MXPA01009227A - Weatherable building products - Google Patents

Abstract

The present invention relates to a weatherable building product comprising a wood member. The wood member has at least a portion which is coated with a coating composition comprising an interpenetrating polymer network of an acrylic latex and a vinylidene chloride polymer. The wood member comprises solid wood or fiber-based materials.

Description

PRODUCTS FOR CONSTRUCTION CAPACIES TO RESIST IN THE WEATHER TECHNICAL FIELD The present invention relates to construction products capable of weathering, made of wood elements coated with a weather resistant coating composition.

BACKGROUND OF THE INVENTION Wood elements have long been used in the manufacture of products for construction. Examples of such products for construction include, but are not limited to, door jambs, door ends, doorway ends, rungs, door frames and compression-molded door covers, interior and exterior trim products, pilasters, railings and posts, s , removable poles, dimensional elements, entrances, masonry molds, hardboard of ultra-light, medium or high density, oriented fiber board, laminated fiber wood, laminated joists, polyamide, cardboard particles and plastic wood. These wooden elements can be made of solid wood or fiber-based materials. For fiber-based materials, it is suggested, wood fiber or agricultural derived fibers, waste and recycled. People appreciate these building products made of wooden elements, due to their relatively cheap cost, properties of firmness structure and warm feeling. However, construction products made of wood elements are susceptible to damage due to exposure to water, moisture and sunlight. For example, unprotected wood elements exposed to the weather, are leached by water as soluble sugars, and separated by ultraviolet light in sunlight. Within two or three months, the surfaces of most wooden elements exposed to the weather are damaged enough to not be paintable. In addition, many of the wood elements expand and contract significantly in equilibrium with environmental humidity. The result in the construction industry may include some of the following examples: • remanufacturing techniques used on small elements of undesirable pieces or flanges of wood, such as junctions by junctions of protrusions, often weakened for two or three months. direct exposure to water or moisture vapor contact; • thin veneers after bubbling and peeling when a combination of moisture vapor and a direct water wicking effect on the substrate cause swelling of the substrate or pressures within the thin veneers; and • thin veneers or cardboard for packaging lids, often weakened in the adhesive line due to differential linear expansion of the two substrates due to the response to moisture. The composition of this expansion phenomenon is that the expansion percentage performs an asymptotic relationship when the stagnant water reaches the wood element or when relatively low or very high humidity levels are reached. Such high relative humidity levels are very common in the islands and coastal regions of the southern United States in the summer, as well as the regions of the Northern Great Plains during the winter. A quantifiable measure of the degree of damage to wood elements can be experienced from exposure to water, which can be determined by checking the percentage of linear moisture expansion in accordance with ASTM No. D-1037. The acceptable percentage of linear moisture expansion will vary for each product for construction, depending on a variety of factors. These factors include, but are not limited to, the type of product for construction, type of wood element, allowable tolerance, and presence of expansion inhibitors, such as mechanical coupling with other elements. For example, it has been determined that covers for compression molded doors of Medium Density Hardboard (MDF), which have a wood structure and which have a polyurethane center, require that the linear expansion of humidity be less than about 0.1% for the covers, and more preferably 0.0-0.05% to inhibit the deformation or cupping in the doors when they assemble At entry doors, which include a door embisagramiento connected with a structure comprising a plurality of wings, the traditional opening between the door and each door is less than about 2.3 mm in a high door of 2.4 m. Thus, the linear expansion of net moisture for such entry doors may be less than about 0.01% and preferably less than about 0.005%. Accordingly, it would be desirable to be able to provide construction products, weather resistant, made of wood elements, which are relatively resistant to damage from exposure to water, moisture and sunlight. Typically, it is desirable to provide weather resistant construction products, made of wood elements, which have linear moisture expansions of less than about 0.1%. It would be further desirable to provide weather-resistant, compression molded door covers, formed of wood elements having linear moisture expansions of less than about 0.1%, and preferably less than about 0.05%. It would also be desirable to provide weather resistant door entrances, made of wood elements that have linear moisture expansions of less than about 0.01% and preferably, about 0.005%. Moreover, it would also be desirable to provide weather-resistant construction products, made of wood elements that will withstand attacks of moisture vapor, direct water and sunlight and perform well in a weather resistance test while being handled. and easily handled by the equipment for the construction industry by typical home equipment and which retain the paint, top pores and coloring solutions for finishes, in a manner similar to the prior art construction products, as well as suggest or exceed the structural properties of the products for the construction of the prior art.

DESCRIPTION OF THE INVENTION The present invention comprises a product for the weatherproof construction, made of wood elements coated with a weather resistant coating composition. The present invention also comprises a method for manufacturing a weather resistant construction product comprising coating a wood element with a weather resistant coating composition. Wood elements can be made of materials based on fibers or solid wood, such as wood fibers or fibers of agricultural derivatives, waste and recycled. A final coating of paint, lid pores, dye solutions or other coatings opaque to ultraviolet light, can be applied to all surfaces of weatherproof construction products. In a preferred embodiment, the weather resistant coating composition comprises an interpenetrating polymer network of an acrylic latex and a vinylidene chloride polymer. In a second embodiment, the weather resistant coating composition is selected from the group consisting of polyurethane and acrylic-urethane hybrid polymers.

