Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/24—Homopolymers or copolymers of amides or imides
  • C09D133/26—Homopolymers or copolymers of acrylamide or methacrylamide
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H19/00—Coated paper; Coating material
  • D21H19/10—Coatings without pigments
  • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
  • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H19/30—Polyamides; Polyimides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
  • C08L79/02—Polyamines
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D179/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen, with or without oxygen, or carbon only, not provided for in groups C09D161/00 - C09D177/00
  • C09D179/02—Polyamines
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D201/00—Coating compositions based on unspecified macromolecular compounds
  • C09D201/02—Coating compositions based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/08—Anti-corrosive paints
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
  • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
  • C23C22/34—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H19/00—Coated paper; Coating material
  • D21H19/10—Coatings without pigments
  • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
  • D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds

Definitions

• aqueous compositions of the present invention relate to aqueous compositions for imparting a variety of characteristics to materials.
• aqueous compositions of the present invention include compositions for coating/barrier layers, replacements/extenders for latex, and cross linkers for a variety of substances, as well as in adhesives/binders.
• Such compositions can impart various desired properties to substrates coated and/or impregnated therewith.
• Aqueous compositions of the invention are especially suitable for coating substrates, such as physiological substrates, porous substrates, cellulose substrates, textiles, and building materials, such as wood, metal, and glass.
• aqueous composition of the present invention can also be used in inks, dye fixatives, adhesives, sealants, cellulosic products, personal care products such as cosmetics and hair styling products, resins, paint, coatings, and non-woven structures to provide adhesion, delivery, surface modification, strength and/or texture, and protection from the effects of liquids, and vapor and gases.
• a non-woven structure can be a sheet, web, or batt of directionally or randomly oriented fibers of natural and/or man-made fibers or filaments, bonded by friction, and/or cohesion and/or adhesion, excluding paper and products which are woven, knitted, tufted, stitch bonded, or felted by wet milling or not additionally needled, or that are bonded to each other by any techniques known in the art.
• An example of a non-woven structure includes a non-woven fabric which is a flat, flexible porous sheet structure produced by interlocking layers or networks of fibers, filaments or film-like filamentary structure.
• the composition of the present invention is suitable for use in metal conversion coatings to enhance corrosion resistance of and paint adhesion to metal surfaces.
• the present invention also includes products comprising such compositions as well as methods of producing such products.
• Substrates are often coated with a coating composition to impart desired characteristics to the substrate, including the surface thereof.
• Various substrates have been coated or otherwise treated with coating compositions to impart desired characteristics to the substrate, including the surface thereof.
• a wide variety of building and finishing materials exists, which are employed in construction of static structures, such as residences and other buildings, and commercial structures, schools, public facilities, and the like. Many such materials are based on non-woven materials. Further, many such materials are coated and/or impregnated with a surface finish coating, either during manufacture, prior to installation, or post-installation, or in a combination of the above situations.
• Such materials, particularly ceiling tiles have been provided with prime coats comprising ethyl ene- vinyl chloride copolymer emulsions.
• Particularly suitable materials include those available from Air Products and Chemicals, Inc., of Allentown, Pennsylvania, under the trade name AIRFLEX®. Specific examples of such emulsions are disclosed in U.S. Patent No. 4,673,702 to IACOVIELLO, and U.S. Patent No. 4,962,141 to IACOVIELLO, et al, both assigned to Air Products and Chemicals, Inc., Allentown, Pennsylvania, both of which are hereby incorporated by reference as though set forth in full herein. Paper for certain applications has been customarily strengthened with resins to impart strength thereto when the paper is wet.
• wet strength resins Such resins are commonly referred to as "wet strength resins.”
• a frequently employed wet-strength resin for use in papers is that of the broad class of polyamidoamine-epihalohydrin resin polymers for resins.
• Such resins include those marketed under the trademark KYMENE® by Hercules Incorporated, Delaware.
• Such resins, and processes for their manufacture are disclosed in, for example, U.S. Patents No. 2,926,116 and 2,926,154, both to KEIM; U.S. Patent No. U.S. Pat. 5,614,597 to BOWER; U.S. Patents Nos. 5,644,021 and 5,668,246, both to MASLANKA; all assigned to Hercules Incorporated, all of which patents are hereby incorporated by reference as though set forth in full herein.
• U.S. Patent No. 4,859,527 discloses cellulosic non-woven products of enhanced water and/or solvent resistance obtained by pre-treatment of the cellulosic fibers.
• suitable pre-treatment agents include poly(aminoamide) epichlorohydrin resins.
• Suitable overcoat binders are disclosed as including ethylene-vinyl chloride-acrylamide polymers.
• specific examples of the pre-treatment agents include KYMENE®, and HERCOBOND®, including HERCOBOND® 5100; overcoat binders include binders such as AIRFLEX® "EVC1" co-polymers (AIRFLEX® 4500).
• Such substrates on which a need for a flexible coating exists include substrates subject to bending and flexing. Such substrates also can include those which can be cut. Ceiling tiles are exemplary of such substrates.
• Coating compositions comprising poly(aminoamide) epihalohydrin resins such as KYMENE and latices such as AIRFLEX are used to treat ceiling tiles as disclosed in co-pending Application No. 09/348,346, which is hereby incorporated by reference as though set forth in full herein.
• Nail polish is another example of a coating for substrates.
• Aqueous-based nail polishes are disclosed in commonly assigned co-pending Application No. 09/348,345, which is hereby incorporated by reference as though set forth in full herein.
• Nail polish is most commonly a colored liquid that dries, not unlike paint, into a hard, shiny coating.
• Nail polishes sold as articles of commerce are typically solutions and/or dispersions in an organic solvent, such as toluene or acetone.
• U.S. Patent No. 5,120,259 discloses a water-based nail polish consisting of at least one polyurethane and/or polyurethane copolymer in dispersed form as a binder, with a thickener and acrylated-styrene copolymer.
• the acrylated-styrene copolymer is employed to increase hardness of the dried coating.
• U.S. Patent No. 5,716,603 discloses a nail polish composition comprising an aqueous solution containing an acrylic resin cross linked with a difunctional acrylated urethane oligomer.
• nail polish formulations contain other additives, such as plasticizers and coalescents to modify the film and/or provide other desired or functional properties such as gloss, uniform color or resistance to chipping.
• Substrates are often coated with a coating composition to impart desired characteristics to the substrate, including the surface thereof.
• Porous building materials are illustrative of such substrates.
• a wide variety of building and finishing materials exists, which are employed in construction of static structures, such as residences and other buildings, and commercial structures, schools, public facilities, and the like. Many such materials are based on non-woven webs.
• High grade acoustical ceiling tile is marketed for its appearance and sound characteristics.
• the manufacture of such materials may be generally divided into two stages: a wet end formulation stage and a fabrication stage.
• the baseboard tile is made from a slurry mixture of, for example, mineral wool, paper, perlite, clay and starch, which is drained on a wet-end forming machine or paper machine or similar system and dried, producing a thick mat.
• the resultant mat is subsequently sanded, cut, designed into a pattern and "painted" (or coated).
• the present invention relates to aqueous compositions
• component (A) which comprises at least one water-soluble component comprising molecules which interact with or entangle with each other, such as at least one functional group that undergoes a crosslinking reaction, preferably upon drying and/or heating; and component (B) which comprises at least one film-forming material, preferably a latex material.
