WO2024023704A1 - Solvent-based coating composition and use thereof - Google Patents
Solvent-based coating composition and use thereof Download PDFInfo
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- WO2024023704A1 WO2024023704A1 PCT/IB2023/057540 IB2023057540W WO2024023704A1 WO 2024023704 A1 WO2024023704 A1 WO 2024023704A1 IB 2023057540 W IB2023057540 W IB 2023057540W WO 2024023704 A1 WO2024023704 A1 WO 2024023704A1
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- WO
- WIPO (PCT)
- Prior art keywords
- weight
- coating composition
- percent
- alkyd resin
- compound
- Prior art date
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- 239000008199 coating composition Substances 0.000 title claims abstract description 108
- 239000002904 solvent Substances 0.000 title claims description 12
- 238000001035 drying Methods 0.000 claims abstract description 64
- 229920000180 alkyd Polymers 0.000 claims abstract description 63
- 150000001875 compounds Chemical class 0.000 claims abstract description 36
- 239000006096 absorbing agent Substances 0.000 claims abstract description 17
- 239000011230 binding agent Substances 0.000 claims abstract description 16
- 239000003139 biocide Substances 0.000 claims abstract description 15
- 230000003115 biocidal effect Effects 0.000 claims abstract description 9
- 239000003921 oil Substances 0.000 claims description 70
- 239000000758 substrate Substances 0.000 claims description 49
- 239000000203 mixture Substances 0.000 claims description 46
- 239000002023 wood Substances 0.000 claims description 18
- 239000007787 solid Substances 0.000 claims description 16
- 238000000576 coating method Methods 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 10
- 229910017052 cobalt Inorganic materials 0.000 claims description 9
- 239000010941 cobalt Substances 0.000 claims description 9
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 9
- 239000000654 additive Substances 0.000 claims description 8
- 239000003086 colorant Substances 0.000 claims description 6
- 239000003973 paint Substances 0.000 claims description 6
- 229920005989 resin Polymers 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 239000002966 varnish Substances 0.000 claims description 5
- 210000003298 dental enamel Anatomy 0.000 claims description 4
- 239000004922 lacquer Substances 0.000 claims description 4
- 239000004793 Polystyrene Substances 0.000 claims description 3
- 238000005227 gel permeation chromatography Methods 0.000 claims description 3
- 229920002223 polystyrene Polymers 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 235000019198 oils Nutrition 0.000 description 66
- -1 glycol ether alcohols Chemical class 0.000 description 22
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 21
- 239000003960 organic solvent Substances 0.000 description 13
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 12
- 239000002253 acid Substances 0.000 description 11
- 235000014113 dietary fatty acids Nutrition 0.000 description 11
- 239000000194 fatty acid Substances 0.000 description 11
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- 150000004665 fatty acids Chemical class 0.000 description 11
- 239000011572 manganese Substances 0.000 description 11
- 238000012360 testing method Methods 0.000 description 10
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- 239000000049 pigment Substances 0.000 description 9
- 229910052791 calcium Inorganic materials 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 230000001590 oxidative effect Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000003446 ligand Substances 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical class [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 5
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical class [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 4
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 4
- 150000001412 amines Chemical class 0.000 description 4
- 150000008064 anhydrides Chemical class 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
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- 239000004611 light stabiliser Substances 0.000 description 4
- 229910052748 manganese Chemical class 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
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- FIDRAVVQGKNYQK-UHFFFAOYSA-N 1,2,3,4-tetrahydrotriazine Chemical compound C1NNNC=C1 FIDRAVVQGKNYQK-UHFFFAOYSA-N 0.000 description 3
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical compound C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 description 3
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 3
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
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- QRUDEWIWKLJBPS-UHFFFAOYSA-N benzotriazole Chemical compound C1=CC=C2N[N][N]C2=C1 QRUDEWIWKLJBPS-UHFFFAOYSA-N 0.000 description 3
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- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
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- 230000000855 fungicidal effect Effects 0.000 description 3
- ZEMPKEQAKRGZGQ-XOQCFJPHSA-N glycerol triricinoleate Natural products CCCCCC[C@@H](O)CC=CCCCCCCCC(=O)OC[C@@H](COC(=O)CCCCCCCC=CC[C@@H](O)CCCCCC)OC(=O)CCCCCCCC=CC[C@H](O)CCCCCC ZEMPKEQAKRGZGQ-XOQCFJPHSA-N 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
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- 238000009736 wetting Methods 0.000 description 3
- WXUAQHNMJWJLTG-UHFFFAOYSA-N 2-methylbutanedioic acid Chemical compound OC(=O)C(C)CC(O)=O WXUAQHNMJWJLTG-UHFFFAOYSA-N 0.000 description 2
- XMIIGOLPHOKFCH-UHFFFAOYSA-N 3-phenylpropionic acid Chemical compound OC(=O)CCC1=CC=CC=C1 XMIIGOLPHOKFCH-UHFFFAOYSA-N 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 2
- 241000273930 Brevoortia tyrannus Species 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000004606 Fillers/Extenders Substances 0.000 description 2
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 2
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- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 150000001298 alcohols Chemical class 0.000 description 2
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 2
- 239000003849 aromatic solvent Substances 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- RSOILICUEWXSLA-UHFFFAOYSA-N bis(1,2,2,6,6-pentamethylpiperidin-4-yl) decanedioate Chemical compound C1C(C)(C)N(C)C(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)N(C)C(C)(C)C1 RSOILICUEWXSLA-UHFFFAOYSA-N 0.000 description 2
- POULHZVOKOAJMA-UHFFFAOYSA-N dodecanoic acid Chemical compound CCCCCCCCCCCC(O)=O POULHZVOKOAJMA-UHFFFAOYSA-N 0.000 description 2
- 238000004817 gas chromatography Methods 0.000 description 2
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- YPFDHNVEDLHUCE-UHFFFAOYSA-N propane-1,3-diol Chemical compound OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 2
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- BGFLJYLSEGTACV-UHFFFAOYSA-L calcium;7,7-dimethyloctanoate Chemical class [Ca+2].CC(C)(C)CCCCCC([O-])=O.CC(C)(C)CCCCCC([O-])=O BGFLJYLSEGTACV-UHFFFAOYSA-L 0.000 description 1
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- 239000006224 matting agent Substances 0.000 description 1
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- NYGZLYXAPMMJTE-UHFFFAOYSA-M metanil yellow Chemical group [Na+].[O-]S(=O)(=O)C1=CC=CC(N=NC=2C=CC(NC=3C=CC=CC=3)=CC=2)=C1 NYGZLYXAPMMJTE-UHFFFAOYSA-M 0.000 description 1
