KR101906159B1 - Coating compositions for building materials and coated building material substrates - Google Patents

Abstract

Embodiments of the present invention are directed to coating compositions, coated articles, and methods, wherein the coated article has a variable transmittance profile at 25% average RH when tested at 21 DEG C in accordance with ASTM E96, And about 15 perms at 95% average relative humidity.

Description

TECHNICAL FIELD [0001] The present invention relates to a coating composition for a building material,

The present application relates to coatings for building materials. More particularly, certain embodiments described herein relate to coatings that effectively provide a coating substrate having a variable water vapor transmission rate value as a function of relative humidity (RH).

Building materials include films or facing materials attached thereto to provide desirable physical properties. The film or facing material typically comprises a petroleum product, and thus substantially volatile organic compounds (VOCs) are released during material manufacture and / or use.

Currently available products do not maintain a desirable water vapor transmission rate at low relative humidity. Moreover, current coating formulations are not used with porous substrates, such as porous nonwoven fabrics. What is needed is an innovative solution that can be used in a wide variety of different substrates, for example, porous substrates and especially porous nonwoven substrates, and that will provide new coating compositions that can provide desirable water vapor transmission rates, especially at low relative humidity.

Those skilled in the art will appreciate that any dimension or shape in the figures may be depicted in an enlarged, distorted, or otherwise abnormal or non-proportional manner in order to provide a better view, in view of the benefits of the present invention. While a dimension or value is specified in the following description, a dimension or value is provided for illustrative purposes only. Front, back, plan and bottom reference views are provided for illustration purposes non-limitingly.

Certain embodiments are described with reference to the accompanying drawings:
1 shows a coated substrate according to an embodiment of the present invention.
Figure 2 shows a coating substrate, which penetrates a specific depth into a substrate according to one embodiment of the present invention.
3 is a graph of viscosity measurements of Example 3. Fig.

In general, the present invention relates to a coating composition for building material substrates and to a coating substrate for selectively retarding water vapor, depending on humidity, when cured. These concepts are better understood in the above description.

The coating composition generally comprises a hydrophobic component and a hydrophilic component.

In certain embodiments, the hydrophobic component comprises a water insoluble polymer.

In certain embodiments, the water-insoluble polymer is provided in an aqueous dispersion in a coating composition such that the water-insoluble polymer is dispersed in water.

In highly specific embodiments, the hydrophobic component comprises a latex. For example, the latex includes latexes of styrene butadiene, styrene acryl, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof. In more specific embodiments, the hydrophobic component comprises a styrene butadiene latex.

In certain embodiments, the hydrophobic component may be described as% carboxylation. % Carboxylation means the weight percent of carboxylic acid monomer in the polymer backbone. Thus, in certain embodiments, the% carboxylation of the hydrophobic component is substantially 0%, at least about 0.1%, at least about 0.5%, or at least about 1%. In further embodiments, the% carboxylation of the hydrophobic component is no more than about 20%, no more than about 15%, no more than about 10%, no more than about 5%, or no more than about 3%. Moreover, the% carboxylation of the hydrophobic component is in the range between any of the minimum and maximum values, such as 0% to 20%, 0.1% to 15%, 0.5% to 10%, or 1% to 8%. In very specific embodiments, the% carboxylation of the hydrophobic component is about 0% and in this case the hydrophobic component is substantially absent of the carboxylic acid monomer in the polymer backbone.

A particular advantage of the% carboxylation is the combination with the hydrophilic component to achieve an excellent permeability according to the relative humidity. Without being bound by theory, it is believed that in high levels of carboxylation, the latex tends to have a too high water vapor transmission rate at intermediate relative humidity.

In certain embodiments, the hydrophobic component can be described by its glass transition temperature (Tg). As used herein, the glass transition temperature (Tg) of a hydrophobic component is measured by differential scanning calorimetry or dynamic mechanical behavior analysis. Thus, in certain embodiments, the glass transition temperature (Tg) of the hydrophobic component is at least about -50 캜, at least about -40 캜, or at least about -30 캜. In further embodiments, the glass transition temperature (Tg) of the hydrophobic component is less than about 35 占 폚, less than about 25 占 폚, less than about 25 占 폚, or less than about 15 占 폚. Moreover, the glass transition temperature of the hydrophobic component may be in the range between any of the minimum and maximum values, such as -30 to 25 캜, -30 to 15 캜, or -30 to 0 캜.

In certain embodiments, the hydrophobic component comprises at least about 15 wt.%, At least about 25 wt.%, At least about 35 wt.%, Or at least about 45 wt.%, Based on the total dry weight of the hydrophobic & hydrophilic components of the barrier layer. wt.%. In further embodiments, the hydrophobic component is present in the composition or barrier layer in an amount of up to about 99 wt.%, Up to about 98 wt.%, Or up to about 97 wt.%, Based on the total dry weight of the hydrophobic & hydrophilic components of the barrier layer. Moreover, the hydrophobic component may be present in the composition or in the barrier layer in a range between any of the minimum and maximum values, for example from 15 wt.% To 99 wt.%, From 25 wt.% To 98 wt.%, Based on the total dry weight of the hydrophobic & wt.%, alternatively from 35 wt.% to 97 wt.%.

As noted, in certain embodiments, in addition to the hydrophobic component, the composition comprises a hydrophilic component. The hydrophilic component adsorbs moisture and increases the permeability of the composition at high relative humidity.

In certain embodiments, the hydrophilic component comprises a polymer that is free of cross-linking and is water-soluble.

In certain embodiments, the hydrophilic component is selected from the group consisting of polyvinyl alcohol (PVOH), poly (vinylpyrrolidone), starch, cellulose, salts of polyacrylic acid, polyacrylic acid, highly carboxylated latexes, amines, Ethers, highly hydrolyzed polymers (e.g., hydrolyzed maleic anhydride), polysaccharides, or combinations thereof. In very specific embodiments, the hydrophilic component comprises polyvinyl alcohol (PVOH) or sodium polyacrylate.