• the aqueous compositions of the present invention can be used as coating/barrier layers, replacements/extenders for latex, and cross linkers, as well as in adhesives/binders.
• the aqueous composition of the present invention provides moisture barrier, edge seal, extenders for latices, stam resistance, water resistance/repellency, and porosity control for porous substrates, such as paper and textiles.
• coating/barrier layers include, but are not limited to, additives for texture in paint, binders for coatings (e.g., in paint), paint primers for all surfaces, additives for paper (e.g., paper coatings, paper printability, paper sizing, and paper wet/dry strength agent), precoats for coated paper, primers for printing, and replacements/extenders for latex in all applications using latex.
• the composition of the present invention is suitable for use in metal conversion coating to enhance corrosion resistance of and paint adhesion to metal surfaces.
• the aqueous composition of the present invention can also be used in adhesives/binders, such as adhesives, binders (e.g., for coatings and personal care products such as cosmetics and hair styling products), additives for engineered wood products, dye fixatives, paper wet/dry strength additives, additives in paint, resins such as permanent press resins (e.g., for wrinkle resistance), precoats for coated papers, primers for printing for any surfaces (e.g., wood, paper, metal, etc.), protective coatings, surface modifiers for wood/metal/glass, and replacement/extender for latex as internal binders in all applications using latex.
• adhesives such as adhesives, binders (e.g., for coatings and personal care products such as cosmetics and hair styling products), additives for engineered wood products, dye fixatives, paper wet/dry strength additives, additives in paint, resins such as permanent press resins (e.g., for wrinkle resistance), precoats for coated papers, primers for printing for any surfaces (
• the aqueous composition of the present invention can also be used as cross linkers in additives for engineered wood products, paper sizing agents, paper wet/dry strength additives, permanent press resins, replacement for latex as internal binders in all applications using latex, surface modifiers in wood/metal/glass, ink vehicles, and textile wet processing aids.
• the use of the aqueous composition of the present invention as cross linkers provides sealing properties, stain resistance, textile strength, and water resistance repellency
• component (A) can beneficially be selected from at least one of acrylamide- based crosslinkable polymers (e.g., cationic functionalized polyacrylamides.), polyamidoamine- epihalohydrin resins, polyamines, and polyimines.
• acrylamide- based crosslinkable polymers e.g., cationic functionalized polyacrylamides.
• polyamidoamine- epihalohydrin resins e.g., polyamidoamine- epihalohydrin resins, polyamines, and polyimines.
• the at least one functional group of component (A) can be selected from epoxy, azetidinium, aldehyde, carboxyl group, acrylate and derivatives thereof, acrylamide and derivatives thereof, and quaternary amine.
• the film-forming polymer can be selected, for example, from at least one polymer derived from monomers of alkyl halides of from 2-12 C atoms, alkene halides of from 2-12 C atoms, alkyl acrylamides of from 2-12 C atoms, alkene acrylamides of from 2-12 C atoms, alkyl acrylates of from 2-12 C atoms, and alkene acrylates of from 2-12 C atoms.
• Some preferred polymers include those derived from at least one monomer selected from styrene, dimethylstyrene, vinyltoluene, chloroprene, butadiene, ethylene, acrylamide, acrylonitrile, acrolein, methylacrylate, ethylacrylate, acrylic acid, methacrylic acid, methyl methacrylate, n-butyl acrylate, vinylidene chloride, vinyl ester, vinyl chloride, vinyl acetate, acrylated urethane, hydroxyethyl acrylate, dimethylaminoethyleneacrylate, and vinyl acetate.
• the film-forming polymer can be a latex selected from at least one polymer derived from at least one monomer comprising repeating units derived from an alkyl halide having at least one double bond, such as a vinyl halide, e.g., vinyl chloride, and an alkene, such as ethylene, wherein the alkyl halide has from 2 to 12 C atoms, and wherein the alkene has from 2 to 12 C atoms.
• the alkyl halide can be a vinyl halide, for example.
• the composition further includes at least one acid, preferably fluoacid (e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid).
• the composition can have a dry weight ratio of (A) to (B) of about 5:1 to 1 :1, more preferably about 2:1 to 1 : 1 or about 1.69: 1.
• the invention also relates to methods of preparing a coated substrate comprising, for example coating a substrate with a coating composition including components (A) and (B); and curing the coating composition on the substrate. Further, the methods can include coating a substrate with a coating composition including components (A) and (B), and drying the composition in place on the surface of a substrate or rinsing a substrate with a coating composition.
• the present invention is also directed to coated substrate materials coating substrates such as cellulosic products and coating, non-woven products such as sheets, ceiling tiles, and metal.
• the present invention is also directed to methods of preparing coated substrates such as cellulosic products, non-woven sheets, ceiling tiles, and metal using components (A) and (B), e.g., a cured composition of components (A) and (B).
• the present invention is also specifically directed to methods for metal conversion coating using the composition containing components (A) and (B) and at least one acid, preferably fluoacid (e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid), preferably at a pH from about 1.5 to about 5.0.
• fluoacid e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid
• the present invention is directed to a method of forming a substantially chromium-free conversion coating on a metal surface using the composition containing components (A) and (B) and at least one acid, preferably fluoacid (e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid), preferably at a pH from about 1.5 to about 5.0.
• fluoacid e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid
• the present invention is directed to a method of forming a substantially chromium-free, dried in place conversion coating on a metal surface using the composition containing components (A)and (B) and at least one acid, preferably fluoacid (e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid), preferably at a pH from about 1.5 to about 5.0.
• fluoacid e.g., fluotitanic acid, fluozirconic acid, fluosilicic acid, and fluoboric acid
• the amount of the composition in (1) can preferably be from about 0.1 to about 90% by weight, and the amount of acid can preferably be from about 0.2 to about 20% by weight.
• the present invention is also directed to substrates, preferably metal substrates comprising a cured composition which comprises component (A) which comprises at least one water-soluble component comprising at least one functional group that undergoes a crosslinking reaction, preferably upon drying and/or heating; and component (B) which comprises at least one film- forming material, preferably a latex material
• the present invention also relates to methods of preparing cellulosic products, preferably ceiling tiles and non-woven products such as sheets.
• the invention provides a method of substantially simultaneously or sequentially adding to a system comprising cellulosic fibers, wherein the system is selected from at least one of aqueous system, felt, web, and combinations thereof (A) at least one water-soluble component comprising at least one functional group that undergoes a crosslinking reaction; and
• the present invention also relates to cellulosic products, preferably ceiling tiles and non- woven products such as sheets comprising a composition which comprises component (A) which comprises at least one water-soluble component comprising at least one functional group that undergoes a crosslinking reaction, preferably upon drying and/or heating; and component (B) which comprises at least one film-forming material, preferably a latex material.
• component (A) which comprises at least one water-soluble component comprising at least one functional group that undergoes a crosslinking reaction, preferably upon drying and/or heating
• component (B) which comprises at least one film-forming material, preferably a latex material.
• the present invention provides a coating composition for substrates, and, in particular, porous substrates, especially porous substrates which can be handled or manipulated after coating.
• the invention relates to building materials, including ceiling tiles and the like, which exhibit improved cuttability as shown by low levels of flaking and/or chipping.
• the present invention provides a coating composition for building materials, including ceiling tiles and the like, which achieve a desired finish color and face durability (such as scratch resistance, abrasion resistance and scrubbability properties).