- UJRDRFZCRQNLJM-UHFFFAOYSA-N methyl 3-[3-(benzotriazol-2-yl)-5-tert-butyl-4-hydroxyphenyl]propanoate Chemical compound CC(C)(C)C1=CC(CCC(=O)OC)=CC(N2N=C3C=CC=CC3=N2)=C1O UJRDRFZCRQNLJM-UHFFFAOYSA-N 0.000 description 1
- 150000004702 methyl esters Chemical class 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- JWZXKXIUSSIAMR-UHFFFAOYSA-N methylene bis(thiocyanate) Chemical compound N#CSCSC#N JWZXKXIUSSIAMR-UHFFFAOYSA-N 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
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- FTWUXYZHDFCGSV-UHFFFAOYSA-N n,n'-diphenyloxamide Chemical compound C=1C=CC=CC=1NC(=O)C(=O)NC1=CC=CC=C1 FTWUXYZHDFCGSV-UHFFFAOYSA-N 0.000 description 1
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- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 1
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- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
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- IEQIEDJGQAUEQZ-UHFFFAOYSA-N phthalocyanine Chemical compound N1C(N=C2C3=CC=CC=C3C(N=C3C4=CC=CC=C4C(=N4)N3)=N2)=C(C=CC=C2)C2=C1N=C1C2=CC=CC=C2C4=N1 IEQIEDJGQAUEQZ-UHFFFAOYSA-N 0.000 description 1
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- TVCBSVKTTHLKQC-UHFFFAOYSA-M propanoate;zirconium(4+) Chemical compound [Zr+4].CCC([O-])=O TVCBSVKTTHLKQC-UHFFFAOYSA-M 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- FYNROBRQIVCIQF-UHFFFAOYSA-N pyrrolo[3,2-b]pyrrole-5,6-dione Chemical class C1=CN=C2C(=O)C(=O)N=C21 FYNROBRQIVCIQF-UHFFFAOYSA-N 0.000 description 1
- 239000012744 reinforcing agent Substances 0.000 description 1
- 239000012260 resinous material Substances 0.000 description 1
- 239000006254 rheological additive Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 235000019719 rose oil Nutrition 0.000 description 1
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- 235000019512 sardine Nutrition 0.000 description 1
- 238000004626 scanning electron microscopy Methods 0.000 description 1
- 229940116351 sebacate Drugs 0.000 description 1
- CXMXRPHRNRROMY-UHFFFAOYSA-L sebacate(2-) Chemical compound [O-]C(=O)CCCCCCCCC([O-])=O CXMXRPHRNRROMY-UHFFFAOYSA-L 0.000 description 1
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical class [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000003549 soybean oil Substances 0.000 description 1
- 235000012424 soybean oil Nutrition 0.000 description 1
- 241000894007 species Species 0.000 description 1
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- 239000008117 stearic acid Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
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- 239000004094 surface-active agent Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 235000012222 talc Nutrition 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 239000003784 tall oil Substances 0.000 description 1
- UFDHBDMSHIXOKF-UHFFFAOYSA-N tetrahydrophthalic acid Natural products OC(=O)C1=C(C(O)=O)CCCC1 UFDHBDMSHIXOKF-UHFFFAOYSA-N 0.000 description 1
- UEUXEKPTXMALOB-UHFFFAOYSA-J tetrasodium;2-[2-[bis(carboxylatomethyl)amino]ethyl-(carboxylatomethyl)amino]acetate Chemical compound [Na+].[Na+].[Na+].[Na+].[O-]C(=O)CN(CC([O-])=O)CCN(CC([O-])=O)CC([O-])=O UEUXEKPTXMALOB-UHFFFAOYSA-J 0.000 description 1
- 239000013008 thixotropic agent Substances 0.000 description 1
- KSBAEPSJVUENNK-UHFFFAOYSA-L tin(ii) 2-ethylhexanoate Chemical compound [Sn+2].CCCCC(CC)C([O-])=O.CCCCC(CC)C([O-])=O KSBAEPSJVUENNK-UHFFFAOYSA-L 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 235000010384 tocopherol Nutrition 0.000 description 1
- 229960001295 tocopherol Drugs 0.000 description 1
- 229930003799 tocopherol Natural products 0.000 description 1
- 239000011732 tocopherol Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000010875 treated wood Substances 0.000 description 1
- 150000003852 triazoles Chemical class 0.000 description 1
- 235000013799 ultramarine blue Nutrition 0.000 description 1
- 229940005605 valeric acid Drugs 0.000 description 1
- LSGOVYNHVSXFFJ-UHFFFAOYSA-N vanadate(3-) Chemical compound [O-][V]([O-])([O-])=O LSGOVYNHVSXFFJ-UHFFFAOYSA-N 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 239000003981 vehicle Substances 0.000 description 1
- 239000000341 volatile oil Substances 0.000 description 1
- 239000008170 walnut oil Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 239000011701 zinc Chemical class 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 150000003754 zirconium Chemical class 0.000 description 1
- GVJHHUAWPYXKBD-IEOSBIPESA-N α-tocopherol Chemical compound OC1=C(C)C(C)=C2O[C@@](CCC[C@H](C)CCC[C@H](C)CCCC(C)C)(C)CCC2=C1C GVJHHUAWPYXKBD-IEOSBIPESA-N 0.000 description 1
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
- C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
- C09D167/08—Polyesters modified with higher fatty oils or their acids, or with natural resins or resin acids
Definitions
- the present disclosure is related to a coating composition, and more particularly to a solvent-based coating composition for porous substrates.
- Coatings are designed to protect and/or improve the aesthetic appearance of a substrate such as wood, concrete, cement, brick, and the like.
- stain finishes are coatings that allow retainment of the natural textural appearance of the substrate on which they are applied.
- One key attribute of stain finishes is that they are designed to avoid formation of an appreciable thick surface film on the substrate surface. They are well suited for textured, exposed surfaces such as siding, decks, steps, and the like. The ability to cover the surface without leaving a thick film on the surface minimizes the peeling and cracking that varnishes and other surface coatings can experience.
- Stain finishes can be further subdivided as transparent systems or colored systems. When applied to a porous substrate, stain finishes can protect the substrate from moisture and weather. In addition to their protective characteristics, they can be designed to change the color of the porous surface without hiding the texture or pattern of the substrate, such as showing the grain when the porous surface is wood. Nevertheless, there is room to improve features of stain finishes such as durability and resistance to exterior elements.
- the present disclosure relates to a coating composition, comprising: a binder component comprising an alkyd resin, a drying oil and a non-drying oil; wherein the coating composition optionally further comprises a drier compound, an anti-skinning compound, a UV absorber compound, and a biocide compound.
- the present disclosure also relates to a porous substrate coated at least in part with the coating composition.
- the present disclosure also relates to use of the coating composition as a coating for porous substrates in a varnish, lacquer, paint, stain, enamel, printing ink, or floor covering.
- Mw number average molecular weight
- any numerical range recited herein is intended to include all sub-ranges subsumed therein.
- a range of "1 to 10" is intended to include all sub -ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
- any endpoints of those ranges and/or numbers within those ranges can be combined within the scope of the present invention.
- maximum and minimum amounts any such amounts can be combined to specify ranges of ingredients numbers within those ranges can be combined within the scope of the present invention.