In certain embodiments, the composition comprises one or more hydrophilic components. For example, as discussed in detail below, the composition comprises a hydrophilic filler selected from the hydrophilic component substitution, such as PVOH, or additionally. In certain embodiments, the hydrophilic filler may be an inorganic hydrophilic filler, such as kaolin.

In certain embodiments, the hydrophilic component can be described in percent absorption. As used herein,% absorption is determined by gravimetry as is well understood in the art. The% water absorption increases the transmittance to relative humidity relationship, but if too high, the hydrophilic component dissolves and destabilizes the film.

In certain embodiments, the percent absorption of the polymer in the hydrophilic component is at least about 0.5%, at least about 2%, at least about 5%, or at least about 7%, when measured at 100% relative humidity and at 23 占 폚. In further embodiments, the percent absorption of the polymer in the hydrophilic component when measured at 100% relative humidity and at 23 占 폚 is no more than about 20%, no more than about 15%, or no more than about 10%. Moreover, the percent absorption of the hydrophilic component is in the range between any of the minimum and maximum values, such as from about 0.5% to about 20%, or from about 7% to about 10%.

In certain embodiments, the hydrophilic component can be described by molecular weight. By using a high molecular weight material which is soluble only at a high temperature, dissolution of the hydrophilic component at a low temperature can be avoided.

In certain embodiments, the weight average molecular weight of the hydrophilic component is at least about 50000. In further embodiments, the molecular weight of the hydrophilic component is less than or equal to about 300,000. Moreover, the molecular weight of the hydrophilic component is in the range between any of the minimum and maximum values, for example from 50000 to 300000.

In certain embodiments, the hydrophilic component is present in the composition or barrier layer at least about 0.1 wt.%, At least about 0.5 wt.%, Or at least about 1 wt.%, Based on the total dry weight of the hydrophobic & hydrophilic component. In further embodiments, the hydrophilic component is present in the composition or barrier layer in an amount of up to about 40 wt.%, Up to about 30 wt.%, Up to about 25 wt.%, Up to about 20 wt.% In the composition or barrier layer, based on the total dry weight of the hydrophobic & , Up to about 15 wt.%, Up to about 10 wt.%, Or up to about 8 wt.%. Moreover, the hydrophilic component may be present in the composition or barrier layer in a range between any of the minimum and maximum values, for example from 0.1 wt.% To 35 wt.%, Or from 1 wt.% To 15 wt.%, Based on the total dry weight of the hydrophobic & % exist.

In certain embodiments, the composition further optionally further comprises a desired additive component such as an inorganic filler, a viscosity modifier, a pigment, a dye, a UV absorber, a slip additive, a surfactant, a biocide, a defoamer, a deagglomerator, .

In certain embodiments, the composition comprises a filler. In very specific embodiments, the filler content of the composition is below the critical pigment volume concentration of the filler. For example, the critical pigment volume concentration of the filler is such that the binder does not completely fill the voids between the pigment particles. For example, this is measured by oil adsorption of the pigment. The CPVC varies from 20-68% by volume, but the value is typically about 50-55%.

In certain embodiments, the filler includes clay, montmorillonite, calcium carbonate, barium sulfate, bentonite, muscovite, ilite, couquite, kaolinite, chlorite, or other filler materials. Fillers include inorganic materials, organic materials or combinations thereof. Specific fillers include kaolin clay, CaCO3, CaSO4, BaSO4, silica, talc, carbon black, diatomaceous earth, alumina, titania, or combinations thereof. In some preferred embodiments, fillers having a platelet morphology, such as kaolin clay, can increase the relative permeability versus relative humidity slope. This is due to the increased tortuosity of the film and the coatings can be applied thinner and have excellent performance. In some embodiments, the filler provides reinforcement to the cured coating, provides flame resistance to the cured coating, improves the physical properties of the cured composition (e. G., The CLTE of the cured composition of the filler member , Or other desirable features, for example, to increase the overall viscosity of the composition, allowing for a more uniform coating on the substrate. ≪ tb >< TABLE > Fillers obtained commercially by way of example include, but are not limited to, Bentolite®, Cloisite®, Nanofil®, Nanothix®, and including Permont ^® filler, and Southern Clay Products, Inc. ≪ / RTI >

In certain embodiments, the filler is present in the composition in an amount of 0 wt% to 85 wt%, based on the total dry weight of the composition or barrier layer.

In certain embodiments, the dispersion comprises one or more biocides. The biocides effectively retard or inhibit organic growth on the coating and / or substrate surface. In some embodiments, the biocide is effective as a fungicide, for example, as an antifungal agent, and inhibits the growth of fungi or other fungi on the surface of the substrate. In other embodiments, the biocide is effective to inhibit the growth of bacteria, moss, algae or other organisms on the substrate surface. If present, the biocide is present in an effective amount to retard or inhibit the growth of the biological organism.

In some embodiments, the dispersion comprises a stain-resistance additive. In some embodiments, the antifouling additive reduces or inhibits adsorption of the material to the coating and assists in sealing the coating from penetration by generally water and non-gaseous materials. For example, the antifouling additive provides oil resistance or oil repellency to inhibit non-polar species from being trapped in the coating. The stain resistant additive also prevents fading of the coating when exposed to heat, ultraviolet light or other forms of energy. Exemplary stain resistance additives are, for example, 3M (e.g., SRC-220, PM-5000 , PM-1680, PM-4800) commercially available from and AkzoNobel (e.g., Elotex ^® stain resistance additives) do.