• the invention provides such materials which exhibit a combination of improved cuttability as shown by low levels of flaking and/or chipping and abrasion resistance.
• the invention provides coating compositions lor building materials including ceiling tiles, which, when the building materials are coated with the composition and the composition is cured, exhibit a combination of the foregoing attributes, while also providing good acoustics, low sag, good durability, good aging characteristics, good color or cover characteristics, good fire resistance, and favorable properties for installation.
• the coatings of the invention can be applied to a porous type fiber substrate (such as a ceiling tile) and impart durability properties to that substrate without sealing it off, losing porous properties (such as acoustics) or diminishing aesthetic appearance, while still maintaining a Class A fire performance.
• a porous type fiber substrate such as a ceiling tile
• the invention provides the foregoing advantages.
• the invention also provides a composition that can be easily used.
• the components of the composition can be easily mixed, especially in embodiments where they are in liquid form, such as in the form of an emulsions.
• compositions of the invention when curing do not require a high degree of ventilation. Compositions of the invention are also stable over time.
• compositions of the invention possess properties which render them especially suitable for application to substrates by spraying.
• the compositions of the invention have low viscosities and contain a low level of solids.
• the compositions of the invention may be sprayed without substantial plugging of the spraying equipment during operation.
• the compositions of the invention may be sprayed without the need for large amounts of air for spraying; as a result of the low viscosity of the compositions, the compositions may readily be atomized at lower pump pressures.
• the invention provides a coating composition comprising: (A) at least one polyamidoamine-epihalohydrin resin; and (B) at least one material in an amount sufficient to impart a cuttability value of less than about 15 to a substrate coated with the cured coating composition.
• the invention provides a coating composition comprising:
• the invention provides a coating composition comprising: (A) at least one polyamidoamine-epihalohydrin resin; and (B) at least one polymer comprising repeating units derived from an alkyl halide having at least one double bond and an alkene.
• the invention provides building units coated with a composition comprising: (A) at least one polyamidoamine-epihalohydrin resin; and
• (B) at least one polymer comprising repeating units derived from an alkyl halide having at least one double bond and an alkene.
• the invention provides coating compositions comprising:
• At least one polyamidoamine-epihalohydrin resin at least one polyamidoamine-epihalohydrin resin; and (B) at least one material in an amount sufficient to impart sufficient flexibility, such that when the coating is applied to a substrate and cured, the cured coating exhibits substantially no delamination from the substrate or cracking, when the substrate is bent substantially 180° subsequent to curing.
• the thickness of the coating after curing is preferably in the range of about 5-10 mils when cured.
• such compositions exhibit sufficient flexibility, such that when the coating is applied to a substrate and cured, the cured coating exhibits substantially no delamination or cracking, when the substrate is bent substantially 360°.
• Component (A) can comprise an aqueous solution of component (A) present in an amount in a range of from about 5% to about 95% by weight based on the total weight of all components of the composition, and component (B) can comprise an aqueous emulsion of component (B) present in an amount in a range of from about 5% to about 95% by weight based on the total weight of all components of the composition.
• Component (A) can comprise an aqueous solution of component (A) present in an amount in a range of from about 50% to about 85% by weight based on the total weight of all components of the composition, and component (B) can comprise an aqueous emulsion of component (B) present in an amount in a range of from about 8% to about
• Component (A) can comprise an aqueous solution of component (A) present in an amount of about 75% by weight based on the total weight of all components of the composition
• component (B) can comprise an aqueous emulsion of component (B) present in an amount of about 11% by weight based on the total weight of all components of the composition.
• the coating compositions can further comprise a surfactant.
• the surfactant can comprise an octylphenoxypolyethoxyethanol nonionic surfactant.
• the surfactant can be present in an amount of up to 5%, by weight.
• the surtactant may be present in an amount ot up to about 1% by weight.
• the surfactant may be present in an amount of about 0.05-0.25% by weight.
• the weight ratio of (A):(B) is from about 0.05 to about 19, preferably about 4 to about 12, more preferably from about 6 to about 8, more preferably about 6.5 to about 7.0, and more preferably about 6.75.
• the invention also provides coated building units comprising a substrate such coating compositions as set forth above.
• the substrate can comprise a ceiling tile or a wall board.
• Such coated building units exhibit a Hess Rake Test Value of at least about 8, and a cuttability value of less than about 15.
• Preferably such coated building units exhibit a Hess Rake Test Value at least about 10, and a cuttability value of less than about 10; preferably a Hess Rake Test Value of at least about 12, and a cuttability value of less than about 2; preferably a Hess Rake Test Value of at least about 14, and a cuttability value of less than about 1.
• the substrate can comprise a ceiling tile and/or a wall board.
• such coated building units exhibit a Hess Rake Test Value range of at least about 8, and a cuttability value of less than about 15; preferably a Hess Rake Test Value of at least about 10, and a cuttability value of less than about 10; more preferably a Hess Rake Test Value of at least about 12, and a cuttability value of less than about 2; and more preferably a Hess Rake Test Value of at least about 14, and a cuttability value of less than about 1.
• Component (B) is preferably selected from copolymers which may be derived from monomers including at least one of alkyl halides, alkenes, methyl methacrylate, butyl acrylate, styrene vinylidene chloride, acrylic acid, methacrylic acid, and vinyl acrylic-based materials.
• Component (B) preferably comprises an alkyl halide, preferably a vinyl halide, and preferably vinyl chloride.
• the alkene comprises an olefin, preferably ethylene.
• the cuttability value is less than about 10, more preferably less than about 2, more preferably less than about 1.
• the substrates and compositions employed can be as defined above. DETAILED DESCRIPTION OF THE PREFERRED MBOOIMKN I S The present invention relates to aqueous compositions comprising component (A) as defined herein and component (B) as defined herein
• the aqueous compositions of this invention have va ⁇ ous utilities including uses as coatmg/barrier layers, replacements/extenders for latex, and cross linkers, as well as uses in adhesives/binders
• the aqueous composition of the present invention provides moisture barrier, edge seal, extenders for latices, stam resistance, water resistance/repellency, and porosity control for porous substrates
• porous substrates include, but are not limited to, paper products, non-woven products such as sheets, and textiles
• “Extender of latices” refers to the ability of the composition of the present invention (I e , components (A), and (B)) to be a substitute for latex, and can be used in place of or partial substitution for a latex in any applications where latex could be used
• coatmg/bar ⁇ er layers include, but are not limited to, additives for texture m paint, binders for coatings (e g , in paint), paint primers for all surfaces, additives for paper (e g , paper coatings, paper p ⁇ ntabihty, paper sizing, and paper wet/dry strength agent), precoats for coated paper, p ⁇ mers for p ⁇ ntmg, and replacements/ extendeis for latex as internal binders in all applications using latex
• substantially chromium-free conversion coating refers to a conversion coating that does not intentionally include added chromium, but can contain a trace amount of chromium.
• the present invention also relates to methods of preparing cellulosic products, preferably ceiling tiles and non-woven products such as sheets using the composition containing components (A), and (B).
• the present invention relates to methods of preparing cellulosic products which comprise (1) substantially simultaneously or sequentially adding a composition to a system comprising cellulosic fibers, wherein the system is selected from at least one of aqueous system, felt, web, and combinations thereof, and wherein the composition comprises (A) at least one water-soluble component comprising at least one functional group that undergoes a crosslinking reaction; and (B) at least one film-fo ⁇ riing polymer.