- the word “comprising” and forms of the word “comprising”, as used in this description and in the claims, does not limit the present invention to exclude any variants or additions. Additionally, although the present invention has been described in terms of “comprising”, the processes, materials, and coating compositions detailed herein may also be described as “consisting essentially of’ or “consisting of’.
- a composition or component thereof that is “substantially free of’ another component may include trace amounts and/or non-functional amounts of the component.
- a composition or component thereof e.g., primary drier
- component X e.g., cobalt
- component X may include component X in an amount no more than 1%, no more than 0.5%, no more than 0.1%, no more than 0.01%, no more than 0.001%, no more than 0.0001%, no more than 0.00001%, or no more than 0.000001% by total weight of the composition.
- a composition or component thereof that is “completely free of’ another component does not include a detectable amount of the omitted component (i.e., does not include an amount above any inherent background signal associated with the testing instrument) when analyzed using standard coating composition analysis techniques such as, for example, chromatographic techniques (e.g., thin-layer chromatography (TLC), gas chromatography (GC), liquid chromatography (LC)), or spectroscopy techniques (e.g., Fourier transform infrared (FTIR) spectroscopy).
- TLC thin-layer chromatography
- GC gas chromatography
- LC liquid chromatography
- spectroscopy techniques e.g., Fourier transform infrared (FTIR) spectroscopy.
- the terms “on”, “applied on/over”, “formed on/over”, “deposited on/over”, “overlay” and “provided on/over” a surface mean applied, formed, deposited, overlay, or provided, respectively, on but not necessarily in contact with the surface.
- a coating layer “formed over” a substrate does not preclude the presence of one or more other coating layers of the same or different composition located between the formed coating layer and the substrate.
- the present disclosure relates to a coating composition, comprising: a binder component comprising an alkyd resin; a drying oil; and a non-drying oil; wherein the coating composition optionally further comprises at least one drier compound, at least one anti-skinning compound, at least one UV absorber compound, and at least one biocide compound.
- the coating composition can be substantially free of water.
- the coating composition can exhibit favorable physical properties such as good adhesion to porous substrates and water resistance when applied to any suitable substrate, including porous substrate applications facing high temperature and humidity environmental conditions in exterior environments.
- the coating composition can exhibit weather resistance of at least 4 months and/or a track free dry time of at least 24 hours.
- the disclosed coating composition can also be readily applied and maintained.
- the disclosed coating composition is suitable, for example, for application over a porous substrate, such as wood, concrete, cement, brick, and the like.
- the term “porous substrate” refers to substrates that contain pores or interstices via which a liquid composition may penetrate the substrate surface.
- stain refers to a translucent composition that, upon application to a porous substrate, covers the substrate surface but, rather than flowing and leveling upon the surface, at least partially penetrates the pores or interstices of the substrate. Stains may also color the substrate while allowing some of the substrate’s natural color and patterns to show through. “Stains,” for purposes of the present disclosure, are to be distinguished from other coatings, such as paints, that upon application to a porous substrate, flow and level upon the substrate surface to form a continuous coating film, without significantly penetrating the substrate surface.
- the coating composition of the present disclosure can comprise a penetrating stain composition.
- penetrating refers to a composition that is suitable for application to a porous substrate wherein, after being applied, penetrates the substrate surface to such an extent that there is no significant amount of excess material remaining on the surface to be removed.
- the coating composition can be formulated as a "solvent-based” coating composition.
- solvent-based coating composition refers to a composition wherein the carrier fluid primarily comprises a “solvent medium”.
- an “organic solvent medium” refers to a liquid medium comprising at least 50 weight % organic solvent, based on the total weight of the liquid medium.
- Such liquid mediums can for example comprise at least 60 weight % organic solvent, at least 70 weight % organic solvent, at least 80 weight % organic solvent, at least 90 weight % organic solvent, or at least 95% organic solvent, based on the total weight of the liquid medium.
- Non-limiting examples of suitable organic solvents for use in the solvent medium include polar organic solvents (e.g., protic organic solvents such as glycols, glycol ether alcohols, alcohols, and volatile ketones, glycol diethers, esters, and diesters).
- polar organic solvents e.g., protic organic solvents such as glycols, glycol ether alcohols, alcohols, and volatile ketones, glycol diethers, esters, and diesters.
- Other non-limiting examples of organic solvents include aromatic and aliphatic hydrocarbons (e.g., toluene, xylene, high boiling aromatic solvents and aromatic solvent blends derived from petroleum).
- Binder Component [0025]
- the coating composition of the present disclosure can comprise a binder.
- binder refers to the material(s) in a composition that are film-forming.
- film-forming means that a material forms a film upon drying and/or curing at ambient or elevated temperature. In particular, the used binder does not form a thick film.
- the coating composition of the present disclosure can comprise a binder that comprises an alkyd resin.
- alkyd resin refers to a polyester resin that is the reaction product of a polybasic acid or anhydride and a polyhydric alcohol chemically combined with the acid of an oil fatty acid.
- the oil fatty acid can be coupled into the resin molecule by esterification during manufacture and become an integral part of the polymer.
- oil fatty acid includes drying oils, semi-drying oils, and non-drying oils, including mixtures thereof.
- the alkyd resin can undergo oxidative cure.
- oxidative cure As will be appreciated by those skilled in the art, when one or more drying oils, one or more semi-drying oils or mixtures of drying and semi-drying oils are used, the alkyd resin can undergo oxidative cure.
- a mixture of at least one drying oil and/or the semidrying oil with a non-drying oil is used, with the mixture being predominantly drying and/or semi-drying, the alkyd resin can undergo oxidative cure.
- drying and/or semi-drying means that at least about 45 percent of the oils used in the manufacture of the alkyd resin are drying and/or semi-drying. Both drying and semi-drying oils contain carboncarbon double bonds that can undergo oxidative crosslinking, whereas non-drying oils either do not contain such bonds or do not contain a sufficient number of such bonds to effect cure. The properties are primarily determined by the nature and the ratios of the alcohols and acids used and by the degree of condensation.
- Suitable alkyds include long oil, very long oil and medium oil alkyd resins such as derived from 45 to 85 percent by weight of fatty acids, preferably derived from 45 to 75 percent by weight of fatty acids.
- long oil length refers to alkyd with an oil content of between 60 and 75 percent by weight, and a fatty acid content of 57 to 70 percent by weight.
- medium oil alkyd refers to alkyd with an oil content of between 45 percent by weight and 60 percent by weight, and a fatty acid content of 42 to 57 percent by weight.
- very long oil alkyd refers to alkyd with an oil content of between 75 and 85 percent by weight, and a fatty acid content of 70 to 80 percent by weight.
- Suitable alkyd resins include those commercially available under the trade name AL-228-55 (Reacations Quimicas S.A. de C.V., Santa Catarina N.L., Mexico) and under the trade name SYNTHALAT QL 1910 (Synthopol Chemie, Buxtehude, Germany).
