humidity, medium relative humidity, and high relative humidity. As used herein, moisture permeability is measured at a temperature of 21 ° C. according to ASTM E96.

Thus, in certain embodiments, the article to be coated can have a moisture permeability of about 2 palms or less, or even 1 palm or less, at a 25% average Rhesus factor. In certain embodiments, the article to be coated has a 25% average R.
In H, it can have a moisture permeability of about 1 palm or less.

In a further embodiment, the article to be coated is about 1 at 95% average RH.
It can have a moisture permeability of 2 palms or more, about 15 palms or more, or even about 20 palms or more. In certain embodiments, the article to be coated can have a moisture permeability of about 20 palms or higher at a 95% average Rhesus factor.

In a further embodiment, the article to be coated can have a moisture permeability of 5 palms (perm) or less, or even 2.5 palms (perm) or less at a 45% average RH. In certain embodiments, the article to be coated can have a moisture permeability of 2.5 palm or less at a 45% average Rhesus factor.

In a further embodiment, the article to be coated can have a moisture permeability of 6 palms to 12 palms at a 75% average RH.

The article to be coated can further have various combinations of moisture permeation at different relative humidity given above.

For example, in certain embodiments, the article to be coated has a moisture permeability of less than about 1 palm (perm) at 25% average RH; about 20 palms (perm) at 95% average RH.
) Can have the above moisture permeability.

In a further embodiment, the article to be coated has a moisture permeability of about 1 palm or less at a 25% average RH; and 5 palms or less at a 45% average RH.
Or even with a moisture permeability of 2.5 palm or less; about 2 at 95% average RH.
It can have a moisture permeability of 0 palm or more.

In a further embodiment, the article to be coated has a moisture permeability of about 1 palm or less at a 25% average RH; and 5 palms or less at a 45% average RH.
Or even more, with moisture permeability below 2.5 palm (perm); with moisture permeability in the range of 6 palm (perm) to 12 palm (perm) at 75% average RH; about 20 palm (perm) at 95% average RH. ) Can have the above moisture permeability.

It should be understood that the combinations of moisture permeability at different relative humidity described above are exemplary combinations and that all possible combinations of moisture permeability in the article to be coated described above are within the scope of the present disclosure. ..

If the coating exhibits the above-mentioned moisture permeability at different RH values, the change in moisture permeability with increasing humidity is linear or non-linear as a function of the logarithm of permeance to relative humidity as described herein. Further note that it may be.

Another parameter of the article is the performance of favorable nail tear resistance. Nail tear resistance is a measure of the ability of an article to prevent tearing after puncture. As used herein, nail tear resistance is measured according to EIN 12310-1. Therefore, the article to be coated can have a nail tear resistance of about 1 N / 5 cm or more, about 5 N / 5 cm or more, or even about 10 N / 5 cm or more.

Yet another parameter of the article is its tensile strength. As used herein, tensile strength is measured according to EIN 12311-2. Thus, in certain embodiments, the article to be coated can have a tensile strength of about 10 N / 5 cm or more, about 25 N / 5 cm or more, or even about 40 N / 5 cm or more. Further, in certain embodiments, the article to be coated is about 10 N / 5 cm or more, about 25 N / 5 cm.
It can have UV aging tensile strength of about 40 N / 5 cm or more. As used herein, UV aging tensile strength is ^{measured at 0.8 W / m 2} after 180 hours of UV aging.

Yet another parameter that describes the properties of the article is its tape adhesion. Tape adhesion is a measure of the ability of an article to be coated to adhere to and detach from the adhesive tape. As used herein, tape adhesion is measured according to EIN 12317-2. Therefore, the article to be coated is about 15 N / 5 cm or more and about 20 N / 5 cm.
It can have a tape adhesive force of about 25 N / 5 cm or more.

Specific examples are provided below to aid in a deeper understanding of the techniques described herein.

Item 1. A coating composition adapted to selectively delay the condensation of water vapor depending on the humidity when cured, wherein the composition is a hydrophobic component; and a hydrophilic component;
Including
When the above composition is cured, the above composition is tested according to ASTM E96 at 21 ° C., and when the above composition is coated on kraft paper and cured and tested.
A coating composition that is effective in providing variable moisture permeability that is less than or equal to about 1 palm at a 25% average RH and greater than or equal to about 15 palms at a 95% average relative humidity.