• component (A) preferably include, but are not limited to, acrylamide-based crosslinkable polymers, polyamidoamine-epihalohydrin resins, and polyamines, and polyimines, more preferably cationic functionalized polyacrylamides (HERCOBOND 1000® manufactured by Hercules Incorporated) such as those disclosed in U.S. Patent No. 5,543,446 which is incorporated herein by its entirety, creping aids such as CREPETROL® A 3025 disclosed in U.S. Patent No. 5,338,807 which is incorporated herein by its entirety, and polyamidoamine- epihalohydrin resins such as those disclosed in U.S. Patents No. 2,926,116 and 2,926,154, to KEIM, incorporated by reference in their entirety herein.
• HERCOBOND 1000® manufactured by Hercules Incorporated such as those disclosed in U.S. Patent No. 5,543,446 which is incorporated herein by its entirety
• creping aids such as CREPETRO
• reaction mixture After the epihalohydrin has been added and when heat evolution has subsided, the reaction mixture is heated to effect crosslinking and viscosity increase. During this reaction, azetidinium groups are formed. These functional groups are typically employed to impart wet strength to paper by forming a strong crosslinked network with the paper fibers.
• Preferred polyamidoamine-epihalohydrin resins include polyamidoamine-epichlorohydrins such as those sold by Hercules Incorporated of Wilmington, Delaware, under various trade names.
• Preferred polyamidoamine-epihalohydrin resins available from Hercules include the KYMENE® resins and the HERCOBOND® resins.
• KYMENE 557H® resin and HERCOBOND 5100® are especially preferred polyamidoamines, available in the form of aqueous solutions.
• KYMENE 763® resin (a polyamine) can also be employed as component (A). It is expressly contemplated that equivalents to each of the foregoing resins are within the scope of the present invention.
• Component (B) is expressly contemplated that equivalents to each of the foregoing resins are within the scope of the present invention.
• suitable materials for component (B) include any materials that are capable of forming a continuous phase that can be modified by the network structure of component (A) described above.
• component (B) comprises at least one film-forming material such as a polymer, preferably a latex material.
• Examples of other film-forming material of the present invention preferably include, but are not limited to, polymers derived from monomers including at least one of alkyl halides of from 2-12 C atoms, alkene halides of from 2-12 C atoms, alkyl acrylamides of from 2-12 C atoms, alkene acrylamides of from 2-12 C atoms, alkyl acrylates of from 2-12 C atoms, and alkene acrylates of from 2-12 C atoms.
• Latex refers to an aqueous dispersion of a water-insoluble polymer. Latex materials are prepared in an emulsion polymerization process wherein the insoluble monomer is emulsified, with a surfactant, into small particles of less than about 10,000 nm or 10 microns in diameter in water and polymerized using a water-soluble initiator. The resultant product is a colloidal suspension of fine particles, preferably about 50 to 1000 nm in diameter. See, for example, Kirk-
• Colloidal suspension refers to a dispersion of fine droplets or particles in a liquid medium.
• Suitable latices can be readily identified by those of ordinary skill in the art, based on physical properties using fully conventional considerations, including stability, rheology, film formation and film properties, interfacial reactivity and substrate adhesive can be determined by colloidal and polymeric properties of the latex. Colloidal properties include particle size and morphology distribution solids, pH, viscosity, and stability. Molecular weight distribution, monomer sequence and distribution, glass-transition temperature and crystallmity are well known in the art.
• Latex applications include, but are not limited to, uses as adhesives, binders, coatings, elastic materials, foam products, modifiers, and supports for immobilization of other materials.
• Commercially available latices are derived from a large variety of monomers including, but not limited to, styrene, dimethylstyrene, vinyltoluene, chloroprene, butadiene, ethylene, acrylamide, acrylonitrile, acrolein, methylacrylate, ethylacrylate, acrylic acid, methacrylic acid, methyl methacrylate, n-butyl acrylate, vinylidene chloride, vinyl ester, vinyl chloride, vinyl acetate, acrylated urethane, hydroxyethyl acrylate, dimethylaminoethyleneacrylate, and vinyl acetate.
• the latex material preferably include, but are not limited to, copolymers of alkyl halides and alkene halides, such as copolymers of vinyl or allyl halides and alkenes. Any akyl halides and any alkene halides, which copolymerize to form copolymers with each other, may be employed. Standard textbooks list exemplary materials. See, for example, Organic Chemi try. Morrison & Boyd, Allyn and Bacon, Inc. 1973, which is hereby incorporated by reference as though set forth in full herein for its disclosure of such materials.
• Preferred alkyl halides include allyl and/or vinyl halides of from 2-12 C atoms, preferably from 2-6 C atoms, more preferably from 2-4 C atoms and most preferably about 2 C atoms.
• component (B) can comprise any component that functions to cooperate with or moderate the properties of component (A).
• materials for component (B) comprise materials that function to flexibilize component (A) after the compositions of the invention are applied as a coating, materials that tend to inhibit crosslinking of component (A), and mixtures of such materials are considered exemplary. Materials for component (B) are not limited to these exemplary definitions, however.
• the degree to which component (A) is flexibilized by component (B) may be expressed in terms of a cuttability value.
• An exemplary procedure for determining the cuttability value of a substrate (such as a ceiling tile or a wall board) coated with the composition of the invention is set forth in the Examples, below.
• the degree to which component (A) is flexibilized by component (B) may be expressed in terms of the degree to which a substrate (such as a sheet of aluminum, such as a pie pan), coated with a composition of the invention which is subsequently cured, can be bent substantially without cracking or delaminating the coating from the substrate.
• An exemplary procedure for determining this degree of flexibility is also set forth in the Examples, below.
• the EVC1 copolymer emulsions may additionally contain from 0.1 to 30 wt% of an external crosslinking agent based upon the total weight of the copolymer.
• Suitable external crosslinking agents include melamine/formaldehyde resins, polyisocyanates such as water dispersible polymeric methyl diphenyl diisocyanates and water based phenolic resins.
• the process of forming the EVC1 copolymer emulsions may comprise preparing an aqueous solution containing substantially all of a polyvinyl alcohol dispersing agent.
• This aqueous solution and the initial charge of vinyl chloride may be added to the polymerization vessel and ethylene pressure may then be applied to the desired value.
• the mixture is mixed thoroughly to dissolve ethylene in the vinyl chloride and into the water phase.
• the charge can be conveniently elevated to polymerization temperature during this mixing period.
• a polymerization temperature of about 55° C. and an ethylene pressure in the range of 750 psig to 1000 psig may be employed to provide a copolymer with about 20-30 wt% ethylene.
• Mixing can be effected by means of an agitator or other known mechanism.
• component (B) includes, but are not limited to, NEOCAR® manufactured by Union Carbide (vinyl ester/acrylic acid), RES 3077® manufactured by Rohm & Haas (vinyl acetate/acrylic acid), FLEXTHANE 620® by Air Products (vinyl chloride amide terpolymer), VINAC 884® by Air Products (vinyl acetate), DOW 620® by Dow Chemical
• component (B) can also include FLEXBOND 325® (vinyl acetate- acrylic copolymer latex), LUCIDENE 243® (styrene-acrylic polymer emulsion), HYCAR 26256® (acrylic ester copolymer latex) and MORKOTE 1725® (acrylic copolymer emulsion).