- Non-limiting examples of drying and semi-drying oils suitable for use in preparing the alkyd resin included in the coating composition of the present disclosure include castor oil, dehydrated castor oil, cottonseed oil, fish oil, linseed oil, menhaden oil, oiticica oil, palm kernel oil, perilla oil, safflower oil, sardine oil, soybean oil, sunflower oil, tall oil, Tung oil, walnut oil, white oil, and process oils, essential oils, such as lavender oil, rose oil and pine oil, silicone oil, and mixtures thereof.
- non-drying oils include, without limitation, valeric acid, heptanoic acid, 2-ethyl hexanoic acid, pelargonic acid, isononanoic acid, lauric acid, stearic acid, hydrocarbon/mineral oils, such as paraffin oil, almond oil, babassu oil, baobab oil, coconut oil, macadamia oil, nahar seed oil, olive oil, peanut oil, and branched fatty acids containing 18 carbon atoms.
- the non-drying oil can include the oil commercially available under the trade name CALSOL P910 (R.E. Carroll, Inc., Ewing, NJ). Predominantly drying/semi-drying oils are often more appropriate for use in preparing the alkyd resin.
- Suitable polyhydric alcohols that can be used in forming an alkyd resin present in the coating composition of the present disclosure include, without limitation, glycerol, neopentyl glycol, cyclohexanedimethanol, ethylene glycol, propylene glycol, pentaerythritol, di-pentaerythritol, neononyl glycol, diethylene glycol, dipropylene glycol, trimethylene glycol, trimethylolpropane, dipentaerythritol, tripentaerythritol, and mixtures thereof.
- Suitable polybasic acids/anhydrides that can be used in forming such alkyd resins include, without limitation, polycarboxylic acids and anhydrides thereof.
- suitable polycarboxylic acids include phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, adipic acid, azelaic acid, glutaric acid, 3,3-diethylglutaric acid, malonic acid, pimelic acid, sebacic acid, suberic acid, succinic acid, 2,2-dimethylsuccinic acid, 2-methylsuccinic acid, dodecenylsuccinic acid, itaconic acid, fumaric acid, maleic acid, citraconic acid, diethyl maleic acid, trimellitic acid, and mixtures thereof; the anhydrides of those polybasic acids are also suitable.
- Alkyd resin may contain a compound comprising at least one hydroxy functionality and at least an acid functionality.
- Non-limiting examples of the compound include dimethylol alkane acids and trimethylol alkane acids. Further nonlimiting examples of the compound include dimethylol propionic acid, 3-hydroxy- 2,2-bis(hydroxymethyl)propanoic acid, dimethylol butyric acid, 5,5-dimethylol-6- hydroxyhexanoic acid, dihydroxybenzoic acid, and mixtures thereof.
- the alkyd resin may have a high solid content.
- the term “high solids” and like terms refer to those resin compositions having a total solids content of at least 50 percent by weight, such as at least 75 percent by weight, based on the total weight of the resin composition, whereby the solids content is defined as non-volatile solids content or non-volatile matter (or nvm).
- the term “solids content” refers to the proportion of non-volatile material contained in the alkyd resin. It is the material left after the volatile solvent (which serves as a carrier or vehicle for the solid content) has vaporized. The solids content may be determined by evaporating to dryness a weighed sample of solution and determining the percent residue. The solids content can be measured as described in ISO 3251:2019.
- the alkyd resin may be a pourable resin at one hundred percent solids.
- pourable means that the viscosity of a material is such that the material is capable of flowing down the container in which it is stored, when the container is tipped over.
- the alkyd resin may preferably have low viscosity, wherein the low intrinsic viscosity of the alkyd resin means that less solvent is needed to reach an acceptable application viscosity.
- the alkyd resin can exhibit a viscosity, for example, within a range from 200 cP to 10,000 cP, from 200 cP to 8,000 cP, from 500 cP to 6,000 cP, from 500 cP to 5,000 cP, from 800 cP to 5,000 cP, or from 800 cP to 4,000 cP.
- the viscosity can be measured using a Brookfield RVDV-E viscometer, with a No. 2 spindle, at speed of 20 rpm, and a temperature of 25° C.
- the alkyd resin may have a number average molecular weight (Mn) and/or weight average molecular weight (Mw) of at least 2,000, and in some cases at least 3,000.
- the alkyd resin may have a Mw.
- the alkyd resin may have a Mn and/or Mw of up to 50,000, such as up to 40,000, or up to 30,000, or up to 20,000, or up to 15,000, or up to 10,000, or up to 9,000, or up to 8,000, or up to 7,000.
- the Mn of the alkyd resin can be at least 2,000, but not exceeding 30,000.. Such molecular weights can enable effective drying times of the alkyd due to relatively fewer oligomer species present.
- the Mn and/or Mw of the copolymer may vary in any range of values inclusive of those stated above.
- the Mn and Mw can be determined from gel permeation chromatography using polystyrene standards and have the unit g/mol.
- the polydispersity index (PDI) of the alkyd resin may be less than 10, such as less than 7.5, or less than 5.
- polydispersity index is determined from the following equation: (weight average molecular weight (Mw)/number average molecular weight (Mn)).
- Mw weight average molecular weight
- Mn number average molecular weight
- a monodisperse polymer has a PDI of 1.0.
- the alkyd resin may have an acid value of less than 70 mg KOH/g, such as less than 50 mg KOH/g, or less than 20 mg KOH/g.
- the acid value is defined as mg of potassium hydroxide required to neutralize 1 g of resin.
- 0.1 M KOH in ethanol may be employed.
- the alkyd resin may be a long oil length alkyd with an oil content of between 60 and 75 percent by weight, a fatty acid content of 57 to 70 percent by weight, a number average molecular weight (Mn) from 2,000 to 10,000, an average molecular weight (Mw) from 15,000 to 30,000, an acid value of less than 20 mg KOH/g, a viscosity value from 500 cP to 5,000 cP, and/or may include from 65 to 80 % solids.
- the alkyd resin may be a medium oil length alkyd with an oil content of between 45 and 60 percent by weight, a fatty acid content of 42 to 57 percent by weight, an acid value of less than 15 mg KOH/g, a viscosity value from 800 cP to 4,000 cP, and/or may include from 51 to 65 % solids.
- the alkyd resin can be present in the coating composition of the present disclosure in an amount of 10 percent by weight or more, 15 percent by weight or more, 16 percent by weight or more, 17 percent by weight or more, 18 percent by weight or more, 19 percent by weight or more, or 20 percent by weight or more, including from 10 to 35 percent by weight, or from 15 to 30 percent by weight, from 15 to 25 percent by weight, or a range using any combination of the foregoing values as endpoints, with weight percent being based on the total weight of the coating composition.
- the coating composition of the present disclosure may comprise a drying oil and/or semi-drying oil and/or non-drying oil.