When the composition is described as a whole, the composition may have a wt.% Specific proportion of the hydrophobic component relative to the hydrophilic component. For example, in certain embodiments, the volume percent ratio of hydrophobic component to hydrophilic component is at least about 3: 1, at least about 10: 1, or at least about 30: 1. In further embodiments, the volume percent ratio of hydrophobic component to hydrophilic component is no more than about 200: 1, or no more than about 100: 1. Moreover, the volume percentages of hydrophobic to hydrophilic components may range between any of the above minimum and maximum values, such as from about 2: 1 to about 200: 1.

The composition may also have a desirable viscosity. For example, in certain embodiments, the viscosity of the composition is at least about 1000 cps at a shear rate of 1 s < ^-1 > In further embodiments, the viscosity of the composition is less than or equal to about 1000 cps at a shear rate of 1 s < ^-1 > Moreover, the viscosity of the composition is about 1000 cps or less, at least about 5000 cps, and a shear rate of 1 s ^-1 and 21 ℃ at a shear rate of 1 s ^-1 and 21 ℃.

Compositions can also be described as properties after curing. As used herein, a cured composition is referred to as a barrier layer. In certain embodiments, the barrier layer has a specific coat weight. For example, the coat weight of the barrier layer is at least about 10 gsm, at least about 20 gsm, or at least about 40 gsm. In further embodiments, the coat weight of the barrier layer is less than or equal to about 120 gsm. Moreover, the coat weight of the barrier layer is in the range between any of the minimum and maximum values, such as from about 10 gsm to about 120 gsm, or from about 40 gsm to about 100 gsm.

The composition is applied and cured and has variable water vapor permeability according to relative humidity. As discussed herein, water vapor permeability is measured at 21 DEG C and selected average relative humidity (RH) values in accordance with ASTM E96. Water vapor permeability is a measure of the water vapor content that can pass through the material. Water vapor permeability, which is used when discussing cured composition properties, is measured by coating the composition on a point-bonded polypropylene nonwoven substrate with a coating weight of 75 gsm and curing the composition. In this way, the variable water vapor permeability is standardized and compared and evaluated on a specific substrate. The vapor permeability is then measured according to ASTM E96 at 21 DEG C and different relative humidity. Thus, in certain embodiments, the composition is configured to have variable water vapor permeability according to relative humidity after application and curing to the substrate.

In certain embodiments, the composition exhibits desirable water vapor permeability at low, medium, and high relative humidity.

For example, in certain embodiments, the moisture rating of the composition at a 25% average RH is less than 1 perm.

In further embodiments, the water vapor transmission rate of the composition at 45% average RH is 5 perms or less, or 2.5 perms or less. In certain embodiments, the water vapor transmission rate of the composition at 45% average RH is less than or equal to 2.5 perms.

In further embodiments, the water vapor transmission rate of the composition at 75% average RH is 6 perms to 12 perms.

In further embodiments, the water vapor transmission rate of the composition at 95% average RH is at least about 12 perms, at least about 15 perms, or at least about 20 perms. In certain embodiments, the water vapor transmission rate of the composition at 95% average RH is at least about 20 perms.

The coating composition may further have a combination of various water vapor permeability values provided at different relative humidity.

For example, in certain embodiments, the water vapor transmission rate of the composition at 25% average RH is less than or equal to about 1 perm; At a 95% average RH the water vapor transmission rate is at least about 20 perms.

In further embodiments, the water vapor transmission rate of the composition at 25% average RH is less than or equal to about 1 perm; At 95% average RH the water vapor transmission rate is at least about 20 perms; And 45% average RH, the water vapor transmission rate is 5 perms or less, or 2.5 perms or less.

In yet other embodiments, the water vapor transmission rate of the composition at 25% average RH is less than or equal to about 1 perm; At 95% average RH the water vapor transmission rate is at least about 20 perms; At 45% average RH, the water vapor transmission rate is 5 perms or less, or 2.5 perms or less; And 75% average RH, the water vapor transmission rate is 6 perms to 12 perms.

It should be understood that the combination of the cited moisture vapor transmission rates at different relative humidity is an exemplary combination, and that the possible combinations of all the above-cited moisture vapor transmission rates in the composition are within the scope of the present invention.

It should also be appreciated that when the coating exhibits the water vapor transmission rate at different RH values, the transmittance change with increasing humidity can be linear or non-linear in the log plot of transmittance versus relative humidity, as described herein.

Another aspect of the present invention relates to a coated substrate. For example, the composition is coated on the substrate and cured. A particular advantage of certain embodiments of the present invention is that the composition can be used in conjunction with a relatively porous substrate. For example, the characteristics of certain embodiments of the compositions described herein may completely fill the void space within the porous substrate, thus providing an effective coating for water vapor retardation. Other compositions capable of providing potentially variable water vapor permeability in accordance with humidity will not be used with relatively porous substrates because they "flow" through the substrate and produce discontinuous and ineffective coatings due to the low viscosity of the coating fluid. The inventors have surprisingly found that a synergistic combination of effective viscosity and variable water vapor permeability can be used for relatively porous substrates. It should be understood, however, that certain embodiments are not limited to relatively porous substrates, since the compositions themselves also have particularly superior water vapor permeability variability.

In certain embodiments, architectural substrates, such as kraft paper for glass fiber insulation backing, spun bond or point bonded nonwovens, coatings in a cured coating on an orienting strand board, or coatings or building envelopes in a household wrap, Such as those used in gypsum sealing, are used. Referring to Figure 1, an article 100 is shown to include a substrate 110 and a coating 120 disposed thereon. The exact thickness of the substrate 110 and coating 120 will vary, but in most cases the thickness of the substrate 110 is substantially greater than the thickness of the coating 120. The thickness of the coating 120 is shown to be substantially the same in the plane of the substrate 110, but such uniformity is not essential. In particular, the thickness need not be uniform across all areas of the substrate 110, provided that the thickness of the coating 120 is effective to provide the variable water vapor transmission rate values described herein.