BEST MODE FOR CARRYING OUT THE INVENTION The present invention relates to a product for weatherproof construction, made of wood elements, which are resistant to water penetration and degradation due to water, moisture, and light. solar, and a method for the construction of products for the construction resistant to the bad weather. Examples of such construction products include, but are not limited to, door jambs, door ends, crossbar ends, rungs, door frames and compression molded door covers, interior and exterior trim products, pilasters, railings and posts, steps , Removed posts, dimensional elements, entrances, masonry molds, hardboard with ultra-light, medium or high density, fiber-oriented cardboard, laminated strand wood, laminated beams, polyamide, cardboard particles and plastic wood. For wood elements, we suggest at least one element of wood made of solid wood or materials based on fibers, such as wood fiber or fibers of agricultural derivatives, waste and recycled. The weather resistant coating compositions are preferably applied to the wood element after the wood element has been made into the finished product for construction. The wooden elements preferably have average thicknesses of at least 0.5 mm, more preferably less than about 75 mm, still more preferably about 0.75 mm to about 45 mm. Wood elements made from solid wood can be made from either hardwood or soft wood. The wood preferably has a moisture content (water) of less than about 20 weight percent, more preferably about 4-12 weight percent, and more preferably about 6-9 weight percent. The wood is preferably dried in an oven, and more preferably, in a drying oven type oven to achieve such a moisture content. Examples of usable woods include, but are not limited to, Ponderosa pine, oak, maple, ash, poplar, radiata pine, southern yellow pine, and cedar. The wooden elements can be either unitary hip elements of wooden elements of pieces together, such as wooden elements joined by splices. Wood elements made from fiber-based materials can be made from wood fibers, mixtures of wood dust-wood fibers, fibers of agricultural derivatives, waste and recycled, and mixtures thereof. The materials based on fibers are moldable or extrusible under pressure and heat to form products for construction, such as compression molded door covers or oriented fiberboard, by methods which are known in the art. Examples of suitable wood fibers include chips, lamellae and wood chips or flanges, most of which have an aspect ratio of about 3-100, preferably 5-80, and more preferably 8-35. Suitable sources of wood chips, chips and chips include, but are not limited to, wood items dried in stove-type ovens, such as logs, bark, dimensional wood, polyimide, thin wood, thin veneers and short veneers . Other sources of chips, chips and wood chips or bark include long lamellae, fibers, particles, flat chips and wood pulp. The wood fibers preferably have a moisture content of less than about 20 weight percent, more preferably about 4-12 weight percent, and more preferably about 6-9 weight percent. The fibers of agricultural, waste and recycled derivatives are preferably those having an aspect ratio of about 3-100, preferably 5-80, and more preferably 8-35. Suitable sources of agricultural derived, waste and recycled fiber include, but are not limited to, corn stems, corn bagasse, corn cobs, sugar cane, sugar beet, straw and all grain waste, wheat stems , flax, linen genera, rice husk, cotton, jute, hemp, bagasse, bamboo, jojoba, ramina and variety of hemp, kraft or strong paper, recycling and newspaper and mixtures thereof. The fibers of agricultural derivatives, waste and recycling preferably have a moisture content of less than about 20 weight percent, more preferably less than 12 weight percent, even more preferably, about 4-12 weight percent, and more preferably about 6-9 weight percent Wood elements made from fiber-based materials may also include fibers such as sawdust, mica and wollastonite, chip, reinforcing glass fibers, matte covers of reinforcing glass fibers, fibers reinforcing carbon, reinforcing aramid fibers, foaming / blowing agents, fungicides, anti-mold substances, pigments, coloring matters, fragrances and combinations thereof. Typically, wood elements made of materials based on fibers include a polymeric or resinous binder to adhere the fibers together. The amount and type of binder varies depending on many factors, which include but are not limited to, the type of wood element desired, type of fiber used, type of binder used, etc. Examples of suitable binders include, but are not limited to, phenol / formaldehyde resole, urea / formaldehyde, melamine / formaldehyde, polyisocyanates and novolac phenolic resins (phenol-formaLdehyde). The preferred binder is the novolac phenolic resin. A preferred novolac phenolic resin is the 2050 resin of the Georgian Pacific brand. When these weather-resistant construction products require a texture similar to wood, the exterior surface can be manufactured to have a textured surface consisting of portions and level depressions. The depressions have a depth range of about 0.25 mm to about 1.0 mm from the level portions. The products for the construction can also include biased cuts adjacent to the depressions. The biased cuts have a range in the extent of the biased cut from about 0.025 mm to about 0.10 mm from the depressions. To assist in the removal of the molded product from such a textured mold, mold release agents such as zinc and calcium stearate can be combined in the novolac phenolic resin system filled with the fiber at 0.25 to 5 percent in weight of the system. A particularly preferred wood element made of fiber-based materials comprises substrates, such as door and door covers or door stops, molded or extruded from novolac phenolic resin materials filled with the fiber. The phenolic content of novolac varies from 2 to 60 weight percent of the wood element (dry base in oven), depending on the durability of the exterior, mechanical strength and economy of the product. More preferably, the novolac phenolic resin is present in an amount of about 4 to about 40 weight percent, still more preferably about 4 to about 30 weight percent, still even more preferably about 7 to about 25 weight percent , still more preferably still about 7 to about 18 weight percent, and more preferably about 7 to about 15 weight percent. The novolac resin can be from commercial sources such as the series 5500 or series Resi-Flake 2000 from Georgia Pacific. The mechanical strength properties of the final product can be adapted whereby the resin is selected. Factors such as residual water content in the resin, molecular weight, melt viscosity and trademark curing agents are among the variables that can be adjusted in the design of the mixture with various fibers and the final product. The wood fibers for the production of novolac phenolic resin wood elements filled with fiber, preferably comprise lignocellulosic fibers, which are prepared from any suitable precursor of lignocellulosic fibers. Examples of suitable lignocellulosic precursor fibers include, but are not limited to, chips, slivers and pieces or barks of wood. Other sources of lignocellulosic fibers are known to those skilled in the art and include agricultural derivative, waste and recycled fibers. The fiber content of wood varies from 40 to 98 weight percent of the wood element (in the dry base in the furnace), more preferably about 60 to 90 weight percent, even more preferably about 70 to about 96 weight percent. weight, still still more preferably about 75 to about 93 weight percent, and more preferably about 85 to about 93 weight percent. Lignocellulosic precursor fibers are digested and refined in lignocellulosic fibers by methods which are known in the art. In general, the lignocellulosic precursor fibers are digested with vapors, between temperatures of about 120-150 ° C for about 20-200 seconds. The best measure of the completion of the digestion and refinement are by the end-use tests such as the crunch of the fiber induced by moisture, moldability in the compression molding and linear expansion of moisture, and by color change in the lignocellulosic fiber mass from light yellow to golden brown. The lignocellulosic fibers preferably have a definable aspect ratio of 4-70 and more preferably 8-30. The fiber-filled novolac phenolic resin material includes suitable crosslinking / curing agents. The most preferred agents are sources of methylene, such as hexamethylenetetramine ("hexa"), paraformaldehyde / ammonium carbonate and reaction products of aldehydes with aromatic amines. The hexa is more preferably used in at least "a stoichiometric amount". This amount is about 8 to 12 weight percent, based on the weight of the solid novolac phenolic resin. Preferably, the hexamethylenetetramine is used in excess, by about 20-30% in excess. It has been found that the excess of "hexa" is surprisingly efficient in the increase of the capacity to resist to the inclemency. However, hexa in quantities in excess of 30% stoichiometry does not significantly improve, its properties, and may cause some properties to decline. An upper limit of hexamethylenetetramine is about 40% in excess of stoichiometry, ie, about 18% based on the weight of the solid novolac phenolic resin. The products for the construction of novolac phenolic resins are filled with fibers, if the covers for doors, molded in detail, stops for doors and / or entrances, boards for walls, sheets of cardboard or similar, are molded in a molding pressure under heat and pressure, in continuous molding or batch processes. The materials can have a textured exterior dictated by the surface of the mold. A variety of molds are suitable. Most preferred are the molds prepared by the nickel coating of a form of a real object whose surface is mimicked by the placement of chemical vapor, as described in U.S. Patent No. 5,169,549, which is incorporated herein by reference. The material is formed under pressure, at a pressure of 120-14,500 kPa with or without steam. The pressure forming process can include high pressure compression molding, low pressure compression molding, tamper extrusion, tamper injection, tamper injection compression, hydroforming, explosive formation, single sheet or double sheet thermoforming with compression assisted, vacuum removal training, and vacuum expansion training. The preferred pressure forming process is compression molding at high pressure between 1,700 kPa and 6,800 kPa. Exposure to steam can vary from 0 to 240 seconds, preferably 0-60 seconds at 198-225 ° C, and can be administered in multiple increments once the template is essentially closed. It may be necessary to ventilate the mold by releasing mold pressure, evacuating the mold, or opening a valve to vent, at various intervals during the pressure-forming cycle to prevent seeding particles and eliminate accumulated volatiles. The material can be pressed to a thickness of 0.75 mm to 45 mm if the steam is applied only to one side of the roller. The thickness can be extended up to 100 mm if the steam is applied on both sides of the roller. The resulting density of ranges produces from 560 kg / m3 to 1200 kg / m3, preferably 800-1000 kg / m3 to eliminate the adequate porosity for capillary infiltration, provides mechanical strength, while facilitating the reduction of material use costs as well as it also reduces the incidence of surface protrusions. To reduce the time of the pressure formation cycle, a post-pressure infrared, preferably very infrared, radio frequency or microwave oven could be substituted to continue the curing of the various resins. The curing furnace varies in temperature from 198 ° C-225 ° C with opposite exposure from 20-120 sec, depending on the thickness of the part formed by pressure and the wavelength of the selected energy. Novolac phenolic resin can be added before or during fiber digestion, or it can be added after digestion. Preferably, the novolac phenolic resin is solid and is introduced into the fiber in a double pressurized steam table to ensure intimate contact and thereby coat the fiber which typically has a moisture content of 4 to 12 weights or after of the forming operation when the stoichiometric amounts of hexamethylenetetramine, which have been incorporated earlier in the full novolac system, are reacted under heat from 170 ° C to 195 ° C. The remarkable thermal degradation of wood fibers is apparent at 185 ° C with correlated loss of mechanical properties of the full system. Part of the thickness, required performance properties, cure rate of the resin and residence times of the high temperature process, determine how tightly a product can be molded up to about 220 ° C. Other non-fibrous filters can be added to the formulation for reasons of economy or other performance increases. To provide construction products (ie wooden elements) that are more resistant to water, linear expansion of moisture, and degradation of water, moisture, and sunlight, the wood element is coated with a coating composition capable of resisting the weather. Preferably, the entire element is coated, although it is contemplated that less of the complete element (i.e. parts of the element more susceptible to water contact) can be coated to minimize the cost of the element. In a preferred embodiment, the weather resistant coating composition is a latex coating composition comprising particles of an