- the drying and/or semi-drying oil and/or non-drying oil can be a separate component from the alkyd resin and is in addition to the oil that is used to prepare the alkyd resin, as previously described. Any of the drying, semi -drying and non-drying oils previously described as being suitable for use in preparing the alkyd resin are also suitable for use in the present composition as the oil with which the alkyd resin is mixed.
- the coating composition of the present disclosure may comprise at least one drying oil and/or at least one non-drying oil in addition to the oil that is used to prepare the alkyd resin.
- the at least one drying oil may be linseed oil, tung oil, fish oil, menhaden fish oil, safflower oil, castor oil, and mixtures thereof.
- drying and/or semi-drying and/or non-drying oils can be present in the coating composition of the present disclosure in an amount of 5 to 55 percent by weight, or from 5 to 45 percent by weight, or from 7 to 42 percent by weight, with weight percent being based on the total weight of the coating composition.
- the coating composition of the present disclosure can also comprise a drying agent to promote the oxidative cure of binder components present in the composition.
- a drier compound can be employed for this purpose.
- the drying agent can comprise a primary drier, and at least one auxiliary drier.
- drier refers to organometallic compounds that are soluble in organic solvents and binders. They can be added to unsaturated oils and binders in order to appreciably reduce their drying times, i.e., the transition of their films to the solid phase. Driers are available either as solids or in solution.
- Non-limiting examples of suitable primary driers include, but are not limited to, various salts of cobalt, zirconium, cerium, calcium, zinc, and manganese. Metal salts of carboxylates having various chain lengths are particularly suitable.
- the primary drier may comprise an iron ligand complex and/or a manganese ligand complex.
- the iron ligand complex and/or a manganese ligand complex may be substantially free of cobalt.
- the primary drier may be substantially free of cobalt.
- the primary drier can comprise the drier commercially available under the trade name BORCHI DRAGON (Borchers Americas Inc, Westlake, OH).
- the primary drier may comprise less than 0.001 percent by weight of cobalt, such as less than 0.0001 percent by weight of cobalt, such as less than 0.00001, 0.000001 or 0.0000001 percent by weight of cobalt based on the total solid weight of the oxidatively drying binder.
- the primary drier may be completely free of cobalt.
- Non-limiting examples of suitable auxiliary driers include calcium, barium, potassium, and lithium metal soaps.
- metal soap refers to a metal salt of an organic acid such as a calcium salt or a zirconium salt of an organic acid.
- suitable calcium (Ca) salts of an organic acid include, but are not limited to, calcium carboxylates such as calcium neodecanoates, calcium octoates, calcium tallates, calcium linoleates, calcium naphthenates, and mixtures thereof.
- zirconium (Zr) salts of an organic acid include, but are not limited to, zirconium carboxylates such as zirconium propionate, zirconium neodecanoates, zirconium octoates, zirconium naphthenates, and mixtures thereof.
- the drier may comprise a mixture of iron ligand complex and/or a manganese ligand complex as a primary drier and a calcium carboxylate as an auxiliary drier.
- any suitable amount of such primary drier may be employed.
- the primary drier can be present an amount ranging of 0.01 to 5.0 percent by weight, such as 0.1 to 3.0 percent by weight, such as 0.5 to 2.0 percent by weight with weight percent being based on total weight of the coating composition.
- any suitable amount of such at least one auxiliary drier may be employed.
- the at least one auxiliary drier can be present an amount ranging of 0.01 to 5.0 percent by weight, such as 0.5 to 3.0 percent by weight, such as 1.0 to 2.0 percent by weight with weight percent being based on total weight of the coating composition.
- the coating composition may comprise an anti-skinning compound.
- suitable anti-skinning compound include methyl ethyl ketoxime, n-butyl ketoxime, cyclohexane ketoxime, methyl isobutyl ketoxime, di-methyl ketoxime, 2-cyclohexylphenol, 4-cyclohexylphenol, mono-tertiary butylhydroquinone, diethyl hydroxylamine, 2-[(l-methylpropyl)amino]ethanol, 3- methoxybutyl acetate, triphenyl phosphite, tocopherol, hydroxy acetone, tin octoate, isoascorbic acid, and 2,4-pentadione and the like, and mixtures thereof.
- any suitable amount of such anti-skinning compound may be employed.
- the anti-skinning compound is present an amount of 0.01 to 5.0 percent by weight, such as 0.05 to 3.0 percent by weight, such as 0.1 to 2.0 percent by weight, such as 0.1 to 1.0 percent by weight with weight percent being based on total weight of the coating composition.
- the coating composition of the present disclosure may comprise a UV absorber compound.
- UV absorber refers to compositions which absorb wavelengths typically associated with binder degradation, for example, wavelengths of from 250 to 400 nm.
- the UV absorber can avoid absorbing, or absorbs an insignificant amount of, visible light, e.g., wavelengths of from 400 to 700 nm, and can be non-opacifying.
- the coating composition of the present disclosure may comprise at least one UV absorber such as a benzotriazole (including derivatives thereof), triazine (including derivatives thereof), triazole (including derivatives thereof), hindered amine light stabilizer (HALS, including derivatives thereof), oxanilide (including derivatives thereof), benzophenone (including derivatives thereof), and mixtures thereof.
- a UV absorber such as a benzotriazole (including derivatives thereof), triazine (including derivatives thereof), triazole (including derivatives thereof), hindered amine light stabilizer (HALS, including derivatives thereof), oxanilide (including derivatives thereof), benzophenone (including derivatives thereof), and mixtures thereof.
- Non-limiting examples of suitable benzotriazole UV absorbers include 2- (2'-hydroxy-5'-methylphenyl)-benzotriazole, 2-(3',5'-di-tert-butyl-2'- hydroxyphenyl)-5-chlorobenzotriazole, 2(2'-hydroxy-3',5'-di-tert- amylphenyl)benzotriazole, benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(l,l- dimethylethyl)-4-hydroxy-,C7-9-branched alkyl esters, 2-(3',5'-bis(l-methyl-l- phenylethyl)-2'-hydroxyphenyl)benzotriazole, 2-(2-hydroxy-3- dimethylbenzylphenyl-5-(l,l,3,3-tetramethylbutyl))-2H-benzotriazole, iso-octyl-3- (3-(
- the benzotriazole UV absorber may be Benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)- 5-(l,l-dimethylethyl)-4-hydroxy-, methyl ester.
- the UV absorber can comprise the composition commercially available under the trade name TINUVIN 1130 (BASF, Ludwigshafen, Germany).