• FLEXBOND 325® vinyl acetate- acrylic copolymer latex
• LUCIDENE 243® styrene-acrylic polymer emulsion
• HYCAR 26256® acrylic ester copolymer latex
• MORKOTE 1725® acrylic copolymer emulsion
• the present invention is preferably prepared by adding 75 g of component (A), preferably Hercobond 5100® or Kymene 557H® to 11.11 g an emulsion of component (B), preferably
• the coating compositions of the invention are preferably employed in the form of an aqueous admixture, preferably an aqueous emulsion, and conveniently in prefe ⁇ ed embodiments, in the form of an aqueous emulsion system resulting from the admixture of an solution of component (A) and an emulsion of component (B), and optionally water and a surfactant.
• compositions of the invention may be prepared by mixing commercially available solutions of component (A) and component (B). Because such products are commercially available, it is expedient and convenient to employ components (A) and (B) "as received” from the suppliers, although this is not required. As illustrative examples, such solutions are available in concentrations of about 12.5% ((conveniently expressed as percent solids) based on weight of resin to total weight of "as received” solution) for component (A), and concentrations of about 50% (based on weight of resin to total weight of "as received” emulsion) for component (B).
• solutions of component (A) are employed in the compositions in amounts of from about 5 to about 95%, preferably from about 50% to about 85%, more preferably about 75% (based on the total weight of all components of the composition), and emulsions of component (B) are employed in the compositions in amounts of from about 5% to about 95%, preferably from about 8% to about 50%, more preferably about 11% (based on the total weight of all components of the composition).
• Compositions of about 75% for component (A) and 11.11% for component (B) have been found to be particularly prefe ⁇ ed, with the remaining components of the composition being surfactant (preferably in an amount of about 0.06%), and water.
• the amounts of component (A) and component (B) employed in the aqueous compositions of the invention may also be expressed in terms of a ratio (A):(B), based on dry weight of polymer of component (A) to the dry weight of the polymer of component (B).
• the aqueous compositions of the invention preferably include those wherein the ratio of (A):(B) is from about 5:1 to about
• compositions of the invention may also be expressed in terms of a ratio (A):(B), based on the weight of polymer of component (A) to the weight of the polymer of component (B) (that is (A)/(B), compositions of the invention include those wherein the ratio of (A):(B) is from about 0.05 to about 19, preferably from about 4 to about 12, more preferably from about 6 to about 8, more preferably from about 6.5 to about 7.0, most preferably about 6.75.
• ratio of (A):(B) is from about 0.05 to about 19, preferably from about 4 to about 12, more preferably from about 6 to about 8, more preferably from about 6.5 to about 7.0, most preferably about 6.75.
• compositions also preferably comprise a surfactant.
• Suitable surfactants include non- ionic, anionic and cationic surfactants.
• a prefe ⁇ ed surfactant is TRITON X-100® (an octylphenoxypolyethoxyethanol nonionic surfactant) available from Union Carbide Chemicals and Plastics Company, Incorporated, Danbury, Connecticut.
• Surfactants are preferably employed in amounts of up to about 10%>, by weight.
• Prefe ⁇ ed ranges for amounts of surfactant are in the range of about 0-5%, by weight; more preferably about 0-1%, most preferably, surfactants are employed in amounts of about 0.05-0.25%) by weight, based on the total weight of the composition.
• the aqueous composition of the present invention can also include additives, such as pigments to provide colors.
• Suitable pigments include those of the organic type and those of the inorganic type.
• Preferred organic pigments include D and C Red, Nos. 10, 1 1, 12 and 13, D and C Red No. 7, D and C Red Nos. 5 and 6, D and C Red Nos.30 and 40, D and C Yellow No. 5 and D and C Red No. 2.
• Inorganic pigments include titanium dioxide, bismuth oxychloride, brown iron oxide and the red iron oxides.
• the pigments may preferably be employed in amounts of up to about 5% by weight, preferably from about 0.01% to about 5% by weight, more preferably in amounts of from about
• Drying accelerators may be added in amounts of from of up to about 5%, by weight, more preferably from about 0.01 % by weight to about 5% by weight; more preferably from about 0.5% to about 2.5% by weight.
• plasticizers and coalescing agents may also be employed. These include, for example, those disclosed in U.S. patent No. 5,716,603, which patent is hereby incorporated by reference as though set forth in full herein. Thickeners may also be employed, in amounts in a range of from about 0.01% to about
• Suitable thickeners include cellulose and derivatives, including carboxymethylcellulose and hydroxyethyl cellulose, natural gums such as ca ⁇ ageenan, pectin and xanthan gum, silicates, clays, such as laponite and synthetic polymers such as ethylene oxide, vinyl alcohol, acrylic or polyurethane-type polymers, and the like.
• fillers to the coatings to give properties of face durability, color and fire performance.
• a high amount of fillers for example, 40% or greater by weight
• Fillers also serve to "hide” the color of the substrate (in many compositions, the binder itself will not hide the substrate).
• Additives can also be employed.
• the term "additives” includes a broad range of solid and liquid materials normally added to coating compositions. Suitable additives can be readily identified and employed by those of ordinary skill in the art.
• Additives include fillers, such as silicas, clays (including Kaolin, Ball, Delaminated, Calcined, etc.); calcium carbonate, titanium dioxide, pigments, optical brighteners, etc. When employed, additives may be employed in amounts in the range of from about 0-40%, based on total weight of the composition.
• Suitable acids that can be used in combination with the composition of the present invention include, but are not limited to, fluoacid. Examples of fluoacid include, but are not limited to, fluotitanic acid, fluozirconic acid, fluosilicic acid and fluoboric acid, preferably fluotitanic acid and fluozirconic acid.
• the aqueous compositions of the present invention can be used as additives for texture in paint, additives for engineered wood products, adhesives, binders for coating, control porosity of paper and textiles, dimensional stability control for paper, wood and textiles, dye fixative, edge seal, edge seal extenders for latices, hair styling, ink vehicles, latex replacement/extender, moisture barriers, paint binders, paint primers for all surfaces, paper coating additives, paper printability additives, paper size, paper strength additives (such as wet and dry additives, permanent press resins, porosity control, precoated for coated paper, primer for printing, protective coating, replacement for latex as an internal binder in all applications, sealants, stain resistance, surface modifiers for wood, metals and glass, textile strength, textile wet processing aids, and water resistance/repellency.
• the paint product of the present invention preferably comprises a cured composition comprising components (A) and (B) in the amount of up to about 25% dry weight, more preferably up to about 20% dry weight.
• compositions of the present invention are very suitable for use as chromium-free conversion coatings for metal surfaces, for example to improve co ⁇ osion resistance and adhesion of later-applied coatings on metals such as steel, galvanized steel, aluminum, zinc-aluminum coated steel and aluminum alloys.
• later-applied coatings can include paints, inks, lacquers, plastics and other siccative coatings.
• the inventive composition can be applied as an aqueous solution and can be used alone or with additives such as one or more of acetic acid, glycolic acid, and fluoacids such as dihydrohexafluotitanic acid, dihydrohexafluosilicic acid, dihydrohexafluozirconic acid, and fluoboric acid.
• the manner of treating a metal surface can include applying an aqueous solution ot the composition (e.g., up to about 90% by weight), and drying the composition in place on the surface or rinsing as by a water bath or shower, preferably drying the composition in place on the surface.