interpenetrating polymer network of an acrylic polymer and a vinylidene chloride polymer. More specifically, the latex coating composition comprises polymer particles suspended in an aqueous solution. The polymer particles comprise an interpenetrating polymer network of an acrylic polymer and a vinylidene chloride polymer. In general, the process for the preparation of the lacquer coating composition according to the present invention comprises providing an acrylic latex comprising an aqueous medium having therein, dispersed particles of an acrylic seed particle, and adding to the latex. acrylic, vinylidene chloride and other monomers under conditions to which vinylidene chloride will form a polymer within acrylic seed particles, thereby forming a latex coating composition, comprising acrylic seed particles having a polymer of vinylidene chloride polymerized here. More specifically, the latex compositions of the interpenetrating polymer network of the present invention are made by polymerizing a vinylidene chloride polymer and more preferably, a vinylidene chloride copolymer, with initiator particles or acrylic seeds. The vinylidene chloride polymer forms an interpenetrating polymer network in which the acrylic latex seed particles. By "interpenetrating polymer network", it is suggested that the acrylate polymers and vinylidene chloride polymers described in the present invention be intimately mixed at a molecular level. While we define an interpenetrating polymer network as an intimate molecular mixture of polymers, they do not prevent the possibility of grafting or physical entanglement or chemical reaction between the polymers, since the precise mechanism is still speculative. Indeed, such associations are likely, and are believed to be the reason for the increased properties of the finished interpenetrating polymer network. Many factors including the selection of the ingredient and the polymerization conditions, such as polymerization temperature, instantaneous monomer-free concentration, initiator type, and the presence of double bonds or extractable hydrogen in the seed polymer, can influence the splice vertical between the acrylate and vinylidene phases, and thus may have consequences on the final structure and resolution of the finished interpenetration polymer network. Preferably, the latex coating composition comprises, by weight, about 30% to about 70% solids, based on the weight of the coating composition, more preferably about 50% to about 65% and more preferably about 60%. The latex coating composition preferably comprises by weight, based on the total weight of the acrylic latex and the vinylidene chloride polymer, about 2% to about 50% acrylic latex and about 50% to about 98% of the chloride polymer. vinylidene The coating composition more preferably comprises by weight, based on the total weight of the acrylic latex and the vinylidene chloride polymer, about 5% to about 15% acrylic latex, and about 85% to about 95% of the chloride polymer. vinylidene There is no criticality in the manufacture of the acrylic seed particles, although the seed particles of the styrene-acrylic copolymer are preferred. Particles of small size are preferred, since the resulting interpenetrating polymer network can also have a smaller particle size and vinylidene latexes of smaller particle size tend to be less fixed, and have an advantage in the formation of film. A preferred size for the seed particles is about 2000 Angstroms or less. It is important that the latex of the seed particle swell in the presence of the fed vinylidene chloride monomer. A sowing particle latex that does not swell will not form an adequate IPN. Acrylic and styrene polymer latexes, proposed for industrial coating applications impart good water resistance characteristics, and are thus, typically good selection of seed polymer. It should be noted that the seed particle latex should not contain excess surfactants because they promote the initiation in excess of new and separate vinylidene particles and may also compromise the water resistance of the polymeric films. A preferred acrylic and styrene latex is commercially available from Carboset CR-760 acrylic latex, available from B F Goodrich Company as 42% by weight of the acrylic copolymer emulsion. Others include Carboset CR761 polymer and Carboset CR763 polymer from B F Goodrich, HG 54 from Rohm &; Hass, the A622 polymer from Zeneca, Inc., and the Pliolite 7103 polymer from Goodyear. The acrylic and styrene latexes are made by emulsion polymerization techniques known to those skilled in the art, such as U.S. Patent No. 4,968,741, which is incorporated herein by reference. There is no criticality in the ratio of styrene to acrylate, nor in the particular acrylate used as soon as the seed particle swells in the fed vinylidene monomer. Other acrylic latexes can be used as soon as they provide a seed particle that swells in the way styrene acrylate does. The amount of styrene acrylate seeding particle polymer to be employed in the latex polymer composition is not critical. If too little seed polymer is used, then larger particle sizes may result and result in consequential handling difficulties. If many polymers of seed particles are also used, it will result in a latex polymer with decreased properties. Usually, about 2 to 50 weight percent of the acrylate and styrene polymer, based on the total weight of the acrylate polymer and the vinylidene chloride polymer, will be employed with about 5 to 15% by weight being preferred. The vinylidene chloride copolymer comprises a combination of vinylidene chloride monomer, one or more alkyl acrylates having from 1 to 18 carbon atoms in the alkyl group and / or one or more alkyl methacrylates having from 1 to 18 carbon atoms in the alkyl group, one or more aliphatic alpha-beta-unsaturated carboxylic acids, and a copolymerizable surfactant. The amount of the vinylidene chloride monomer will be in the range of about 65 to 90 parts by weight, based on percent parts by weight of the monomer by the vinylidene chloride polymer, with 70 to 83 parts by weight being preferred. The amount of alkyl acrylates and / or methacrylates will be in the range of about 2 to 30 parts by weight, based on percent parts by weight of the monomer by the vinylidene chloride polymer, with 16 to 25 parts by weight being preferred. The amount of the carboxylic acids will be in the range of about 0.1 to 10 parts by weight, based on parts by weight percent of the monomer for the vinylidene chloride polymer, with 1 to 5 parts by weight being preferred. The amount of copolymerizable surfactant will be in the range of about 0.1 to 5 parts by weight, based on percent parts of the monomer for the vinylidene chloride polymer, with 0.4 to 1.0 parts by weight being preferred. The vinylidene chloride monomer can be used with up to 25% by weight of the vinyl chloride monomer, based on the weight of the vinylidene chloride monomer. Although the use of 100% of the vinylidene chloride monomer is preferred. The alkyl acrylates or methacrylate monomers are (meth) acrylic acid (meth) acrylate ester monomers having the formula wherein R is selected from the group consisting of an alkyl radical containing from 1 to 18 carbon atoms, an alkyloxyalkyl radical containing a total of 1 to 10 carbon atoms, and a cyanoalkyl radical containing from 1 to 10 carbon atoms. carbon, and R1 is selected from the group consisting of hydrogen and methyl. The alkyl structure may contain primary, secondary or tertiary carbon configurations and usually contains 1 to 8 carbon atoms. Examples of such (meth) acrylic esters are ethyl (meth) acrylate, propyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, n-pentyl, isoamyl (meth) acrylate. , n-hexyl (meth) acrylate, 2-methylpentyl (meth) acrylate, n-octyl (meth) acrylate, (meth) acrylate, 2-ethylhexyl, n-decyl (meth) acrylate, n-dodecyl (meth) acrylate, n-octadecyl (meth) acrylate, and the like; methoxymethyl (meth) acrylate, ethoxypropyl (meth) acrylate, and the like; α, β, and α - cyanopropyl (meth) acrylate, cyanobutyl (meth) acrylate, cyanohexyl (meth) acrylate, cyanooctyl (meth) acrylate, and the like; hydroxyalkyl (meth) acrylates such as hydroxyethyl (meth) acrylates and the like and mixtures thereof. More preferred are (meth) acrylic esters, wherein R is an alkyl group containing 1 to 8 carbon atoms or an alkoxyalkyl group containing a total of 1 to about 6 carbon atoms. Examples of such more preferred monomers are ethyl (meth) acrylate, propyl (meth) acrylate, n-butyl (meth) acrylate, n-pentyl (meth) acrylate, n-hexyl (meth) acrylate, n-octyl acrylate, 2-ethylhexyl (meth) acrylate and the like, methoxyethyl (meth) acrylate, ethoxyethyl (meth) acrylate, and the like; and mixtures thereof. The selection of the (meth) acrylates is not critical and various combinations can be employed. The selection will depend on the requirements for the film with respect to hardness, flexibility and / or sensitivity to water. The swelling capacity of the monomer combination in phase should be considered in the selection of (meth) acrylates. The carboxylic monomers used in the production of the polymer latexes of this invention are aliphatic alpha-beta-olefinically unsaturated carboxylic acids and dicarboxylic acids containing at least one activated carbon-to-carbon olefinic double bond, and at least one carboxyl group, that is, an acid containing an olefinic double bond which easily functions in the polymerization due to its presence in the monomer molecule either in the alpha-beta position with respect to the carboxyl group as well I I -C = C-COOH or as part of a terminal methylene group so CH2C < . Olefinically unsaturated acids of this broad class include such widely divergent materials as acrylic acids, such as acrylic acid itself, methacrylic acid, ethacrylic acid, alpha-chloro acrylic acid, alpha-cyanoacrylic acid and others, crotonic acid, acid sorbic, cinnamic acid, hydromuconic acid, itaconic acid, cyclochronic acid, mesaconic acid, muconic acid, glutaconic acid, nicotinic acid, β-carboxyethylacrylate and others. As used herein, the term "carboxylic acid: includes the polycarboxylic acids and acid anhydrides, such as maleic anhydride, wherein the anhydrous group is formed by the removal of a water molecule from two carboxyl groups located on the same molecule of polycarboxylic acid The preferred carboxylic monomers for use in this invention are monoolefinic acrylic acids having the general structure R2 CH2 = C-COOH wherein R 2 is a substituent selected from the class consisting of hydrogen, halogen, monovalent alkyl radicals, monovalent aryl radicals, monovalent aralkyl radicals, monovalent alkaryl radicals, and monovalent cycloaliphatic radicals. Illustrative acrylic acids of this class are acrylic acids themselves, methacrylic acid, ethacrylic acid, chloroacrylic acid, bromoacrylic acid, cyanoacrylic acid, alpha-phenylacrylic acid, alpha-benzylacrylic acid, afa-cyclohexylacrylic acid, and others. Of this class, acrylic acid and methacrylic acid are preferred. The copolymerizable surfactant facilitates and becomes part of the vinylidene interpenetration polymer network in the particles. Although higher levels of surfactants can be employed to replace the copolymerizable surfactant, low, free surfactant levels offer advantages in water and particularly moisture resistance. In addition, higher surfactant levels can plasticize the vinylidene chloride interpenetration polymer network, possibly damaging moisture vapor resistance and gas transmission. Thus, preferred levels of copolymerizable surfactants allow the use of very low levels of free surfactant, leading to performance advantages. In applications where the performance demands allow it, lower levels of copolymerizable surfactant within the stated ranges can be used with higher levels of free surfactants. Adjustments in polymerization conditions and ingredients known to those skilled in the art may be necessary to produce latex with acceptable morphology and cleanliness as the levels of copolymerizable surfactant and free surfactants are changed. The preferred copolymerizable surfactant is the sodium salt of an allyl ether solfonate. They are commercially available, for example, as COPS 1 from Rhone Poulenc, Inc., which is the l-allyloxy-2-hydroxypropyl sodium sulfonate, which is supplied as a 40% solution in water. Aqueous latex coating compositions can be formulated with, for example, anticorrosive pigments, and if the coating is expected to cure more than three months of weathering outdoors, the coating should be covered with a pore lid or primer or paint, which it is substantially opaque to ultraviolet light. The latex coating compositions of the present invention are prepared by the use of emulsion polymerization techniques known to those skilled in the art. The vinylidene chloride monomers and other monomers, together with the copolymerizable surfactant and any surfactants and initiators can be blended, measured or otherwise, added to the acrylate particles of seed particles dispersed in an aqueous medium. Polymerization is usually done between about 50 ° C and 75 ° C, although temperatures can vary between 5 ° C and 100 ° C, and take about 2 to 24 hours. The reaction time is widely dictated by the heat removal capabilities of the reactor employed, with shorter reaction times being preferred. The polymerizations are preferably conducted in the absence of air or oxygen.