- HALS hindered amine light stabilizer
- suitable hindered amine light stabilizer include Bis-(l-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate, Bis-(N- methyl,2,2,6,6-tetramethyl-4-piperidinyl) sebacate, Methyl-(N-methyl,2,2,6,6- tetramethyl-4- piperidinyl) sebacate, Methyl l,2,2,6,6-pentamethyl-4-piperidyl sebacate, Bis(l,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis (2,2,6,6-tetramethyl-l- (octyloxy)-4-piperidinyl) ester, Bis (1, 2, 2, 6, 6-pentamethyl-4-piperidinyl)-[[3, 5-bis (1, 1 -dimethylethyl) -4- hydroxyphenyl] methyl] butyl mal
- Non-limiting examples of suitable triazine UV absorbers include 2-(4-(2- hydroxy-3-tridecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6-bis (2,4,dimethylphenyl)- 1 ,3,5-triazine, 2-(4-(2-hydroxy-3 -dodecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6- bis(2,4-dimethylphenyl)-l ,3,5-triazine, and 2-(4-(2-hydroxy-3-(2'-ethyl)hexyl)oxy)- 2-hydroxyphenyl)-4,6-bis(2,4-dimethylphenyl)-l,3,5-triazine.
- Triazine UV absorbers can include a mixture of 2-(4-(2-hydroxy-3-tridecyl oxypropyl)oxy)-2- hydroxyphenyl)-4,6-bis (2, 4, dimethylphenyl)- 1, 3, 5-triazine and 2-(4-(2-hydroxy-3- dodecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6-bis(2,4-dimethylphenyl)-l,3,5- triazine.
- the UV absorber may be provided in a suitable carrier, such as an organic solvent.
- the organic solvent can include ketones, acetates, esters, glycol ethers, aliphatic hydrocarbons, aromatic hydrocarbons, and mixtures thereof.
- suitable UV stabilizers include products under the tradenames CYASORB (Solvay, Butte, MT), UVINUL (BASF, Ludwigshafen, Germany), and TINUVIN (BASF, Ludwigshafen, Germany).
- the UV absorber can be present in the coating compositions of the present invention in an amount of 0.01 to 9.0 percent by weight, such as 0.1 to 6.0 percent by weight, such as 0.5 to 5.0 percent by weight, with weight percent being based on the total weight of the coating composition.
- the coating composition of the present disclosure can comprise at least one biocide compound.
- a biocide can be added as a precautionary measure to preclude potential problems associated with yeast, mold, aerobic bacteria, and other biological products.
- the biocide can provide antimicrobial protection of the coating composition in its "dry film” form after use.
- suitable biocides include, but are not limited to, organotin biocides; methylene thiocyanate biocides; isothiazolinones biocides; nitro-biocides; carbamate biocides, chlorinated and brominated compounds; hydrazine derivatives; and combinations thereof.
- the biocide can be present in the coating composition of the present disclosure in an amount of 0.01 to 4 percent by weight, such as 0.05 to 3.0 percent by weight, such as 0.1 to 2.0 percent by weight, such as 0.5 to 1.5, with weight percent being based on the total weight of the coating composition.
- the coating composition may include other additives, such as catalysts, other pigments and pigment pastes, dyes, fillers, stabilizers, thixotropic agents, antisagging agents, anti- oxidants, antifouling agents, anti-gelling agents, bactericides, fungicides, algaecides, insecticides, anti-settling agents, antifoaming agents, slip agents, flow and levelling agents, rheological modifiers, photo-initiators, corrosion inhibitors, matting agents, waxes, flame retardants, anti-static agents, loss of dry inhibitors, optical brighteners, adhesion promoters, diluents, elastomers, plasticizers, air release agents, desiccants, anti-crater additives, reinforcing agents, dispersing aids, substrate wetting agents, odorants, corrosion-inhibitive pigments, additional hardeners, and/or additional curable compounds.
- additives such as catalysts, other pigments and pigment pastes, dyes, fillers, stabilizer
- the coating composition may include surface active agents, such as an anionic, cationic or nonionic surfactant or dispersing agent.
- surface active agents such as an anionic, cationic or nonionic surfactant or dispersing agent.
- Other resinous materials can be utilized in conjunction with the aforementioned alkyd resins.
- the metal drier combinations and optionally colorants, pigments and extenders and optionally other additives may be formulated into the coating compositions by mixing and, if appropriate, dispersing and grinding with the liquid binder.
- Various additives, when used, can comprise no more than about 30 percent by weight, such as no more than about 10 percent by weight, of the present coating composition.
- the coating composition may comprise further components, such as colorants.
- the colorant component may comprise an inorganic or organic, transparent or nontransparent pigment.
- Non-limiting examples of such pigments include titanium dioxide, iron oxides, mixed metal oxides, bismuth vanadate, chromium oxide green, ultramarine blue, carbon black, lampblack, monoazo and disazo pigments, anthraquinones, isoindolinones, isoindolines, quinophthalones, phthalocyanine blues and greens, dioxazines, quinacridones and diketo-pyrrolopyrroles; and extender pigments including silica, barium sulfate, magnesium silicate, calcium silicate, mica, micaceous iron oxide, calcium carbonate, zinc oxide, aluminium hydroxide and aluminium silicate, gypsum, feldspar, talcum, kaolin, and mixtures thereof.
- the amount of pigment that can be used to form the coating composition can vary depending on the particular composition
- the colorant can be present in the coating composition of the present disclosure in an amount of 0.01 to 10 percent by weight, such as 0. 1 to 8.0 percent by weight, such as 0.5 to 5.0 percent by weight, with weight percent being based on the total weight of the coating composition.
- the coating composition may be formulated as a one package coating composition, also referred herein as a one-component (I K) coating composition.
- a “1 K” or “one package” composition refers to a composition wherein all of the components are maintained in the same container after manufacture, during storage, etcetera.
- the coating composition can be formulated as varnish, lacquer, paint, stain, enamel, printing ink, or floor covering and similar compositions which contain auto-oxidizable alkyd resins.
- the components of the coating composition of the present disclosure can be blended together to form the coating compositionby any means known in the art. For example, the components may be blended together using a Cowles blade or any known blade or a Hockmeyer mill or any known mill in the coating industry.
- the coating composition of the present disclosure is suitable for application to, for example, porous substrates, such as paper, cardboard, particle board, fiber board, concrete, cement, brick, wood and wood products.
- Wood substrates are particularly suitable.
- Various woods can be stained with the present coating composition, including, for example, oak, cedar, maple, pine, or any known wood substrate. These types of woods are often used in the preparation of, for example, kitchen cabinets, bath cabinets, tables, desks, dressers, and other furniture or floors.
- the present disclosure also relates to a porous substrate coated at least in part with the coating composition.
- the coating composition may also color the substrate, while allowing some of the substrate’s natural color and grain to show through.
- the porous substrate may be wood.
- the coating composition of the present disclosure can be applied to the substrate by any known method in the art.
- Non-limiting examples of such application methods include spreading (e.g. with paint pad or doctor blade, or by brushing or rolling, or wiping), spraying (e.g. air-fed spray, airless spray, hot spray, and electrostatic spray), and flow coating (e.g. dipping, curtain coating, roller coating, and reverse roller coating). Multiple layers can be applied.
- the present coating composition can then be cured by initiating oxidative cure of the binder components. Such oxidative cure can be accomplished by allowing the coated substrate to be exposed to ambient or elevated temperature conditions.
- a substrate partially or fully coated with a coating composition of the present disclosure may be pre -treated before application of the coating composition.