In certain embodiments, the substrate 110 is any suitable number of substrates commonly used in the construction industry. For example, a building typically has some form of insulation in walls, floors and / or ceiling spaces. Such insulation sometimes includes vapor retarders as glass fiber insulation to prevent moisture from entering the thermal insulation space. Conventional vapor retarders are kraft paper coated with asphalt. Kraft paper itself has a high moisture permeability. When used in conjunction with asphalt coatings and / or adhesives, kraft paper can serve as a suitable vapor retarder. Moisture reduction in the wall space can help to reduce energy costs by preventing building material collapse and thermal conductivity reduction inside the wall space. In some instances, the substrate 110 may be a kraft paper, which is applied to a larger construction substrate, such as glass fiber insulation, using an adhesive or other suitable attachment means. The exact kraft paper weight varies, and exemplary weights include, but are not limited to, from about 25 pounds per square foot to about 75 pounds per square foot, for example, about 39 pounds. In some embodiments, substrate 110 is a fiber. In some embodiments, the fibers are woven or nonwoven. In other instances, the coating is applied to a drywall or other material commonly used for interior surface finishes of architectural structures. For example, a gypsum board is coated with a coating to provide a gypsum board with a variable water permeability. Similarly, wood panels, wood panels, plywood, fiberboard or other materials used in exterior or interior wall or ceiling finishes are coated with the coatings described herein to provide a variable water vapor transmission rate. Additional architectural substrates that can be coated with coatings can be readily selected by those skilled in the art in view of the benefits of the present invention.

In highly specific embodiments, the substrate includes facing paper, a scrim, a polymer sheet, a gypsum board, or a combination thereof. In further specific embodiments, the substrate may be described as a synthetic substrate. The substrate may also be porous or have a pore structure so that the coating composition or barrier layer may be disposed within the pore structure of the substrate as discussed in detail below. In very specific embodiments, the substrate comprises fibers, such as synthetic fibers, having a pore structure as described herein.

In certain embodiments, the coating 120 is disposed on the substrate 110 by rolling, spraying, roll coating, or other means capable of placing a layer of aqueous dispersion on the substrate. If desired, additional coating layers are added to the cured coating layer to form the thickness of the coating layers.

In certain embodiments, the substrate comprises facing kraft paper.

In certain embodiments, the substrate may be a fibrous substrate. For example, the fibrous substrate comprises a woven and / or nonwoven material. In certain embodiments, the substrate comprises a nonwoven material. Certain nonwoven materials include radially-bonded or point-bonded fibers.

In certain embodiments, the coatings provided herein are used to provide pre-coated architectural substrates or enable on-site coating of architectural substrates. For example, a glass fiber insulation batt with kraft paper is pre-coated with one or more components and then coated with additional on-site components to provide a final functional coating. In other instances, the coating is produced at the point of production and the installer does not need anything to provide the coating. In yet another example, after installation, the installer may spray the coating onto the substrate to provide a coating on the substrate. In some instances, the substrate may be a porous substrate, such as a nonwoven substrate.

In certain embodiments, the coating substrate has certain desirable properties.

In certain embodiments, the integrated thickness of the substrate and barrier layer is at least about 25 microns, at least about 50 microns, or at least about 100 microns. In further embodiments, the combined thickness of the substrate and barrier layer is less than about 1000 microns, less than about 800 microns, or less than about 750 microns. Furthermore, the combined thickness of the substrate and the barrier layer is in the range between any of the minimum and maximum values, for example from 25 um to 1000 um.

2, when the composition is coated and cured on a relatively porous substrate 110, the barrier layer 120 penetrates into the substrate by a desired depth P _D , and in certain embodiments, , It does not flow through the entire substrate. For example, in certain embodiments, the substrate thickness ST is greater than P _D , so that one major surface of the substrate is substantially free of the barrier layer. The barrier layer also has a thickness BL _T measured from the outermost surface of the barrier layer to the distance the barrier layer penetrates into the substrate as indicated in FIG.

Thus, in certain embodiments, the barrier layer can penetrate into the substrate at least about 1%, at least about 5%, or at least about 10% of the substrate thickness. In further embodiments, the barrier layer may penetrate into the substrate to 95%, 90%, or 85% of the substrate thickness.

Also, in certain embodiments, the barrier layer can penetrate into the substrate at least about 1%, at least about 5%, or at least about 10% of the barrier layer thickness. In further embodiments, the barrier layer can penetrate into the substrate to no more than 95%, no more than 90%, or no more than 85% of the barrier layer thickness.

In other embodiments, the substrate is fully saturated such that a continuous layer of the composition is disposed on both major surfaces of the substrate. For example, P _D is equal to or greater than ST. In addition, the barrier layer may have a desired thickness above both major surfaces of the substrate.

Embodiments of the present invention exhibit very beneficial variable water vapor permeability that varies with relative humidity. Similar to those described above with respect to compositions, substrates and compositions comprising the compositions exhibit desirable water vapor permeability at low, medium, and high relative humidity. As used herein, the water vapor permeability is measured at 21 DEG C in accordance with ASTM E96.

Thus, in certain embodiments, the water vapor transmission rate of the coated article is about 2 perms or less, or 1 perm or less, at 25% average RH. In certain embodiments, the water vapor transmission rate of the coated article is less than about 1 perm at 25% RH.

In further embodiments, the water vapor transmission rate of the coated article is at least about 12 perms, at least about 15 perms, or at least about 20 perms at 95% average RH. In certain embodiments, the water vapor transmission rate of the coated article is at least about 20 perms at 95% average RH.