The PERMAX 801 latex coating composition supplied by BF Goodrich (Cleveland, OH) is a preferred latex coating composition comprising particles of an interpenetrating polymer network of an acrylic polymer and latex chloride polymer coating compositions. vinylidene of the present invention. The latex coating composition is preferably applied to a wood element, whose surface temperature exceeds the minimum film-forming temperature (MFFT) of the coating composition, and more preferably more than about 3 ° C above MFFT. For PERMAX 801 the MFFT is 20 ° C. Thus, the surface temperature of the element, when PERMAX 801 is applied, is at least about 23 ° C, more preferably at least about 40 ° C, and is usually less than about 90 ° C. The wood element should be in a condition in terms of other environmental properties, such as moisture content, this is desirable for the finished product and provides acceptable levels of service for the proposed life. The preferred moisture content of the coating is about 4.12% moisture, more preferably about 6-9% by weight. The application of the coating composition to the product in one step can be carried out by a brush or other device having a relatively low cut during application such as a curtain coater, a flow coater, dipping, or a roll. A cutting condition that does not cause polymerization induced by the cutting of the polymer producing small polymer groups is intended for low cutting. A typical process condition near the cut-off limit for the latex composition is mixing at 60 revolutions per minute with a 76 mm CONN IT low cut blade in a mixing vessel of approximately 150 mm in diameter. The thickness of the coating can be from 0.01 mm to approximately 3 mm, preferably 0.05 mm to 1 mm, more preferably for economic reasons 0.05 mm to 0.15 mm. The element and the coating can be dried at room temperature that exceeds the MFFT. More preferably, the element and the coating are dried for at least about 15 minutes, and more preferably about 30 minutes to about 3 hours, at temperatures at least about 3 ° C above the MFFT. More preferably, the element and the coating are dried for at least about 45 to about 90 minutes, and more preferably about 60 minutes, at temperatures of about 25 ° C to about 75 ° C, and more preferably about 45 ° C to about 55 ° C. It has been found that drying under these elevated temperatures minimizes the formation of micro-pieces, which may result from unglutinated films. The resulting coated wood elements have linear moisture expansion measured by ASTM D-1037 of at least about 0.1%, and more preferably less than 0.05%. Specifically, the MDF compression molded door covers, coated with the vinylidene acrylic chloride IPN coating composition of the present invention, have linear moisture expansions according to ASTM D-1037 of at least about 0.1%, more preferably less of about 0.05%, still more preferably less than about 0.03% and more preferably 0.0%. The solid Ponderosa pine sheets coated with the IPN vinylidene acrylic chloride coating composition of the present invention, as used for door jambs or stops, have linear moisture expansions according to ASTM D-1037 of less of about 0.1%, more preferably about 0.05%, still more preferably less than about 0.03% and more preferably about 0.0%. Nevertheless, the wood elements coated with the vinylidene acrylic chloride IPN coating composition of the present invention, pass the accelerated weathering and outdoor weathering tests of the Middle East of the United States shown below. An environmental chamber test which exposes only the exterior face of a construction product to provide an extreme environment, provides an accelerated aging test for the substrate and coating of the product. The environmental cycle of selection of two simulated environments: • a continuous 95% relative humidity and 35 ° C exposure as found in the environment along the southern coast of the United States; and • a cycle of extreme temperature and humidity characteristics: from 95 ° C to minus 29 ° C and wet and dry conditions. The test uses extremes of temperature and humidity to accelerate changes in the product for construction, which occurs naturally during exposure to changes in weather conditions. The product or products to be tested are placed inside the walls of the chamber to expose the product to the degree of exposure similar to that which may be received in the installation field. The chamber is equipped with spray atomizing heads which are capable of completely moistening the exposed surface of the product under test. The test is capable of maintaining any of those conditions as described below.