Item 2. An article adapted to selectively delay condensation of water vapor in response to humidity.
This article contains a building material substrate; and a barrier layer placed on the building material substrate, which is a hydrophobic component; and a hydrophilic component;
Including
The above article was less than about 1 palm at 25% average Rhes and about 15 palms at 95% average relative humidity when tested at 21 ° C. according to ASTM E96.
An article having a moisture permeability of perm) or higher.

Item 3. An article adapted to selectively delay condensation of water vapor in response to humidity.
A building material substrate containing a cloth in which this article has a pore structure; and a barrier layer disposed on the building material substrate;
Including
The above article was less than about 1 palm at 25% average Rhes and about 15 palms at 95% average relative humidity when tested at 21 ° C. according to ASTM E96.
It has a moisture permeability of perm) or higher;
An article in which about 10% or more of the barrier layer is contained in the pore structure of the cloth.

Item 4. An article adapted to selectively delay condensation of water vapor in response to humidity.
This article is a building material substrate containing a non-woven fabric having a pore structure; and a barrier layer;
Including
The above article was less than about 1 palm at 25% average Rhes and about 15 palms at 95% average relative humidity when tested at 21 ° C. according to ASTM E96.
It has a moisture permeability of perm) or higher;
An article in which about 10% or more of the barrier layer is contained in the pore structure of the non-woven fabric base material.

Item 5. A method of forming an article adapted to selectively delay the condensation of water vapor in response to humidity, which method prepares the coating composition;
Preparing the substrate;
Applying the above composition to the above substrate; and drying the above composition thereby forming a barrier layer on the above substrate;
Including
The above article was less than about 1 palm at 25% average Rhes and about 15 palms at 95% average relative humidity when tested at 21 ° C. according to ASTM E96.
A method having a moisture permeability of perm) or higher.

Item 6. A method of forming an article adapted to selectively delay the condensation of water vapor in response to humidity, which method prepares an aqueous coating composition;
Preparing the building material base material;
Applying the above composition to the above building material substrate; and drying the above composition thereby forming a barrier layer on the above building material substrate;
Including
The above article was less than about 1 palm at 25% average Rhes and about 15 palms at 95% average relative humidity when tested at 21 ° C. according to ASTM E96.
A method having a moisture permeability of perm) or higher.

Item 7. The composition, article or method according to any one of items 1 to 6, wherein the hydrophobic component comprises a water-insoluble polymer.

Item 8. The composition, article or method according to any one of items 1 to 7, wherein the hydrophobic component comprises a water-insoluble polymer dispersed in water.

Item 9. The composition according to any one of items 1 to 8, wherein the hydrophobic component contains latex.
Goods or methods.

Item 10. The above hydrophobic components are styrene butadiene, styrene acrylic, acrylic,
The composition, article or method according to any one of items 1 to 9, which comprises latex of ethylene vinyl acetate, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or a combination thereof.

Item 11. The composition, article or method according to any one of items 1 to 10, wherein the hydrophobic component comprises styrene-butadiene latex.

Item 12. The composition according to any one of items 1 to 11, wherein the hydrophobic component has% carboxylation of about 15% or less, about 10% or less, about 5% or less, or even about 3% or less.
Goods or methods.

Item 13. The above hydrophobic component is about 35 ° C or lower, about 25 ° C or lower, or even about 15 ° C.
The composition, article or method according to any one of items 1 to 12, having a glass transition temperature (Tg) of ° C. or lower.

Item 14. The above hydrophobic components are -30 to 35 ° C, -30 to 25 ° C, or even-
The composition, article or method according to any one of items 1 to 13, having a glass transition temperature (Tg) in the range of 30 to 15 ° C.

Item 15. The hydrophobic component is about 15% by weight or more, about 25% by weight or more, about 35% by weight or more, or even about 45% by weight, based on the total dry weight of the hydrophobic component and the hydrophilic component. The composition, article or method according to any one of items 1 to 14, which is present in the above composition or in the barrier layer in the above amount.

Item 16. The above hydrophobic component is in an amount of about 99% by weight or less, about 98% by weight or less, or even about 97% by weight or less, based on the total dry weight of the hydrophobic component and the hydrophilic component of the barrier layer. The composition, article or method of any one of items 1 to 15, which is present in the composition or the barrier layer of.

Item 17. The above hydrophobic component is in the range of 15 to 99% by weight, 25 to 98% by weight, or even 35 to 97% by weight based on the total dry weight of the hydrophobic component and the hydrophilic component of the barrier layer. The composition, article or method of any one of items 1 to 16, which is present in the composition or the barrier layer of.