In further embodiments, the water vapor transmission rate of the coated article is no more than 5 perms, or no more than 2.5 perms, at 45% average RH. In certain embodiments, the water vapor transmission rate of the coated article is less than or equal to 2.5 perms at 45% average RH.

In further embodiments, the water vapor transmission rate of the coated article is 6 perms to 12 perms at 75% average RH.

The coated articles also have a variety of water vapor permeability value combinations provided above at different relative humidity.

For example, in certain embodiments, the water vapor transmission rate of the coated article is less than about 1 perm at 25% average RH; The water vapor transmission rate is at least about 20 perms at 95% average RH.

In further embodiments, the water vapor transmission rate of the coated article is about 1 perm or less at 25% average RH; The water vapor transmission rate is 5 perms or less, or 2.5 perms or less, at 45% average RH; And the water vapor transmission rate is at least about 20 perms at 95% average RH.

In yet other embodiments, the water vapor transmission rate of the coated article is less than or equal to about 1 perm at 25% average RH; The water vapor transmission rate is 5 perms or less, or 2.5 perms or less, at 45% average RH; The water vapor transmission rate is 6 perms to 12 perms at 75% average RH; The water vapor transmission rate is at least about 20 perms at 95% average RH.

It should be understood that the combination of the above-cited moisture vapor transmission rates at different relative humidity is an exemplary combination and that possible combinations of all the above-cited water vapor transmission rates in the coated article are within the scope of the present invention.

It should also be appreciated that when the coating exhibits the vapor transmissivity at different RH values, the change in transmittance with increasing humidity can be linear or non-linear in the logarithm of the permeability versus relative humidity, as described herein.

Another parameter of the article is to achieve beneficial nail tear resistance. Nail tear resistance is an article performance measure that prevents tearing after holes are formed. As used herein, the nail tear resistance is measured in accordance with EIN 12310-1. Thus, the coated article has a nail tear resistance of at least about 1 N / 5 cm, at least about 5 N / 5 cm, or at least about 10 N / 5 cm.

Another parameter of the article is the tensile strength. As used herein, the tensile strength is measured in accordance with EIN 12311-2. Thus, in certain embodiments, the tensile strength of the coated article is at least about 10 N / 5 cm, at least about 25 N / 5 cm, or at least about 40 N / 5 cm. Further, in certain embodiments, the UV aging tensile strength of the coated article is at least about 10 N / 5 cm, at least about 25 N / 5 cm, or at least about 40 N / 5 cm. As used herein, UV aging tensile strength is measured after UV aging at 0.8 W / m < 2 > for 180 hours

Another parameter describing article properties is tape adhesion. The tape adhesion is a measure of the performance of the coated article adhered to and falling off the adhesive tape. As used herein, the tape adhesion is measured in accordance with EIN 12317-2. Thus, the tape adhesion of the coated article is at least about 15 N / 5 cm, at least about 20 N / 5 cm, or at least about 25 N / 5 cm.

Certain specific embodiments are described below to facilitate a better understanding of the techniques described herein.

Item 1. A coating composition for selectively delaying water vapor according to humidity when cured, comprising:

Hydrophobic component; And

Hydrophilic component; / RTI >

After being cured when tested at 21 占 폚 according to ASTM E96 and cured on a kraft paper, the composition after curing has a water vapor permeability of less than about 1 perm at 25% average RH and at least about 15 perms at 95% Lt; RTI ID = 0.0 >% < / RTI > transmittance.

Item 2. An article which selectively delays water vapor according to humidity:

Building material base; And

Disposed on a building material substrate,

Hydrophobic component; And

A barrier layer comprising a hydrophilic component; / RTI >

The article has a water vapor permeability of at least about 1 perm at 25% average RH and at least about 15 perms at 95% average relative humidity when tested at 21 DEG C in accordance with ASTM E96.

Item 3. An article which selectively delays water vapor according to humidity:

A building material substrate comprising fibers having a pore structure; And

A barrier layer disposed on the building material substrate; / RTI >

When tested at 21 DEG C in accordance with ASTM E96, the article has a water vapor transmission rate of about 1 perm at 25% average RH and about 15 perms at 95% average relative humidity;

Wherein at least about 10% of the barrier layer is embedded within the pore structure of the fiber.

Item 4. Optionally delaying water vapor according to humidity:

A building material substrate including a nonwoven fabric having a pore structure; And

Barrier layer; / RTI >

When tested at 21 DEG C in accordance with ASTM E96, the article has a water vapor transmission rate of about 1 perm at 25% average RH and about 15 perms at 95% average relative humidity;

Wherein at least about 10% of the barrier layer is embedded within the pore structure of the nonwoven substrate.

Item 5. A method of forming an article that selectively delays water vapor according to humidity, comprising:

Providing a coating composition;

Providing a substrate;

Applying a composition to a substrate; And

Drying the composition to form a barrier layer on the substrate; Lt; / RTI >

The article has a water vapor transmission rate of less than about 1 perm at 25% average RH and greater than about 15 perms at 95% average relative humidity when tested at 21 DEG C in accordance with ASTM E96.

Item 6. A method of forming an article that selectively delays water vapor according to humidity, comprising:

Providing a water based coating composition;

Providing a building material substrate;

Applying a composition to a building material substrate; And

Drying the composition to form a barrier layer on the building material substrate; Lt; / RTI >

The article has a water vapor transmission rate of less than about 1 perm at 25% average RH and greater than about 15 perms at 95% average relative humidity when tested at 21 DEG C in accordance with ASTM E96.

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

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

Item 9. The composition, article or method according to any one of the preceding items, wherein the hydrophobic component comprises a latex.

Item 10. In any one of the preceding items, the hydrophobic component is selected from the group consisting of styrene butadiene, styrene acryl, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, Or a combination of these latexes.