Cycle 1 Cycle 2 A construction product passes the previous accelerated aging test if it has no recorded performance or aesthetic defects after 90 days of Cycle 2 followed immediately by 30 days of cycle 1. A field evaluation in outdoor weatherproof conditions in the Middle East of the United States, involves assembling a door in flaps or stops and other components necessary to develop a door entry system. The assembled unit is then shod in a dimensional wood structure of approximately 100 square mm having approximately the interior size of the structure slightly exceeded from the outer dimension of the entrance door assembly. The entry system can either undergo non-salient testing or other measure to protect the entry system from precipitation, sunlight, or other environmental corrosive agents or the entry system is placed behind a storm door of view complete where temperatures can reach 95 ° C. The entry system is observed periodically for faults. The test can last for 5-10 years, without defects in performance or aesthetics allowed. This test can also be used for other types of construction products.

Example 1 The coating composition of the preferred vinylidene acrylic chloride interpenetration polymer network PERMAX 801 is applied by brush to Ponderosa pine door jambs or joins joined by splices. The coating is allowed to dry on the wings or stops at room temperature (> 20 ° C) for 7 days to ensure complete drying. Each coating is approximately 1 mm thick. The linear wet expansion of the hinges or door stops of Example 1 according to ASTM D-1037 when changing from 50% relative humidity to 90% relative humidity is approximately 0.053%.