Item 18. Items 1-1, wherein the above hydrophilic component comprises a polymer which is water-soluble without cross-linking.
The composition, article or method according to any one of 7.

Item 19. The above hydrophilic components are polyvinyl alcohol (PVOH), poly (vinylpyrrolidone), starch, cellulose, polyacrylate, polyacrylic acid, highly carboxylated latex, amine, polyethylene oxide, vinyl ether, highly hydrolyzed polymer (for example). , Hydrolyzed maleic anhydride), polysaccharides, or combinations thereof, the composition, article, or method of any one of items 1-18.

Item 20. The composition, article or method according to any one of items 1 to 19, wherein the hydrophilic component comprises polyvinyl alcohol (PVOH) or sodium polyacrylate.

Item 21. The composition, article or method according to any one of items 1 to 20, wherein the hydrophilic component comprises a hydrophilic filler.

Item 22. The composition, article or method according to any one of items 1 to 21, wherein the hydrophilic component comprises an inorganic hydrophilic filler.

Item 23. The composition, article or method according to any one of items 1 to 22, wherein the hydrophilic component comprises a polymer which is water-soluble without cross-linking and an inorganic hydrophilic filler.

Item 24. Percentage water absorption of the above hydrophilic components at about 1% or more, about 3% or more, about 5% or more, or even about 7% or more when measured at a relative humidity of 100% and 23 ° C. according to a weighing method. The composition, article or method of any one of items 1 to 23, comprising a polymer comprising.

Item 25. The hydrophilic component comprises a polymer having a molecular weight of about 50,000 or more.
The composition, article or method according to any one of items 1 to 24.

Item 26. The composition, article or method according to any one of items 1 to 25, wherein the hydrophilic component comprises a polymer having a molecular weight of about 300,000 or less.

Item 27. The composition, article or method according to any one of items 1 to 26, wherein the hydrophilic component comprises a polymer having a molecular weight in the range of 50,000 to 300,000.

Item 28. The hydrophilic component is about 0.1% by weight or more, about 0.5% by weight or more, or even about 1% by weight or more, based on the total dry weight of the hydrophobic component and the hydrophilic component. The composition, article or method of any one of items 1-27, which is present in the above composition or in the barrier layer in quantity.

Item 29. Based on the total dry weight of the hydrophobic component and the hydrophilic component, the hydrophilic component is about 40% by weight or less, about 30% by weight or less, about 25% by weight or less, about 20% by weight or less, about 20% by weight or less. The composition, article or of any one of items 1-28 present in the above composition or in the barrier layer in an amount of 15% by weight or less, about 10% by weight or less, or even about 8% by weight or less. Method.

Item 30. The above-mentioned composition in an amount in the range of 0.1 to 35% by weight, or even 1 to 15% by weight, based on the total dry weight of the above-mentioned hydrophobic component and the above-mentioned hydrophilic component. The composition, article or method of any one of items 1-29, which is present in or in the barrier layer.

Item 31. The composition, article or method according to any one of items 1 to 30, wherein the composition or barrier layer further comprises a filler.

Item 32. The composition, article or method according to any one of items 1 to 31, wherein the composition or barrier layer further comprises a filler, wherein the composition or barrier layer comprises approximately the limit pigment volume of the filler. A composition, article or method having a filler content below the concentration.

Item 33. The composition, article or method according to any one of items 1 to 32, wherein the composition or barrier layer further comprises a filler, wherein the composition or barrier layer is the composition or barrier layer. A composition, article or method having a filler content in the range of 0-85% by weight based on the total dry weight of.

Item 34. The composition, article or method of any one of items 1-3, wherein the composition or barrier layer further comprises a filler, wherein the filler is clay, CaCO ₃ , CaS.
O ₄ , BaSO ₄ , silica, talc, carbon black, diatomaceous earth, alumina, titanium,
Or a composition, article or method comprising a combination thereof.

Item 35. The volume% ratio of the hydrophobic component to the hydrophilic component is about 2: 1 or more.
And the composition or method of any one of items 1-34, which is about 200: 1 or less.

Item 36. The article or method according to any one of items 1 to 35, wherein the substrate comprises a building material.

Item 37. The article or method according to any one of items 1-36, wherein the substrate comprises a kraft paper exterior material, a scrim, a polymer sheet, or a combination thereof.

Item 38. The article or method according to any one of items 1-37, wherein the substrate comprises a cloth building material.