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

Item 12. The composition, article or method according to any of the preceding items, wherein the% carboxylation of the hydrophobic component is no more than about 15%, no more than about 10%, no more than about 5%, or no more than about 3%.

Item 13. The composition, article or method of any one of the preceding items, wherein the hydrophilic component has a glass transition temperature (Tg) of about 35 DEG C or less, about 25 DEG C or less, or about 15 DEG C or less.

Item 14. The composition, article or method according to any one of the preceding items, wherein the glass transition temperature (Tg) of the hydrophobic component is from -30 to 35 占 폚, from -30 to 25 占 폚, or from -30 to 15 占 폚.

Item 15. In any one of the preceding items, the hydrophobic component comprises at least about 15 wt.%, At least about 25 wt.%, At least about 35 wt.%, At least about 35 wt.%, Or at least about 45 wt.%, Based on the total weight of the composition.

Item 16. In any of the preceding items, the hydrophobic component is present in the composition or barrier layer in an amount of up to about 99 wt%, up to about 98 wt.%, Or up to about 97 wt.%, Based on the total dry weight of the hydrophobic & wt.% or less of the composition.

Item 17. In any one of the preceding items, the hydrophobic component is present in the composition or barrier layer in an amount of from 15 wt.% To 99 wt.%, 25 wt.% To 98 wt.%, Based on the total dry weight of the hydrophobic & hydrophilic components of the barrier layer. wt.%, or 35 wt.% to 97 wt.%, based on the total weight of the composition.

Item 18. The composition, article or method according to any one of the preceding items, wherein the hydrophilic component comprises a water soluble polymer of a cross-linking member.

Item 19. In any one of the preceding items, the hydrophilic component is selected from the group consisting of polyvinyl alcohol (PVOH), poly (vinylpyrrolidone), starch, cellulose, salts of polyacrylic acid, polyacrylic acid, , Amines, polyethylene oxide, vinyl ethers, highly hydrolyzed polymers (e.g., hydrolyzed maleic anhydride), polysaccharides, or combinations thereof.

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

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

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

Item 23. The composition, article or method according to any one of the preceding items, wherein the hydrophilic component comprises a water soluble polymer of crosslinking member and an inorganic hydrophilic filler.

Item 24. In any one of the preceding items, the hydrophilic component is at least about 1%, at least about 3%, at least about 5%, or at least about < RTI ID = Gt; 7%, < / RTI >

Item 25. The composition, article or method of any one of the preceding items, wherein the hydrophilic component comprises a polymer having a molecular weight of at least about 50,000.

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

Item 28. The method of any one of the preceding items, wherein the hydrophilic component comprises at least about 0.1 wt.%, At least about 0.5 wt.%, Or at least about 1 wt.% Of the composition or barrier layer based on the total dry weight of the hydrophobic & %. ≪ / RTI >

Item 29. The method of any one of the preceding items, wherein the hydrophilic component comprises up to about 40 wt.%, Up to about 30 wt.%, Up to about 25 wt.% Of the composition or barrier layer, based on the total dry weight of the hydrophobic & Or less, about 20 wt.% Or less, about 15 wt.% Or less, about 10 wt.% Or less, or about 8 wt.% Or less.

Item 30. In any of the preceding items, the hydrophilic component is present in the composition or barrier layer in an amount of from 0.1 wt.% To 35 wt.%, Alternatively from 1 wt.% To 15 wt.%, Based on the total dry weight of the hydrophobic & hydrophilic component. %, ≪ / RTI >

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

Item 32. The composition, article or method according to any of the preceding items, wherein the composition or barrier layer further comprises a filler, wherein the filler content in the composition or barrier layer is less than or equal to the weaker critical pigment volume concentration of the filler.

Item 33. The method of any one of the preceding items, wherein the composition or barrier layer further comprises a filler, wherein the filler content in the composition or barrier layer is from 0 wt% to 85 wt%, based on the total dry weight of the composition or barrier layer , Composition, article or method.

Item 34. The method of any one of the preceding items wherein the composition or barrier layer further comprises a filler and wherein the filler is selected from the group consisting of clay, CaCO3, CaSO4, BaSO4, silica, talc, carbon black, diatomaceous earth, alumina, titania, Composition, article or method.

Item 35. The composition or method according to any one of the preceding items, wherein the volume% ratio of hydrophobic component to hydrophilic component is at least about 2: 1 and up to about 200: 1.

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

Item 37. The article or method according to any of the preceding items, wherein the substrate comprises facing paper, a scrim, a polymer sheet, or a combination thereof.

Item 38. The article or method according to any of the preceding items, wherein the substrate comprises a fiber building material.

Item 39. The article or method according to any of the preceding items, wherein the substrate comprises a nonwoven material.

Item 40. The article or method according to any of the preceding items, wherein the substrate comprises a fabric material.

Item 41. The article or method according to any of the preceding items, wherein the substrate comprises a nonwoven material comprising radially-bonded or point-woven fibers.

Item 42. The article or method of any one of the preceding items, wherein the coat weight of the barrier layer is at least about 20 gsm.

Item 43. In any one of the preceding items, the viscosity of the barrier layer is selected from the group consisting of shear rate 1 s-1; RTI ID = 0.0 > 21 C < / RTI > and the viscosity of the barrier layer is determined prior to curing of the barrier layer.

Item 44. The method of any one of the preceding items, wherein the viscosity of the barrier layer is at least about 5000 cps at a shear rate of 1 s-1 and the viscosity is less than 1000 cps at a shear rate of 1000 s-1 and 21 캜, Is determined before curing of the barrier layer.

Item 45. The article or method according to any of the preceding items, wherein the integrated thickness of the substrate and the barrier layer is from 50 μm to 1000 μm.