Example 2 and Comparative Example 1 The Ponderosa pine leaves or stops of Example 1, joined by splices, were subjected to consecutive treatments of accelerated aging of 95% relative humidity at 35 ° C for 90 days, followed by days of temperature cycles twice daily from -29 ° C to 95 ° C that have simulated rain during one of these cycles. The result is not significant degradation. Comparative example 1 is Ponderosa pine bungs or stops joined by commercially available, painted, pore-capped joints. The wings of Comparative Example 1 are not coated with the vinylidene acrylic chloride coating composition of the present invention. The leaflets of Comparative Example 1 were subjected to the same accelerated aging test of Example 2. These commercially available leaflets have been replaced three times. Failure modes of painted panes covered with pores include degradation of joints by splicing, dimensional swelling where water has penetrated, as well as the growth of mold and blight.

Example 3 and Comparative Examples 2, 3 and 4: Example 3 is an assembled door with molded covers of medium density or high density hardboard containing at least 7% by weight of cured novolac phenolic resin, preferably 7% by weight up to 25% by weight and more preferably 8-15% by weight; and equilibrated to about 4-8% moisture has been treated with a coating of approximately 1 mm thick of the vinylidene acrylic chloride coating composition employed in Example 1. The door assembled with the coated cover of Example 3 is subjected to to consecutive treatments of 95% relative humidity at 35 ° C for 90 days, followed by 30 days of temperature cycles of -29 ° C to 95 ° C twice a day that have simulated rain during one of these cycles. The result is not significant degradation. Comparative Example 2 is a commercially available molded door cover, coated with a melamine coating. The lignocellulosic solid cardboard door cover contains approximately 4% by weight of phenolic-formaldehyde resin (resole). This coated door assembly is accommodated by at least 8 mm in the center of the roof exposed to the environmental test within two days. It also presents delamination of the roof of the wooden structure after six days. Comparative Example 3 is a door identical to Comparative Example 2, except that the melamine coating is not applied. Comparative Example 3 is absorbed by at least 30 mm in the center of the cover and delaminates within two days.

Comparative Example 4 is an assembled door identical to Example 3 except that the acrylic vinylidene chloride coating is not applied. He Comparative Example 4 is accommodated approximately 6 mm in the center of the cover within four days. After exposing the above environmental simulations in the laboratory, the samples of Example 3 and the recent samples of Examples 2-4 are placed in outdoor weatherproof conditions of the Middle East of the United States of America without either protection from outgoing from atmospheric conditions or behind a full view storm door where the temperature can reach 95 ° C. No degradation or cupping of the doors or hinges of Example 3 is observed after at least 15 months of exposure to outdoor weathering conditions of the Middle East of the United States of America. In Comparative Example 2, it coats, deforms and delaminates to the point where they are not so widely commercially acceptable within three months. In Comparative Example 5, it coats, deforms and delaminates to the point where they are not so widely commercially acceptable within two months. In Comparative Example 4, it coats, deforms and delaminates to the point where they are not so widely acceptable within four months. The linear moisture expansion of the door cover used in the door assemblies of Example 3, measured according to ASTM D-1037 when changing from 50% relative humidity to 90% relative humidity is 0.02%. The linear moisture expansion of the door covers used in the door assemblies of Comparative Example 4, measured according to ASTM D-1037 when changing from 50% relative humidity to 90% relative humidity is 0.461%.

Example 4 and Comparative Example 5: Example 4 is identical to Example 3, except that two holes are inclined guided in the door to allow the insertion of "doorlites" and a drill hole of 54 mm for lock has been drilled approximately 70 mm in front of the edge of the step of the lock where the lock and locksmith of the latch will be inserted. The edge of one of the two "doorlite" openings was treated with an additional layer of approximately 0.5 mm thickness of the vinylidene chloride coating composition used in Example 1. The other "doorlite" opening is left without try. Both "doorlite" openings are fixed with standard "doorlite" inserts effectively sealing the cut edges of direct exposure to water, but without moisture vapor. After the laboratory simulations and approximately 15 months for field exposure for Example 3, the uncoated "doorlite" opening has minor swellings in thickness with sufficient strength to break the "doorlite" structure pressed to it, while none of the "doorlite" coated openings or the lock hole reveal some degradation. Comparative Example 4 is identical to Comparative Example 2, except that a similar 54 mm hole was drilled in the lock step approximately 70 mm from the rung of the lock step. Comparative Example 5 is exposed to the weather in the same way and shows swelling in the perforation for the lock after exposure to laboratory simulations within 8 days. In a second embodiment, the weather-resistant coating composition comprises a polyurethane or coating composition of acrylic-urethane hybrid polymers. Preferably, the polyurethane or the acrylic-urethane hybrid polymers have an average molecular weight number greater than 100,000. The coating composition based on the polyurethane or the acrylic-urethane hybrid polymers can be mixed with various ultraviolet protection packages known in the art, as well as fungicides. The coating composition based on polyurethane or acrylic-urethane hybrid polymers have also been found to provide a limited and uniform surface porosity, which allows to increase the dyeing and painting of the finished products, especially at lower densities of the products. The application of any coating composition of the second embodiment of the product in one step may be accompanied by a brush or other device having a relatively low cut during application such as a curtain coater, a flow coater, dipping or a roller. By low cut, it means a cutting condition that does not cause the polymerization induced by cutting the polymer, providing little polymer grip. A typical process condition near the cut-off limit of the latex composition is mixing at 60 revolutions per minute with a 76 mm low cut knife CONN IT in mixing vessels with a diameter of approximately 150 mm. The coating thickness (dry) may be from 0.01 mm to approximately 3-mm, preferably 0.05-mm to lmm, more preferably for economic reasons 0.05 mm to 0.15 mm. More preferably, the coating thickness of the coatings of the second embodiment is 0.018 mm to 0.125 mm. The coatings of the second embodiment can be dried at room temperature or at elevated temperatures from about 25 ° C to about 75 ° C.