• An acid can beneficially be supplied in the solution to produce a pH of up to about 5.
• Suitable methods of application include spraying, immersion, flow coating, roll coating, and the like.
• Co ⁇ osion resistance of the coated metals can be measured using the "Neutral Salt Spray” test; peel resistance can be measured by the "T-Bend” test, “Reverse Impact” test, or “Cross- Hatch” test.
• the MEK (methyl ethyl ketone) rub test is used to determine whether a paint has properly cured on a metal surface. These tests are detailed hereafter in the Example section. Uses of Composition in Oriented Strand Board
• aqueous composition of the present invention can also be used in oriented strand board (OSB).
• OSB oriented strand board
• Oriented strand board refers to a composite wood product based upon the use of special forms of wood flakes.
• Flake is a long, flat piece of wood that is about 1 to 4 inches (about 25-100 mm) in length. The length is in the longitudinal (grain) direction; the thickness is 0.010-0.040 inches (0.25-1.00 mm); and the width is variable.
• a flake has a length to thickness ratio of at least about 100.
• OSB is produced by mixing dried flakes, or strands with resin adhesive, wax and other additives, and then forming the strands into mats on a wide screen caul. The strands are oriented in specific directions. The mat is then pressed, at temperatures up to about 218 °C. (See Kirk- Othemer, Encyclopedia at Chemical Technology, Fourth Edition, Supplement Volume, J. Wiley ad Sons, (New York, 1998, pp 803-807).)
• OSB is a reconstituted wood product. It provides a lower cost alternative to plywood and solid sawn wood and can be produced in a wide range of densities.
• the pH of the emulsion used in oriented strand boards is at least about 4, preferably at least about 7.5, more preferably from about 8.8 to 11.5, and most preferably about 10.2.
• cellulosic products is intended to refer to products containing cellulosic fibers, such as paper, paper board, cardboard and any related product.
• the following discussion concerning paper is illustrative and applies to all related materials and processes.
• Paper is made by a process that includes preparing a paper making pulp or slurry, followed by forming the pulp or slurry into a membrane from which the paper sheet is eventually formed.
• compositions include (internal and external) sizing agents (materials) and wet and/or dry strength resins.
• internal sizing refers to sizing associated with the addition of size at the wet part of the paper making process, and thus internal sizing or sizing at the wet part of the paper making process refers to the addition of size at any of the stages of the wet part of the process.
• Surface sizing refers to the addition of materials to the formed or forming pulp as well as formed or forming paper.
• Wet and/or dry strength resins are a common additive to papermaking compositions.
• the coating of the present invention is highly suitable for ceiling boards (ceiling tiles), since the coating gives the coated board an improved face durability and cuttability.
• the coating can be used on a ceiling board of any suitable composition
• the boards for which the present coating compositions have been found to be suitable comprise fiber in an amount in the range of from about 5 to about 85% by weight, filler in an amount in the range of from about 5 to about 90%) by weight, and a binder in an amount in the range of from about 1 to about 25% by weight.
• the board is an acoustical board comprising fiber in an amount in the range of from about 20% to about 80% by weight, filler in an amount in the range of from about 20 to about 75% by weight, and a binder in an amount in the range of from about 1 to about 20% by weight.
• the acoustical board comprises from about 10 to about 80% by weight of a fiber selected from at least one of mineral wool and cellulosic fibers, a filler at an amount in the range of from about 5 to about 90%o by weight, said filler being selected from the group consisting of perlite and clay, and an organic binder at an amount in the range of from about 1 to about 20% by weight.
• Patent 4,963,603 to FELEGI et al. assigned to Armstrong World Industries, Inc., which patent is hereby incorporated by reference as though set forth in full herein.
• compositions of the invention reduce the porosity of the substrate upon coating and curing by less than about 10%, more preferably less than about 5%, more preferably, less than about 2%, and most preferably less than about 0.5%.
• Reduction in porosity can be measured by running an NRC test (described in the test section (Reverberation Room Sound Absorption Test) below) and determining the change after a coating of the invention has been applied to a substrate and cured. Using this test, the compositions of the invention should not change the rounded NRC number ol substrates coated with compositions of the invention and cured, by more than about 15, in comparison with the uncoated substrate.
• NRC test described in the test section (Reverberation Room Sound Absorption Test) below
• Cuttability The ease of the knife to cut through the board without chipping or flaking the coating. This is measured by the cuttability test. In this test, a straight cut is made in the center of the ceiling tile using a sharp razor blade. The cut is then covered with a 6 inch long piece of tape, having a width of 2", such that the length of the tape is aligned with the length of the cut and such that the width of the tape completely covers the cut, making sure to cover the end of the cut where the knife was withdrawn from the cut. The tape is then peeled off manually, while maintaining the rate of peel at a constant speed, and the number of paint chips which develop are counted. A cuttability number is then calculated : (# flakes / sq. inch) X 10.
• Coating compositions of the invention preferably have a relatively low viscosity.
• coating compositions of the invention have a viscosity of 100 cps or less, preferably 50 cps, or less and most preferably 35 cps or less, as measured on a Brookfield viscosimeter using a No. 1 spindle, unless otherwise specified in specific example, at a temperature of 25 U and spindle speed of 100 rpm to standard depth on the spindle.
• HERCOBOND 5100® alone or in combination with each other have also been found to form a clear coating which enables subsequent finish coats to hide the color of the substrate.
• compositions of the invention provide coatings wherein the L and b values (L and b being discussed in the "color section" above) are substantially unchanged after application of the coating to the substrate followed by curing of the coating.
• substantially unchanged in reference to L and b values herein is meant that the L value changes by less than about 5, preferably less than about 1 ; and the b value changes less than about 1, preferably less than about .1.
• compositions based on emulsions of copolymers of alkyl chloride and alkenes, such as copolymers of vinyl chloride and ethylene provided very good cuttability and no flaking or chipping; however, these compositions did not achieve the desired finished color in ceiling tile application (for example, there was no holdout from the primecoat, i.e., they did not hide the color of the substrate).
• polyamidoamine-based compositions provided very good scratch durability and finish color, but provided poor results with regard to cutting or flaking. It was expected that these negative or poor aspects of the individual components would be retained by the combined composition. However, contrary to expectations, these poor aspects were not exhibited, but the desirable aspects were retained.
• compositions of the invention may be applied to substrates in any suitable way, such as by coating equipment, including spraying, brushing, roller application, and the like.
• coating equipment including spraying, brushing, roller application, and the like.
• the substrates may preferably be coated by spraying.
• the coated substrate may be dried in a drying oven at a temperature in the range of about 350°F to about 460°F, preferably 350° to about 450°F. A temperature of about 450°F has been found to be particularly suitable. Alternatives such as heat lamps without the use of specialized drying ovens may be employed alternatively, or in addition thereto.
• the compositions of the invention exhibit stability over time. Thus, the compositions of the invention do not gel when stored at room temperature (20°C) in a closed, sealed container for a period of at least about 2 weeks; preferably at least about 1 month.
• composition of the present invention can also be used as binders, e.g., to adhere pigments in coating formation to the surface of papers.
• the use of the binders also provides cohesive strength to the pigment.
• the composition of the present invention is an emulsion and has a ratio of component (A) to component (B) preferably from about 5:1 to about 1 :5, more preferably from about 2 : 1 to about 1 : 1, and most preferably from about 169:1.