- the substrate may additionally or alternatively be post-treated after application of the coating composition, for example with any other compositions.
- the coating composition can be applied and cured at ambient temperature conditions in the range of from -10°C to 50°C. Curing of the coating compositions can proceed rapidly, and in general can take place at a temperature within the range of from -10°C to +50°C, such as from 0°C to 40 °C, such as from 3 to 25°C. However, the coating compositions may be cured by additional heating.
- the coating composition may be used as a single coating, a top coating, a base coating in a two-layered system, as a layer of a multi-layered system including a clear top coating composition, colorant layer, and base coating composition, and/or as a primer layer.
- the present disclosure also relates to the use of the coating compositions as a coating for porous substrates in a varnish, lacquer, paint, stain, enamel, printing ink or floor covering.
- Example coating compositions were formulated within the parameters shown in Tables 1A - 1C. Component amounts are listed by % wt. The Mw values for the alkyd resins were determined via gel permeation chromatography using polystyrene standards.
- the example coating compositions also included a hydroxyphenyl benzotriazole UV absorber component (included at 0.1 to 4.5 % wt.) and a hindered amine light stabilizer (HALS) (included at 0.1 to 4.5 % wt.).
- HALS hindered amine light stabilizer
- Solvent comprised naphtha, toluene, and/or xylene.
- Solvent comprised naphtha, toluene, and/or xylene.
- Solvent comprised naphtha, toluene, and/or xylene.
- Examples 1 and 5 did not include a drying oil component.
- Example 8 included an acrylic resin (an IB MA resin commercially available under the trade name PARALOID B67 (100%) (Dow Chemical Company, Midland, MI)) rather than an alkyd resin.
- the example coating compositions were applied to cumaru wood and subjected to a weather resistance test (according to EN 927-3:2012), a drying test (according to ASTM D 1640-03(09)), a wood absorption test (based on scanning electron microscopy evaluation of cross sections of treated wood substrate), and natural appearance testing (according to ASTM D 3964-10(2020)). The results are summarized in Tables 2A and 2B. Negative/f ailed results are shown in italics.
- Example 1 failed to be adequately absorbed by the wood substrate and produced a glossy film appearance rather than a desired natural wood appearance.
- Example 5 failed to dry during the drying test, failed the absorption test, and produced a semi-gloss film appearance rather than a desired natural wood appearance.
- Example 8 failed to dry during the drying test, failed the absorption test, and produced a semi-gloss film appearance rather than a desired natural wood appearance.
- Examples 1 and 5 did not include a drying oil component.
- Example 8 did include a drying oil component, but included an acrylic resin rather than an alkyd resin.
- the Examples that included both a drying oil and an alkyd resin exhibited effective weather resistance, drying times, and wood absorption, and also resulted in a natural appearance when applied to a wood substrate.
- Examples 3 and 4 exhibited effective weather resistance
- Examples 2, 6, and 7 exhibited superior weather resistance. This may be due to the relatively higher alkyd resin allowances of Examples 2, 6, and 7 relative to Examples 3 and 4.
- a coating composition with an alkyd resin content of 17 percent by weight or more, 18 percent by weight or more, 19 percent by weight or more, or 20 percent by weight or more can exhibit particularly effective weather resistance.
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Abstract
A coating composition comprises: (i) a binder component comprising an alkyd resin, (ii) a drying oil separate from the alkyd resin; and (iii) a non-drying oil separate from the alkyd resin; wherein the coating composition optionally further comprises (iv) a drier compound, (v) an anti-skinning compound, (vi) a UV absorber compound, and/or (vii) a biocide compound.
Description
SOLVENT-BASED COATING COMPOSITION AND USE THEREOF
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of Unites States Provisional Patent Application Serial No. 63/369,310, filed July 25, 2022, and titled “COATING COMPOSITIONS AND USE THEREOF,” which is incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure is related to a coating composition, and more particularly to a solvent-based coating composition for porous substrates.
BACKGROUND
[0003] Coatings are designed to protect and/or improve the aesthetic appearance of a substrate such as wood, concrete, cement, brick, and the like. In particular, stain finishes are coatings that allow retainment of the natural textural appearance of the substrate on which they are applied. One key attribute of stain finishes is that they are designed to avoid formation of an appreciable thick surface film on the substrate surface. They are well suited for textured, exposed surfaces such as siding, decks, steps, and the like. The ability to cover the surface without leaving a thick film on the surface minimizes the peeling and cracking that varnishes and other surface coatings can experience.
[0004] Stain finishes can be further subdivided as transparent systems or colored systems. When applied to a porous substrate, stain finishes can protect the substrate from moisture and weather. In addition to their protective characteristics, they can be designed to change the color of the porous surface without hiding the texture or pattern of the substrate, such as showing the grain when the porous surface is wood. Nevertheless, there is room to improve features of stain finishes such as durability and resistance to exterior elements.
SUMMARY
[0005] The present disclosure relates to a coating composition, comprising: a binder component comprising an alkyd resin, a drying oil and a non-drying oil; wherein the coating composition optionally further comprises a drier compound, an anti-skinning compound, a UV absorber compound, and a biocide compound.
[0006] The present disclosure also relates to a porous substrate coated at least in part with the coating composition.
[0007] The present disclosure also relates to use of the coating composition as a coating for porous substrates in a varnish, lacquer, paint, stain, enamel, printing ink, or floor covering.
DETAILED DESCRIPTION
Selected Terms & Definitions
[0008] For purposes of the following detailed description, it is to be understood that the disclosed coating composition and related methods may assume various alternative variations and step sequences, except where expressly specified to the contrary.
[0009] Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term “about” unless specified otherwise. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[0010] The term “about” may be taken to mean an amount, value, or condition that deviates by 10% or less, 5% or less, 1% or less, 0.1% or less, or 0.01% or less from the stated amount, value, or condition. For example, a recited number average
molecular weight (Mw) of “about” X includes Mw values that differ from X (higher or lower) by up to 10%, up to 5%, up to 1%, up to 0.1%, or up to 0.01%.
[0011] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0012] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub -ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
[0013] When ranges are given, any endpoints of those ranges and/or numbers within those ranges can be combined within the scope of the present invention. When maximum and minimum amounts are given, any such amounts can be combined to specify ranges of ingredients numbers within those ranges can be combined within the scope of the present invention. The word “comprising” and forms of the word “comprising”, as used in this description and in the claims, does not limit the present invention to exclude any variants or additions. Additionally, although the present invention has been described in terms of “comprising”, the processes, materials, and coating compositions detailed herein may also be described as “consisting essentially of’ or “consisting of’.
[0014] In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. For example, and without limitation, this application refers to coating compositions that comprise an “oil”. Such references to “an oil” are meant to encompass compositions comprising one oil as well as compositions that comprise more than one oil, such as compositions that comprise two or more oils.
[0015] Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims.