Item 46. The composition of any of the preceding items, wherein the barrier layer penetrates into the nonwoven substrate at least about 5% of the barrier layer thickness.

Item 47. The composition according to any one of the preceding items, wherein the composition penetrates into the nonwoven substrate at 90% or less of the substrate thickness.

Item 48. The article or method according to any of the preceding items, wherein the barrier layer penetrates into the substrate at least about 5% of the substrate thickness.

Item 49. The article or method of any one of the preceding items, wherein the water vapor transmission rate of the article is less than or equal to about 2.5 perms at 45% average RH when tested at 21 캜 according to ASTM E96.

Item 50. The article or method of any of the preceding items, wherein the water vapor transmission rate of the article is from 6 to 12 perms at 75% average RH when tested at 21 캜 according to ASTM E96.

Item 51. The article or method of any one of the preceding items, wherein the nail tear resistance of the article is at least about 10 N / 5 cm when tested according to EIN 12310-1.

Item 52. The article or method of any one of the preceding items, wherein the nail tear resistance of the article is at least about 30 N / 5 cm when tested according to EIN 12310-1 EIN 12311-2.

Item 53. The article or method of any one of the preceding items, wherein the tape adhesive strength of the article is at least about 25 N / 5 cm when tested according to EIN 12317-2.

It is to be understood that not all of the acts described above in the broad description or embodiments are required, that some of the specific acts may not be required, and that one or more other acts may be practiced in addition to those described. In addition, the order in which the actions are listed does not have to be the order in which they are executed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, it is to be understood that advantages (s), advantages, solutions to problems, and any feature (s) that may cause or may cause any benefit, advantage, , Nor should it be interpreted as a required or essential feature.

And embodiments described herein are provided for the purpose of aiding a comprehensive understanding of the various embodiments and structures. The specification and description may not be taken to provide a thorough and comprehensive description of all elements and features of the apparatus and system using the structure or methods described herein. The individual embodiments are also provided in combination in a single embodiment, and conversely, the various features described in a single embodiment for brevity may also be provided individually or in any subcombination. Also, references to range values include each and every value falling within the range. Many other embodiments may become apparent to those skilled in the art after reading this specification. Other embodiments can be applied and derived from the present invention, and structural substitutions, logical permutations, or other modifications are possible without departing from the scope of the present invention. Accordingly, the present invention is considered as illustrative and not restrictive.

Examples

Example 1 - Transmittance

Samples were prepared and tested for water vapor transmission rates at 21 占 폚 and relative humidity of 25% RH, 45% RH, 75% RH, and 95% RH according to ASTM E96.

Water vapor permeability test samples were prepared by mixing the components at room temperature for 5 minutes with a pneumatic cowles blade, or a homogenizer, or manually. The coatings were applied to a thickness of approximately 75 microns by a wound wire rod (Meyer rod) or slot die extrusion process.

The wt.% Values for the hydrophobic and hydrophilic components are based on the total weight of the hydrophobic and hydrophilic components in the solid membrane. The wt.% 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 low 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 and the glass transition temperature is 9 ° C.

C-PVOH Selvol 9-325 was obtained from Sekisui - this is a pre-dissolved PVOH with a high molecular weight of 98.4% hydrolyzed 8.5% solids.

D-PAA Acumer 1510 was obtained from Dow - it is a 25% solids polyacrylic acid.

E-kaolin clay was obtained from Sigma Aldrich.

Non-woven substrate available under the trade name Elite from NW-Hanes.

SD - Slot die coating process

MR - Meyer Rod Coating Process

Table 1: Sample formulation and transmittance value

Hydrophobicity Hydrophilic Filler materials fair Transmittance Sample A B C D E 25% 45% 75% 95% One 96 4 NW SD 2 3.4 5.3 2 95 5 NW SD 1.3 3 11.7 25.1 3 94 6 NW SD 1.2 3.3 16.8 43 4 95 5 NW SD 0.8 15.6 55.8 152.3 5 95 5 NW MR One 2.7 12.5 31.6 6 95 5 NW MR One 1.7 3.1 4 7 94 6 33 NW MR 0.39 0.76 7.2 27 8 94 6 33 Kraft MR 0.5 1.1 6 26 9 94 6 40 NW MR 0.32 1.5 8.2 34 10 94 6 47 NW MR 0.28 1.5 9.1 38 11 94 6 55 NW MR 0.2 1.5 9.6 41 12 100 Kraft MR 0 21 50 156 13 100 Kraft MR 0.8 23 74 142 14 100 Kraft MR 1.4 3.7 9 20 15 100 Kraft MR 0.9 16 40 116 16 Nylon 2 Wheat BB - 0.8 2.4 11.9 37.1

As noted above, several coated substrates exhibit desirable transmittance values that are equivalent to, or even better than, nylon 2 mil films compared to comparative nylon 2 mil films (Sample 16). In particular, Sample 9 is performed in much the same way as Sample 16, but is more closed at 25% humidity and more open at 95% humidity, both of which are preferred and improved over nylon 2-mil films.

As an illustration of the particular advantages of certain embodiments of the present invention, that is to say the specific component ratios, it is clear that when comparing the transmittance profiles of samples 1, 2, and 3 in the table, the slope increases significantly as the hydrophilic component increases.

As an illustration of the particular advantages of certain embodiments of the present invention, that is to say of the selected specific materials, it is clear that comparing the transmittance profiles of samples 2 and 4 in the table, the hydrophobic material selection has a significant influence on the transmittance profile.

As an illustration of the particular advantages of certain embodiments of the present invention, i.e. selected specific materials, it is clear that comparing the transmittance profiles of samples 5 and 6 in the table, the hydrophilic component C is more effective for the transmittance profile than the hydrophilic component D .