• the pH of the emulsion is preferably greater than about 3, more preferably greater than about 6, and most preferably greater than about 7.5.
• Samples 1-11 shown in Table 1 below. Specifically, this example illustrates properties of Samples 1-9 containing different latices, and Samples 10 and 11 containing different polymers. Samples 1 -9 are prepared as follows:
• Samples 10 and 1 1 are prepared as follows:
• Sample 10 is prepared using the procedures for preparing Samples 1-9 with the exception that Reten® 201 (dimethylamine-epichlorohydrin polymer) obtained from Hercules Incorporated, Delaware is used.
• Reten® 201 dimethylamine-epichlorohydrin polymer obtained from Hercules Incorporated, Delaware is used.
• Sample 11 is prepared using the procedures for preparing Sample 10 with the exception that Reten® 203 (polyDADMAC (diallyldimethylammonium chloride)) obtained from Hercules Incorporated, Delaware is used.
• Reten® 203 polyDADMAC (diallyldimethylammonium chloride) obtained from Hercules Incorporated, Delaware is used.
• Brookfield viscosity of each Sample is initially measured and then measured again after one week (on the eighth day) using the Brookfield programmable LV DV-II and Viscometer
• Dispersion and color of each sample is also initially observed and then observed again after one week (on the eighth day) by naked eye and recorded in Table 1.
• Application and General Observations for Aluminum and Wood A 20-g aliquot of the emulsion of each of Samples 1-11 (prepared as discussed above) is absorbed onto a 4-inch by I -inch paint roller and applied to 11 pieces of aluminum and 11 pieces of wood at the rate of 0.046 pounds per square meter.
• composition of the present invention has excellent binding properties as compared to conventional binding compositions in the art.
• a one liter of emulsion is prepared by adding 42.2 dry g of HERCOBOND® 5100 wet strength resin (obtained from Hercules Incorporated, Wilmington, DE) to 25 dry g of DOW® 620
• Control Composition Composition of Conventional Binding Composition:
• a control coating formulation is prepared by adding 0.1 part of (0.5 g) sodium polyacrylate dispersant (Dispel N40 obtained from Allied Colloids, Suffolk, VA) to 102 g of water under agitation. 100 parts of calcium carbonate (obtained from Omya Inc., Florence, VT), followed by the addition of 10 parts of a control composition (containing one liter of the emulsion prepared as described above (using HERCOBOND® 5100 and DOW® 620) at a reduced agitation rate. 0.3 parts of carboxyme hylcellulose (CMC 9M31 obtained from Hercules Incorporated, Wilmington, DE) is added and the mixture is sti ⁇ ed for several hours.
• CMC 9M31 carboxyme hylcellulose
• Brookfield viscosity of both the coating mixtures containing the composition of the present invention and the control composition are measured using a Brookfield viscometer (which is a product of Brookfield Engineering, Stoughton, MA) using a No. 5 spindle at 100 rpm of the coatings).
• the Brookfield viscosity of the coating mixture containing the composition of the present invention is 234 cps.
• the Brookfield viscosity of the coating mixture containing the composition of the control sample is 214 cps.
• Three drops of the coating mixture containing the composition of the present invention is placed on a first piece of bleached board.
• a second piece of bleach board is used to cover the first piece of bleached board to create a sandwich structure.
• a 5- lb weight is placed on the structure for about 18 hours at ambient temperature.
• Three drops of the coating mixture containing the control sample is placed on a tirst piece of bleached board.
• a second piece of bleach board is used to cover the first piece of bleached board to create a sandwich structure.
• Example 3 A 5- lb weight is placed on the structure for about 18 hours at ambient temperature. Both of the sandwich structure prepared above are then separated by hand. The structure made with the composition of the present invention requires more force to separate. The structure with the control composition is easily separated and has a fragile dried film. In contrast, the structure with the composition of the present invention has excellent adhesive properties. In addition, the film formed by the composition of the present invention is not totally dried, and thus has water-holding properties.
• Samples 1-8 in Table 2 below illustrates Neutral Salt Spray (NSS) performance and physical durability of painted metal panels.
• NSS Neutral Salt Spray
• Each of Samples 1 -5 is prepared as follows: A one liter of emulsion is prepared by adding 42.2 dry g of KYMENE® 557H wet strength resin (obtained from Hercules Incorporated, Wilmington, DE) to 25 dry g of Airflex® 4530 with mechanical sti ⁇ ing. 62.5 g of demineralized water is added to the emulsion to yield a slightly blue opaque white dispersion. The dispersion is then allowed to stir for 15 minutes at room temperature. The dispersion has a total solids of 14.6%, pH of 4.5 to 5.0, and a Brookfield viscosity of
• the dispersion (prepared as described above) is added to 0.30 weight percent of fluozirconic acid (obtained from Allied Signal).
• the amount of the dispersion used to prepare each of Samples 1-5 is: 0.7 weight %, 3.4 weight %, 6.75 weight %, 33.8 weight
• Sample 6 contains 0.30 weight %. by volume of fluozirconic acid.
• Sample 7 contains 10% by volume of Permatreat 1500 which is a chrome no-rinse treatment obtained from BetzDearborn.
• Sample 8 has 15% by volume of Permatreat 102 IB which is a non-chrome treatment obtained from BetzDearborn.
• Hot-dipped galvanized metal panels are obtained from ACT Corp and cleaned with BetzDearborn KL4010, a commercial alkaline cleaner available from BetzDearborn.
• the metal panels are rinsed with deionized water for 5 seconds, and subsequently coated with Samples 1-8 by spin coat application, followed by forced air drying.
• Duplicate panels are coated for each sample.
• the treated panels are painted with a two-coat paint typically used in coil applications, available from Akzo-Nobel.
• the primer and top coat are applied and cures according to the manufacturers specifications.
• the coated metal panels then undergo NSS testing, T-Bend, Cross-Hatch, Reverse Impact, and methyl ethyl ketone (MEK) double rub testing.
• the metal panels are observed and the results are shown in Tables 2 (NSS) and 3 (other test data).
• Neutral salt spray results are reported in Table 2 as scribe, field.
• Table 2 recites "/" for results of duplicated metal panels coated with each sample (as shown in column 5 of Table 2). Results are for duplicate panels and are rated as per ASTM D-1654 (with 10 being perfect); T-Bend data describes the tendency for paint to disadhere from a 180° bend in the metal measured according to ASTM D4145-83 (wherein OT is perfect); Cross-Hatch data describes the tendency to disadhere from areas between closely spaced lines through the paint.
• NCCA Network Association
• Samples 1-4 and 6-8 shown in Table 4 below are directed to Samples 1-4 and 6-8 shown in Table 4 below.
• the procedure for preparing Samples 1-4 is the same as Samples 1-4 in Example 3 with the exception that 0.45 weight % of fluozirconic acid is used.
• Samples 6-8 are prepared using the same procedures for preparing Samples 6-8 in Example 3.
• the data in Table 4 is for a one- coat black polyester paint obtained from PPG.