Example 5: The second embodiment of the present invention can be directed to a door assembly having a complete partial center inserted or a center formed in situ, placed within a structure. A pair of opposed molded covers with rods that remain descendingly made by the present invention, are attached to the structure, which can also be made by the present invention. There are edges adjacent to the cover. The covers are made from a table composed of full novolac phenolic resin prepared from 15 to 25 weight percent novolac. The filling is a softwood wood powder dried in a stove-type oven, derived from oven-dried wood, varnish of various thicknesses, lamellae, chips, chips, strands, wood particles or wood fiber bundles. High lignin wood powders work better because lignin is the major subject of acid hydrolysis in reactions with phenolic resins. The main one is lignin, hemicellulose and cellulose. In reported reactions, the acidity of the wood is neutralized by the reaction with sufficient amounts of phenolic resins. The shredded paper products are less suitable, because during the manufacture of the paper, the wood products have delignified. Oven-dried materials with moisture contents of 4 to 12 weight percent are preferred, so as to avoid any passage of instantaneous duct / evaporation processes, typically encountered when using wet or green wood sources. Softwood has more lignin content than hardwood that varies from 25 to 35 weight percent versus 18 to 25 weight percent depending on the tree species. However, hardwood powders will perform well in this product. Each of the door covers has an interior surface and an exterior surface. The inner surface is adjacent to the center. The outer surface has either a textured surface consisting of level portions and depressions. The depressions have a depth range of about 0.25 mm to about 1.0 mm from the level portions. The covers also include biased cuts adjacent to the depressions. This makes possible the flexibility of the material to adapt and mold the release agents when they are partially cured and heated. The process window of the resin content, the curing state and the type is very difficult to measure or predict due to the test and time constraints. A test of use is more applicable. The biased cuts have a range in the context of the biased cuts from about 0.25 mm to about 0.10 mm from the depressions. Calcium stearate can be combined in the cement-based formulation at 1 to 3 weight percent to aid in the release of biased cuts. Each door cover has a rod that remains down on the edge to provide resistance to compression damage from the board during manufacturing, transportation or use. In addition, these rods that remain downward can help to align during assembly because they engage or are adjacent to the structure or other components such as a lock block. Each of the door covers is sealed in this embodiment or on the inside, exterior surfaces and some side that may originate from the thickness of the cover with a coating of aliphatic or cycloaliphatic urethane polymer film of high coarse molecular weight of 0.1 -1 mm. Film coatings can include other conventional additives, adjuvants and stabilizers. Dyes, pigments and / or fillers may also be included for practical purposes, such as dye, color, opacity, fungal resistance, microbial resistance, antiestrope development agents and gloss, as desired. This coating imparts additional surface durability, additional moisture resistance and surface uniformity by subsequent coatings without experiencing significant shaking of the coating on the surface of the product. If this coating is trimmed in the field, the intimately bound novolac phenolic resin will remain sufficiently impermeable to prevent dimensional change of the objectionable product or desiamination.

Example 6: The second embodiment of the present invention can be directed to the exterior trimming and paneling for walls for residential housing that have a single profile produced by an extrusion process possibly accompanied by a mold in rotary form or vacuum slab flanges with slots for the expansion or contraction with heat and humidity. The flanges are bent by the adjacent piece of wall sheathing. The material contains 15 to 40 weight percent phenolic resin. The upper limit is determined by the design allowed for linear thermal expansion and humidity. The coefficients of linear moisture expansion vary with the thickness of a redundant seal coating, as well as the resin fraction present. Water based on water-based acrylic-polyurethane hybrid polymer seal coatings, such as Air Products 620 or Sancure ™ AU4010 from BF Goodrich (Brecksville, Ohio), the resin is mixed with 0.25 to 1.0 percent by weight of a water miscible fungicide such as Polyphase P20T by Tyrosan to * cover all exposed exterior surfaces. The coefficients of thermal expansion are dominated by the fraction of resin present in the design. At about 50%, the phenolic resin matrix becomes effectively continuous, thereby significantly changing the physical properties, such as the coefficient of linear thermal expansion. The lower limit allows both good resistance to water absorption and flow, through a single or double ring extruder. The resin and sealant are prepared in the same manner as in Example 5. The surface can also be textured as in Example 5.

Example 7: The second embodiment of the present invention can be directed to a composite beam, such as guardrails of non-structural portals. The profiles of tables of medium density, of density 590 kg / m3 up to 800 kg / m3 and the novolac phenolic resin content of 25 to 40 weight percent (on dry basis), are extruded as a tube and form in a vacuum gauge with outgoing nozzle or are extruded near the net size. The average density table can also be extruded into L-shaped or linear sections and adhered in a rectangle. The assembly of the composite beams, involves injecting the tube of medium density board with foam, including polyurethane foam of 32 kg / m3 up to 250 kg / m3, foam packed polystyrene of 16 kg / m3 up to 50 kg / m, or blocks of several foams adhered to the interior of the walls of the beam. The beam, as formed from adhered profiles, may have rods that remain down adjacent to the additional profiles for ease of fixation during assembly. The texturization of the exterior surface to simulate the wood grain can be introduced after the product has emerged from the nozzle and is still hot and not fully cured, using an accessory stamping incorporating the texture.

Example 8: The second embodiment of the present invention can be directed to a reinforced composite sheet for the exterior coating of a residence. The medium density board reinforced with novolac phenolic resin content of 20 to 40 weight percent (based on dry weight), is compression molded with a reinforcement located either between multiple grids or on the outer surface of a grid outermost. The reinforcement can cover only specific areas of the product that needs to reinforce or cover the entire area of the product. The reinforcement may be a tow, interwoven grid, recessed grid, high density grid, webs, symmetrically or asymmetrically oriented layers of crushed reinforcing fibers or randomly shredded reinforcing fibers. Reinforcing may include, but not limited to fiberglass, aramid fibers, polyamide fibers, oriented thermoplastic fibers, carbon fibers; polyester fibers and polyethylene terephthalate fibers and mixtures thereof. The percentage of reinforcement is determined by the implementation of the application of the product, but may vary up to 70 weight percent on a dry basis. The reinforced composite sheet can be additionally covered with surface layers of wet barriers, thermal reflectors or decorative films. These may be integrally molded to the surface during the compression molding operation or adhered to the surface after molding.