As an example of the particular advantage of certain embodiments of the present invention, i.e. filler selection, comparing the transmittance profiles of samples 3, 7, 9, 10, and 11 in the table shows that inclusion of kaolin filler improves barrier properties at low humidity It is clear that it increases considerably and increases the vapor transmission rate at high humidity.

As an illustration of the particular advantages of certain embodiments of the present invention, comparing the transmittance profile of sample 16 with the individual components (i.e., samples 12, 13, 14, and 15) in the table, It is clear that there is nothing to be done.

As an example of certain advantages of certain embodiments of the present invention, it can be seen that comparing the transmittance profile of Sample 9 with the individual components (Samples 12 and 14) in the table, it is evident that none of the components are individually consistent with Sample 9 performance Do. Thus, Sample 9 shows a synergistic improvement in the transmittance profile as compared to the individual components individually. This synergy was entirely unexpected.

As an illustration of the particular advantages of certain embodiments of the present invention, it is evident that the highly carboxylated latex from the transmittance profile of Sample 15 is substantially hydrophilic enough to exhibit a strong dependence of transmittance on RH; However, the transmittance value of this material at 45% humidity is too high to achieve the performance of sample 16.

As an example of the particular benefit of certain embodiments of the present invention, i.e. coating fastness properties, comparing the transmittance profiles of samples 2 and 8 in the table shows that substrate selection has a negligible effect on performance if the substrate is opened to more steam than the coating .

As an example of certain advantages of certain embodiments of the present invention, i.e., coating fastness properties, it is clear that comparing the transmittance profiles of samples 2 and 6 in the table, the coating process has little effect on performance.

Example 2: Mechanical data

The following samples were prepared as follows:

Sample 2A: 94 wt.% Styron DL-226 and 6 wt.% PVOH-325 based on the total weight of both components. The sample further comprises 33 wt.% Kaolin filler based on the total weight of the composition. This was applied to the Hanes Elite 100 fibers in the machine direction.

Sample 2B: 94 wt.% Styron DL-226 and 6 wt.% PVOH-325 based on the total weight of these two components. The sample further comprises 33 wt.% Kaolin filler based on the total weight of the composition. This was coated on a Hanes Elite 200 fiber in a machine direction.

Sample 2C is a comparative example and includes a 50 micron thick Vario KM film available from Saint-Gobain Corporation and used intact.

The following samples were 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, and the following results were obtained:

Table 2: Mechanical performance

2A 2B 2C Tensile (N / 5cm) 98 197 197 Tensile UV aging (N / 5 cm) 65 88 64 Nail Resistance (N / 5cm) 31 61 15

Example 3: Measurement of viscosity

Three samples were prepared as follows and the viscosity measured according to the method described herein before curing:

Sample 3A: Containing 95 wt.% Styron DL-226 and 5 wt.% PVOH-325 based on the total weight of both components.

Sample 3B: Containing 94 wt.% Styron DL-226 and 6 wt.% PVOH-325 based on the total weight of both components. The sample further comprises 33 wt.% Kaolin filler based on the total weight of the composition.

Sample 3C is a comparative sample and contains 100 wt.% Of DL 226.

Sample 3D is a comparative sample and contains 100 wt.% Of Selvol 9-325.

The results are shown in Figure 3, which is a graph of the measured viscosity (Pa * s) at different shear rates measured in s ^-1 . As shown, the viscosities of samples 3A and 3B were significantly higher than comparative samples 3C and 3D.

Claims (19)

1. A coating composition for selectively delaying water vapor according to humidity when cured to a barrier layer, comprising:
a. A hydrophobic component comprising a styrene butadiene latex having 0% to 20%% carboxylation; And
b. A hydrophilic component comprising a polymer selected from polyvinyl alcohol and sodium polyacrylate and a hydrophilic filler selected from kaolin clay; / RTI >
When tested at 21 ° C according to ASTM E96 and tested by coating and curing the composition on kraft paper, the cured coating composition has a variable water vapor transmission rate of less than 1 perm at 25% average RH and 15 perms at 95% To provide a coating composition. The composition according to claim 1, wherein when tested at 21 ° C according to ASTM E96 and coated and cured on a kraft paper, the cured coating composition has a water vapor transmission rate of less than 2.5 perms at 45% average RH and a water vapor transmission rate of less than 75% Effective to provide a water vapor transmission rate of 6 to 12 perms. The coating composition of claim 1, wherein the glass transition temperature of the hydrophobic component is from -30 ° C to 0 ° C. The coating composition of claim 1, wherein the hydrophobic component is present in an amount of from about 35 wt% to about 97 wt%, based on the total dry weight of the hydrophobic and hydrophilic component. The coating composition of claim 1, wherein the polymer of the hydrophilic component has a weight average molecular weight of at least 50000 to 300000 or less. An article which selectively delays water vapor according to humidity:
a. Building material base; And
b. An article comprising a barrier layer disposed on a building material substrate and obtained by curing a coating composition according to any one of claims 1 to 5. 7. The article of claim 6 wherein the water vapor transmission rate of the article when tested at 21 DEG C. in accordance with ASTM E96 is less than or equal to 2.5 perms at 45% average RH and the water vapor transmission rate is 6 to 12 perms at 75% average RH. 7. The article of claim 6, wherein the substrate comprises facing paper, a scrim, a polymer sheet, a gypsum board, or a combination thereof. The article of claim 6, wherein the substrate comprises kraft paper applied to a glass fiber insulation. 7. The article of claim 6, wherein the substrate comprises a fabric or nonwoven material. 11. The article of claim 10, wherein the substrate comprises a nonwoven material comprising radially-bonded or point-woven fibers. 7. The article of claim 6, wherein the substrate comprises a gypsum board. 7. The article of claim 6, wherein the coat weight of the barrier layer is at least 20 gsm. delete delete delete delete delete delete

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