• KYMENE 557H® available from Hercules Incorporated, Wilmington, DE
• KYMENE 450® available from Hercules Incorporated, Wilmington, DE
• HERCOBOND 1000® (available from Hercules Incorporated, Wilmington, DE)
• HERCOBOND 2000® (available from Hercules Incorporated, Wilmington, DE)
• HERCOBOND 5100® (available from Hercules Incorporated, Wilmington, DE)
• PICCONAL AA101® thermoplastic resin available from Hercules Incorporated, Wilmington, DE
• PICCOTAC 95-55wk® thermoplastic resin available from Hercules Incorporated
• TACCOLYN 5001® thermoplastic resin available from Hercules Incorporated, Wilmington,
• AIRFLEX320® available from Air Products and Chemicals, Allentown, PA
• FLEXBOND 325® available from Air Products and Chemicals, Allentown, PA
• CHARTWELL® B523.6WH as an additive, available from Chartwell, International, Attleboro Falls, MASS
• HYCAR 26256 available from BF Goodrich, OHIO
• LUCIDENE® 243 available from Morton International, Chicago, IL
• LUCIDENE® 245 available from Morton International, Chicago, IL
• MORKOTE® 1725 available from Morton International, Chicago, IL
• TRITON X-100 available from Union Carbide Chemicals and Plastics Company
• testing of the different materials was performed on boards that were taken from the production line before the surface was painted with anything but after being textured or designed.
• the grade used for testing was standard grade, 0.710 inches thick SAG from the Armstrong World Industries Beaver Falls plant.
• the boards were then hand sprayed using the chemicals from the above listing, as described in Table 5, below. After spraying, the boards were put through a fabrication dryer to dry the coating (oven temp range 400-460°F).
• the boards were then finished with 2 coats of finishing paint (standard water-based paint of about 48 wt% solids for finishing ceiling tile) and oven dried at a temperature in the range of 400- 460°F, and set aside for testing.
• the testing was directed to three parameters for grading the products. They are: scratch test using the HESS rake (also referred to as a finger rake), cut test with a razor knife, and color.
• the cut and scratch tests are somewhat subjective but provide a very good feel for how the different products compare. The results are set forth in Table 5, below.
• the goal is to achieve a white value of: L from about 92 to about 93; b of about 1.6 to about 2.4, after application of the finish coats (that is, after application of finish coats over or on top of the coatings of the invention).
• the above data demonstrate that the AIRFLEX precoat (formula A2) provided the best scratch and cut numbers but did not optimize the ability of the finish coat to hide the color of the substrate when the finish coat was applied over the coating of the invention.
• the HERCOBOND 5100® (formula C9) provided good scratch numbers and good color numbers. The most promising results include those at a weight ratio of 75% HERCOBOND 5100® and 11% AIRFLEX 4530®, remainder water and surfactant (formula D2, for example).
• Example 6 The following illustrates how the coating of the invention imparts two types of improved durability on ceiling tile product: improved face durability and improved adhesion/cutting/flaking characteristics. Face durability is measured by the Hess Rake/Finger scratch (BF.5), Taber abrasion (A7), Scrubbability (BS.10), and Ball hardness (BH.10) tests. These tests simulate the repetitive motion of moving ceiling tiles out of the grid for access to heating, ventilation, electrical systems, and plumbing Adhesion/cuttmg/flakmg is measured by cuttability test or the six inch tape test, discussed above
• Example 5 the coatings of the invention were developed from coating systems which showed promise in lab testing
• One type of coating (A2), was a dilute penetrant solution of AIRFLEX 4530®, water, and TRITON X-100®
• this coating provided good face strength durability and cutting, but poor color numbers (L and b values)
• Another coating was non-diluted HERCOBOND 5100® This coating provided good face strength durability and color numbers, but poorer cutting characteristics
• the two different chemistries were then combined It was found that at a weight ratio of 75% HERCOBOND 5100® and 11% 0 AIRFLEX 4530® (remainder surfactant and water, formula D2), optimum face durability, cuttability and color numbers were achieved
• the next example illustrates scale-up for a capability study.
• the coating was substituted in place of a conventional prime paint on a production line.
• the coating was sprayed onto the board and dried on-line, then finished as normal on the fabrication line.
• the coating formulation was the same as in the lab scale tests - 75% HERCOBOND 5100®, 11.11% AIRFLEX 4530®, 0.06% TRITON X-100®, and 13.83% water.
• the application rates were as follows:
• This example illustrates that the coatings of the invention can be applied to a porous type fiber substrate (such as a ceiling tile) and impart durability properties to that substrate without sealing it off, losing porous properties (such as acoustics) or detracting from the aesthetics, while still maintaining a Class A fire performance, and yet not undesirably impacting the sag performance of the tile.
• Acoustic properties were measured by CAC (AL20), NRC (AL10), and AC (AL60) tests, while fire properties were measured by a 30/30 Tunnel test (A5.21). The results are set forth in Table 9.
• a composition of the invention (D2 in TABLE 5) was prepared. 50g of the composition was poured onto the interior bottom surface of an aluminum pie pan (9" diameter). The pie pan was then placed in a drying oven for a sufficient period of time to drive off all of the water moisture at that temperature (about 3 hours). The resultant cured coating on the bottom of the pan had a thickness of about 5-10 mils and was firmly adhered to the bottom of the pan.
• the pan with coating adhered thereto was then bent back upon itself so that the bend in bottom of the pan had an overall angle of substantially about 180°. At this extent of bending, the coating had still not delaminated or otherwise separated from the pan, and the coating exhibited substantially no visible cracking.
• the pan was then re-flattened and the bend was continued until the pan was again bent 180° from the flat configuration, in the direction opposite that of the first 180° bend (thus the total excursion, combining both bends was substantially 360°). Again, the coating had still not delaminated or otherwise separated from the pan, and the coating exhibited no visible cracking.
• Sample Preparation Employ sufficient material for at least 8' x 8' ceiling installation. Wall materials should be a sufficient amount to install in a 7.5' x 9' area when the samples are 30" wide or an 8' by 9' area when the samples are 24" wide. Samples smaller than 46ft 2 are not to be employed for this test.
• Test Parameters The type of mounting(s) employed should be consistent between samples. The following mounting systems may be employed, as long as consistent between samples being prepared:
• Test Parameters The type of grid is to be consistent between samples.
• the standard grid types are:
• the sample height should be at least 5 feet high and no greater than 8 feet high.
• the width of the sample should be at least 2 times the height but no greater than 20 feet wide. Supports for the sample and joint details should be consistent between samples.
• Wall Finishes Sufficient material to cover a 9 feet high by 10 feet wide hard reflecting surface is required. The mounting method should be consistent between samples. Sufficient fiberglass material to be installed in the ceiling of the test space to a thickness of 6 inches may be employed, if consistent between samples.
• Ceilings A minimum amount of material to cover a 15 feet by 30 feet area is required. In some cases, a 20 feet x 30 feet area may be required.
• One cycle consists of 17 hr @ 82 F/90% RH and 6 hr @ 82 F/35% RH.
• a hard bristle brush is used to scrub the board.
• Sample Preparation Submit one 2-1/2 inch x 8 inch specimen.
• test machine Universal test machine, Instron Corporation, Canton, Mass.
• a 2" diameter steel ball is forced into the surface of the specimen to a depth of 0.25" at a rate of O.lO'Vmin.
• Tunnel Test 30-30 (AS.21 ) References: TM 179 R.4 Purpose: To determine the surface flame spread characteristics of materials. Sample Preparation: Submit three 3 3 A" x 29 7/8" specimens. Test Parameters:
• TM 191 Purpose To obtain the resistance of a given material to abrasion.

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• Organic Chemistry (AREA)
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• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
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