Item 39. The article or method according to any one of items 1-38, wherein the substrate comprises a non-woven material.

Item 40. The article or method according to any one of items 1 to 39, wherein the substrate comprises a woven material.

Item 41. The article or method according to any one of items 1 to 40, wherein the substrate comprises a non-woven material, including a spunbonded fabric or a pointbonded fabric.

Item 42. Item 1 in which the above barrier layer has a coating weight of about 20 gsm or more.
The article or method according to any one of ~ 41.

Item 43. The barrier layer is about 500 at a shear rate of 1s- ¹ and a temperature of 21 ° C.
The article or method according to any one of items 1 to 42 having a viscosity of cps or more, wherein the viscosity of the barrier layer is measured before the curing of the barrier layer.

Item 44. The barrier layer is about 5000 at ^{a shear rate of 1s -1} at a temperature of 21 ° C.
The article or method according to any one of items 1 to 43, which has a viscosity of cps or more and a viscosity of ^{less than 1000 cps at a shear rate of 1000 s-1, has a viscosity of the barrier layer.}
An article or method to measure before curing the barrier layer described above.

Item 45. The combined thickness of the above base material and the above barrier layer is 50 um to 1000 um.
The article or method according to any one of items 1-44, which is within the scope of.

Item 46. The composition according to any one of items 1 to 45, wherein the barrier layer is adapted so as to penetrate the non-woven fabric substrate by about 5% or more of the thickness of the barrier layer.

Item 47. The composition according to any one of items 1 to 46, wherein the above composition is adapted so as to penetrate the above base material by 90% or less of the thickness of the non-woven fabric base material.

Item 48. The article or method according to any one of items 1 to 47, wherein the barrier layer is adapted to penetrate the substrate by about 5% or more of the thickness of the substrate.

Item 49. 45% when the above article was tested at 21 ° C. according to ASTM E96
The article or method according to any one of items 1-48, having a moisture permeability of about 2.5 palms or less in average RH.

Item 50. 75% of the above articles when tested at 21 ° C. according to ASTM E96
The article or method of any one of items 1-49, having a moisture permeability of 6-12 palms (perm) on average RH.

Item 51. Approximately 10 N / N when the above article is measured according to EIN 12310-1
The article or method according to any one of items 1 to 50, which has a nail tear resistance of 5 cm or more.

Item 52. Approximately 30 N / when the above article is measured according to EIN 12311-2
The article or method according to any one of items 1 to 51, which has a tensile strength of 5 cm or more.

Item 53. Approximately 25 N / when the above article is measured according to EIN 12317-2
The article or method according to any one of items 1 to 52, which has a tape adhesive force of 5 cm or more.

Not all of the actions described in the general description or examples above are required, and some of the specific actions may not be required, and one or more additional actions may be included in the described actions. Note that it may be done in addition. Moreover, the order in which actions are listed is not necessarily the order in which they are performed.

Benefits, other benefits, and solutions to problems are described above for a particular embodiment. However, the benefits, benefits, solutions to problems, and features may give rise to any benefit, benefit, or solution to produce or become more prominent, any or all of them. Should not be construed as an integral, essential or essential feature of the claims.

The details and description of the embodiments described herein are intended to provide a general understanding of the configuration of the various embodiments. The details and description are not intended to serve as a complete and comprehensive description of all elements and features of devices and systems that use the components or methods described herein. Separate embodiments may be provided in combination in one embodiment, whereas the various features described in the context of one embodiment for brevity are provided separately or in any part. It may be provided in combination. In addition, references to values mentioned in a range include all values within that range. Many other embodiments may be apparent to those skilled in the art simply by reading this specification. Other embodiments may be used such that structural substitutions, logical substitutions or other changes may be made without departing from the scope of the present disclosure, and other embodiments are derived from the present disclosure. May be good. Therefore, this disclosure should be considered as an explanation rather than a limitation.

Example 1-Permeance Samples are prepared and according to ASTM E96, 21 ° C. and 25% RH, 45% R relative humidity.
Water vapor permeance values were tested at H, 75% RH and 95% RH.

Samples for steam permeance testing were prepared using an air-powered Coles blade or homogenizer, or by hand mixing the components at room temperature for 5 minutes. The coating was about 75 microns thick and was applied by rolled wire (Meyer rod) or slot die extrusion.

The weight% values shown for hydrophobic and hydrophilic components are based on the total weight of the hydrophobic and hydrophilic components in the solid membrane. The weight% value for the filler is based on the total weight of the coating composition.