Example 9: The second embodiment of the present invention can be directed to C-channel profiles, approximated to the structural product for windows of linear structures extruded using a rammer extruder and a nozzle capable of orienting the molecules of the novolac resin. In this product, 25 to 40 percent by weight (on dry basis) of the novolac resin is composed of the fiber, but without hexamethylenetetramine. This mixture is then siphoned into a feed extruder before being formed into a compressed log and allowed to cool just below the melting point. The reaction ratio of the hexamethylenetetramine is adjusted in terms of its transition from solid to liquid to allow the material sufficient time to be pushed through a nozzle of approximately special hyperbolic profile which causes the polymer molecules to expand in an oriented alignment of upward rigidity. The filler is also oriented by virtue of the flow. As an alternative, the hexamethylenetetramine is injected into the nozzle or applied to the outlet to allow timely healing. The nozzle is designed with either a constant or to decrease the elongation of the proportion of the strand. The product that leaves the nozzle is placed under tension immediately and left to cool under tension at approximately 100 ° C. The profile can be decorated as described in Examples 5 and 8. While the embodiments of the invention have been illustrated and described, it is not proposed that these embodiments illustrate and describe all possible forms of the invention. Preferably, the words used in the specification are words of the description rather than limitation, and that various changes can be made without departing from the spirit and scope of the invention.

Claims (33)

1. A method for making a product for weatherproof construction, characterized in that it comprises: coating at least a portion of a wood element with a coating composition comprising an interpenetrating polymer network of an acrylic latex and a polymer of Vinylidene chloride

2. The method of claim 1, characterized in that the vinylidene chloride polymer comprises vinylidene chloride, and one or more alkyl acrylates having from 1 to 18 carbon atoms in the alkyl group and / or one or more alkyl methacrylates which they have 1 to 18 carbon atoms in the alkyl group.

3. The method of claim 2, characterized in that the vinylidene chloride polymer further comprises one or more aliphatic alpha-beta-unsaturated carboxylic acids.

4. The method of claim 3, characterized in that the vinylidene chloride polymer further comprises a copolymerizable surfactant.

5. The method of claim 4, characterized in that the surfactant comprises an ethylenically unsaturated sulfonate.

6. The method of claim 2, characterized in that the acrylic latex comprises a seed particle of acrylic latex.

7. The method of claim 6, characterized in that the seed particle comprises acrylic latex of styrene.

8. The method of claim 7, characterized in that the particle size of the seed particle is less than about 2000 Angstroms.

9. The method of claim 2, characterized in that the vinyl chloride polymer comprises about 65 to 90 parts by weight of vinylidene chloride, about 2 to 30 parts by weight of alkyl acrylates and / or methacrylates, about 0.1 to 10 parts by weight. weight of carboxylic acid, and about 0.1 to 5.0 parts by weight of copolymerizable surfactant, all parts are based on percent parts by weight of the monomer.

10. The method of claim 1, characterized in that it further comprises drying the coated wood element at a temperature from about 25 ° C to about 90 ° C for at least about 5 minutes.

11. The method of claim 1, characterized in that the wood element comprises materials based on fiber or solid wood.

12. The method of claim 11, characterized in that the wooden element comprises pine.

13. The method of claim 11, characterized in that the wood element is made of fiber or resin.

14. The method of claim 13, characterized in that the resin comprises novolac phenolic resin and is present in an amount of about 2 to about 30 weight percent, based on the weight of the wood element.

15. The method of claim 14, characterized in that the fiber comprises lignocellulosic fiber precursor material.

16. The method of claim 15, characterized in that the fiber is made of chips, laminates and pieces or bridles of wood, most of which have an aspect ratio of about 3-100.

17. The method of claim 1, characterized in that the wood element has an average thickness of about 0.5 mm to about 75 mm.

18. The method of claim 15, characterized in that the wood element has an average thickness of about 0.75 mm to about 45 mm.

19. The method of claim 18, characterized in that the wood element is made by pressing the fiber and the resin together under a pressure of 120-14,500 kPa, without steam being present.

20. The method of claim 18, characterized in that it further comprises drying the coated wood element at a temperature from about 25 ° C to about 90 ° C for at least about 5 minutes.

21. A product for weatherproof construction, characterized in that it comprises: a wooden element; at least a portion of the element is coated with a coating composition comprising an interpenetrating polymer network of an acrylic latex and a vinylidene chloride polymer.

22. The weatherproof construction product of claim 21, characterized in that the vinylidene chloride polymer comprises vinylidene chloride, and one or more alkyl acrylates having from 1 to 18 carbon atoms in the alkyl group and / or one or more alkyl methacrylates having 1 to 18 carbon atoms in the alkyl group.

23. The weather-resistant construction product of claim 22, characterized in that the vinylidene chloride polymer further comprises one or more aliphatic alpha-beta-unsaturated carboxylic acids.

24. The weatherproof construction product of claim 23, characterized in that the vinylidene chloride polymer further comprises a copolymerizable surfactant.

25. The product for the weatherproof construction of claim 24, characterized in that the surfactant comprises an ethylenically unsaturated sulfonate.

26. The product for the weatherproof construction of claim 22, characterized in that the acrylic latex comprises a seed particle of acrylic latex.

27. The product for the weatherproof construction of claim 26, characterized in that the seed particle comprises an acrylic latex of styrene.

28. The product for the weatherproof construction of claim 27, characterized in that the particle size of the seed particle is less than about 2000 Angstroms.

29. The weatherproof construction product of claim 22, characterized in that the vinyl chloride polymer comprises about 65 to 90 parts by weight of vinylidene chloride, about 2 to 30 parts by weight of alkyl acrylates and / or methacrylates, about 0.1 to 10 parts by weight of carboxylic acid, about 0.1 to 5.0 parts by weight of the copolymerizable surfactant, all parts are based on parts per thousand weight of monomer.

30. A product for construction, characterized in that it comprises an elaborate substrate of from about 15 to about 40 weight percent of novolac phenolic resin and from about 60 to 85 weight percent of the filler selected from the group consisting of wood fiber having a moisture content of about 4 to about 12 weight percent and agricultural waste having a moisture content of less than 12 weight percent, and said substrate is coated with a polymer coating film selected from the group consisting of of polyurethane and hybrid polymers of acrylic-urethane.

31. The product for the construction of claim 30, characterized in that said agricultural waste is selected from the group consisting of corn stalks, corn bagasse, corn cobs, straw, wheat stems, flax, rice husk, cotton, jute, hemp, bagasse, bamboo, jojoba, ramina and variety of hemp.

32. The product for the construction of claim 30, characterized in that said polymer film coating has an average molecular number greater than 100 000.

33. The product for the construction of claim 30, characterized in that said film coating of the polymer includes additives selected from the group consisting of dyes, pigments and gloss control agents.