Ingredient A-Styron DL-226 was obtained from Styron. This is a styrene-butadiene latex with a low degree of carboxylation and a glass transition temperature of -14 ° C.
B-Styron DL-490 was obtained from Styron. This is a highly carboxylated styrene-butadiene latex with a glass transition temperature of 9 ° C.
C-PVOH Selfol 9-325 was obtained from Sekisui. This is PVOH that has a high molecular weight and is pre-dissolved in an 8.5% solid that is 98.4% hydrolyzed.
D-PAA Acumer 1510 was obtained from Dow. This is a 25% solid polyacrylic acid.
E-kaolin clay was obtained from Sigma Aldrich.
NW-Non-woven fabric substrate obtained from Hanes under the trade name Elite.
SD-slot die coating processing MR-Mayer rod coating processing

As shown above, the multi-coated substrate exhibits desirable permeance values comparable to the comparative nylon 2 mil membrane (Sample 16) and is even better than the nylon 2 mil membrane. More specifically, sample 9 showed almost the same performance as sample 16, but sample 9 was 2.
It is more closed at 5% humidity and more open at 95% humidity, both of which are preferable and better than nylon 2 mil membranes.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, ie, as a particular component ratio, comparing the permeance properties of Samples 1, 2 and 3 in the table, the slope increases as the hydrophilic component increases. It is clear that it will increase dramatically.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, ie, as the particular material selected, comparing the permeance properties of Samples 2 and 4 in the table, the choice of hydrophobic material is significant for the permeance properties. It is clear that it can have a significant effect.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, ie, as the particular material of choice, comparing the permeance properties of Samples 5 and 6 in the table, the hydrophilic component C adapts the permeance properties. In particular, it is clear that it is much more effective than the hydrophilic component D.

As a specific example of a particular advantage of a particular embodiment of the present disclosure, i.e., as a filler selection, comparing the permeance properties of Samples 3, 7, 9, 10 and 11 in the table, the incorporation of a kaolin filler It is clear that the barrier properties at low humidity were significantly improved and the vapor permeance at high humidity was improved.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, the permeance properties of sample 16 are compared to the permeance properties of the individual components of the table (ie, samples 12, 13, 14 and 15), separately of nylon. It is clear that there are no components that can match the properties.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, the permeance properties of Sample 9 may be comparable to those of Sample 9 separately when compared to the permeance properties of the individual components (Samples 12 and 14) in the table. It is clear that there are no ingredients. Therefore, Sample 9 shows a synergistic improvement in permeance properties when compared individually with the individual components. This synergistic effect was completely unexpected.

As a specific example of the particular advantages of certain embodiments of the present disclosure, highly carboxylated latex may actually be sufficiently hydrophilic to show a strong dependence of permeance on Rhesus; It is clear from the permeance characteristics of sample 15 that the permeance value at 45% humidity is too high to achieve the characteristics of sample 16.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, i.e., as for the strength of the coating, comparing the permeance properties of Samples 2 and 8 in the table, the substrate is more open to vapors than the coating. If so, it is clear that the choice of substrate has only a small effect on permeance.

As a specific example of the particular advantages of the particular embodiments of the present disclosure, i.e., as for the strength of the coating, comparing the permeance properties of Samples 2 and 6 in the table, the coating process has little effect on the properties. It is clear that.

Example 2: Physical data The following samples were prepared as follows.

Sample 2A: 94% by weight of Styron DL-226 based on the total weight of the two components.
6% by weight PVOH-325. The sample further contained 33% by weight kaolin filler based on the total weight of the composition. This was coated on a Hanes Elite 100 cloth in the length direction.

Sample 2B: 94% by weight of Styron DL-226 based on the total weight of the two components.
6% by weight PVOH-325. The sample further contained 33% by weight kaolin filler based on the total weight of the composition. This was coated on a Hanes Elite 200 cloth in the transverse direction.

Sample 2C: Sample 2C is a comparative example and contains a 50 micron thick Vario KM membrane.
The Vario KM membrane was obtained from the Saint-Gobin Corporation and used as received.

The sample was then tested for initial tensile strength, tensile strength ^{after UV aging at 0.8 W / m 2} for 180 hours, and nail resistance according to the test method described above, with the following results:

Example 3: Viscosity Measurement Three samples were prepared as follows and the viscosity before curing was measured according to the method described herein.
Sample 3A: Sample 3A is 95% by weight Styron DL based on the total weight of the two components.
It contained -226 and 5% by weight PVOH-325.
Sample 3B: Sample 3B is 94% by weight of Styron DL based on the total weight of the two components.
It contained -226 and 6% by weight PVOH-325. The sample further contained 33% by weight kaolin filler based on the total weight of the composition.
Sample 3C was a comparative sample and contained 100% by weight DL 226.
Sample 3D was a comparative sample and contained 100% by weight Selfol 9-325.

The results are reported in FIG. 3 at different shear rates measured in ^{s-1 units (P.}
A graph of viscosity measured in a × s) units is shown. As shown, the viscosities of Sample 3A and Sample 3B were significantly higher than those of Comparative Samples 3C and 3D.

Claims (15)

A coating composition configured to selectively delay water vapor according to humidity when cured into a barrier layer, wherein the composition is a. Component A containing a butadiene-based latex having 0 to 20% carboxylation, and b. Component B containing kaolin clay and a polymer selected from polyvinyl alcohol (PVOH) and sodium polyacrylate.
Including
c. Once the composition has hardened, the composition is variable to be less than or equal to 1 palm at 25% average RH and greater than or equal to 15 palm at 95% average relative humidity when tested at 21 ° C. according to ASTM E96. A coating composition that is effective in providing good moisture permeability and that the composition does not contain stearate. An article configured to selectively delay water vapor in response to humidity, wherein the article is a. Building material base material and b. Select from component A containing a barrier layer disposed on the building material substrate, the barrier layer containing a butadiene-based latex having 0 to 20% carboxylation, polyvinyl alcohol (PVOH), and sodium polyacrylate. Contains the polymer to be produced and component B containing kaolin clay.
The barrier layer has a variable moisture permeability of 1 palm or less at 25% average RH and 15 palm or more at 95% average relative humidity when tested at 21 ° C. according to ASTM E96. The barrier layer is an article that does not contain stearate. An article configured to selectively delay water vapor in response to humidity, wherein the article is a. Building material substrates including synthetic fabrics with pore structures, and b. A barrier layer containing a component A containing a butadiene-based latex having 0 to 20% carboxylation, a polymer selected from polyvinyl alcohol (PVOH) and sodium polyacrylate, and a component B containing kaolin clay.
The barrier layer has a variable moisture permeability of 1 palm or less at 25% average RH and 15 palm or more at 95% average relative humidity when tested at 21 ° C. according to ASTM E96. The barrier layer does not contain stearate and
c. An article in which 1% or more of the barrier layer has entered the pore structure of the base material of the synthetic cloth. Once the composition has cured, the composition has a moisture permeability of 2.5 palm or less at 45% average RH and 6-12 palms at 75% average RH when tested at 21 ° C. according to ASTM E96. The composition according to claim 1, which is effective for providing perm) moisture permeability. The article has a moisture permeability of 2.5 palm (perm) or less at a 45% average RH and a moisture permeability of 6-12 palm (perm) at a 75% average RH when tested at 21 ° C. according to ASTM E96. , The article according to any one of claims 2 to 3. The article according to any one of claims 2 to 3, wherein the base material comprises a kraft paper exterior material, a scrim, a polymer sheet, a gypsum wall board, or a combination thereof. The article according to any one of claims 2 to 3, wherein the base material contains a woven material or a non-woven material. The article according to any one of claims 2 to 3, wherein the base material comprises a non-woven material including a spunbond cloth or a point bond cloth. The article according to any one of claims 2 to 3, wherein the barrier layer penetrates into the base material by 5% or more of the thickness of the barrier layer. The article according to any one of claims 2 to 3, wherein the article has a nail tear resistance of 10 N / 5 cm or more when measured according to EIN 12310-1. The composition according to claim 1, wherein the volume% ratio of the component A to the component B is 2: 1 or more and 200: 1 or less. The composition according to claim 1, wherein the component B comprises a material having a percentage water absorption of 1% or more. The component A comprises or is derived from the latex of styrene butadiene, styrene acrylic, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof. , The composition according to claim 1 . The composition according to claim 13, wherein the component A is the latex of styrene-butadiene. The component B further comprises starch, cellulose, highly carboxylated latex, amine, vinyl ether, highly hydrolyzed polymer, polysaccharide, poly (vinylpyrrolidone), polyacrylic acid salt, polyacrylic acid, polyethylene oxide, or a combination thereof. The composition according to claim 1 .

Images