[0016] A composition or component thereof that is “substantially free of’ another component may include trace amounts and/or non-functional amounts of the
component. For example, a composition or component thereof (e.g., primary drier) that is “substantially free of’ component X (e.g., cobalt) may include component X in an amount no more than 1%, no more than 0.5%, no more than 0.1%, no more than 0.01%, no more than 0.001%, no more than 0.0001%, no more than 0.00001%, or no more than 0.000001% by total weight of the composition.
[0017] A composition or component thereof that is “completely free of’ another component does not include a detectable amount of the omitted component (i.e., does not include an amount above any inherent background signal associated with the testing instrument) when analyzed using standard coating composition analysis techniques such as, for example, chromatographic techniques (e.g., thin-layer chromatography (TLC), gas chromatography (GC), liquid chromatography (LC)), or spectroscopy techniques (e.g., Fourier transform infrared (FTIR) spectroscopy).
[0018] As used herein, the terms “on”, “applied on/over”, “formed on/over”, “deposited on/over”, “overlay” and “provided on/over” a surface mean applied, formed, deposited, overlay, or provided, respectively, on but not necessarily in contact with the surface. For example, a coating layer “formed over” a substrate does not preclude the presence of one or more other coating layers of the same or different composition located between the formed coating layer and the substrate.
Coating Composition Overview
[0019] The present disclosure relates to a coating composition, comprising: a binder component comprising an alkyd resin; a drying oil; and a non-drying oil; wherein the coating composition optionally further comprises at least one drier compound, at least one anti-skinning compound, at least one UV absorber compound, and at least one biocide compound.
[0020] The coating composition can be substantially free of water.
[0021] The coating composition can exhibit favorable physical properties such as good adhesion to porous substrates and water resistance when applied to any suitable substrate, including porous substrate applications facing high temperature and humidity environmental conditions in exterior environments. The coating composition can exhibit weather resistance of at least 4 months and/or a track free dry time of at least 24 hours. The disclosed coating composition can also be readily applied and maintained.
[0022] The disclosed coating composition is suitable, for example, for application over a porous substrate, such as wood, concrete, cement, brick, and the like. As used herein, the term “porous substrate” refers to substrates that contain pores or interstices via which a liquid composition may penetrate the substrate surface. As used herein, the term “stain” refers to a translucent composition that, upon application to a porous substrate, covers the substrate surface but, rather than flowing and leveling upon the surface, at least partially penetrates the pores or interstices of the substrate. Stains may also color the substrate while allowing some of the substrate’s natural color and patterns to show through. “Stains,” for purposes of the present disclosure, are to be distinguished from other coatings, such as paints, that upon application to a porous substrate, flow and level upon the substrate surface to form a continuous coating film, without significantly penetrating the substrate surface.
[0023] The coating composition of the present disclosure can comprise a penetrating stain composition. As used herein, the term “penetrating” refers to a composition that is suitable for application to a porous substrate wherein, after being applied, penetrates the substrate surface to such an extent that there is no significant amount of excess material remaining on the surface to be removed.
[0024] The coating composition can be formulated as a "solvent-based" coating composition. As used herein, the term “solvent-based” coating composition refers to a composition wherein the carrier fluid primarily comprises a “solvent medium”. As used herein, an “organic solvent medium” refers to a liquid medium comprising at least 50 weight % organic solvent, based on the total weight of the liquid medium. Such liquid mediums can for example comprise at least 60 weight % organic solvent, at least 70 weight % organic solvent, at least 80 weight % organic solvent, at least 90 weight % organic solvent, or at least 95% organic solvent, based on the total weight of the liquid medium. Non-limiting examples of suitable organic solvents for use in the solvent medium include polar organic solvents (e.g., protic organic solvents such as glycols, glycol ether alcohols, alcohols, and volatile ketones, glycol diethers, esters, and diesters). Other non-limiting examples of organic solvents include aromatic and aliphatic hydrocarbons (e.g., toluene, xylene, high boiling aromatic solvents and aromatic solvent blends derived from petroleum).
Binder Component
[0025] The coating composition of the present disclosure can comprise a binder. As used herein, the term "binder" refers to the material(s) in a composition that are film-forming. As used herein, "film-forming" means that a material forms a film upon drying and/or curing at ambient or elevated temperature. In particular, the used binder does not form a thick film.
[0026] The coating composition of the present disclosure can comprise a binder that comprises an alkyd resin. As used herein, the term "alkyd resin" refers to a polyester resin that is the reaction product of a polybasic acid or anhydride and a polyhydric alcohol chemically combined with the acid of an oil fatty acid. The oil fatty acid can be coupled into the resin molecule by esterification during manufacture and become an integral part of the polymer. As used herein, the term "oil fatty acid" includes drying oils, semi-drying oils, and non-drying oils, including mixtures thereof.
[0027] The alkyd resin can undergo oxidative cure. As will be appreciated by those skilled in the art, when one or more drying oils, one or more semi-drying oils or mixtures of drying and semi-drying oils are used, the alkyd resin can undergo oxidative cure. Similarly, when a mixture of at least one drying oil and/or the semidrying oil with a non-drying oil is used, with the mixture being predominantly drying and/or semi-drying, the alkyd resin can undergo oxidative cure.
[0028] As used herein, the terms "predominantly drying" and/or "semi-drying" means that at least about 45 percent of the oils used in the manufacture of the alkyd resin are drying and/or semi-drying. Both drying and semi-drying oils contain carboncarbon double bonds that can undergo oxidative crosslinking, whereas non-drying oils either do not contain such bonds or do not contain a sufficient number of such bonds to effect cure. The properties are primarily determined by the nature and the ratios of the alcohols and acids used and by the degree of condensation.
[0029] Suitable alkyds include long oil, very long oil and medium oil alkyd resins such as derived from 45 to 85 percent by weight of fatty acids, preferably derived from 45 to 75 percent by weight of fatty acids. As used herein, the term "long oil length" refers to alkyd with an oil content of between 60 and 75 percent by weight, and a fatty acid content of 57 to 70 percent by weight. As used herein, the term “medium oil alkyd” refers to alkyd with an oil content of between 45 percent by weight and 60 percent by weight, and a fatty acid content of 42 to 57 percent by
weight. As used herein, the term “very long oil alkyd” refers to alkyd with an oil content of between 75 and 85 percent by weight, and a fatty acid content of 70 to 80 percent by weight. Suitable alkyd resins include those commercially available under the trade name AL-228-55 (Reacciones Quimicas S.A. de C.V., Santa Catarina N.L., Mexico) and under the trade name SYNTHALAT QL 1910 (Synthopol Chemie, Buxtehude, Germany).
[0030] Non-limiting examples of drying and semi-drying oils suitable for use in preparing the alkyd resin included in the coating composition of the present disclosure include castor oil, dehydrated castor oil, cottonseed oil, fish oil, linseed oil, menhaden oil, oiticica oil, palm kernel oil, perilla oil, safflower oil, sardine oil, soybean oil, sunflower oil, tall oil, Tung oil, walnut oil, white oil, and process oils, essential oils, such as lavender oil, rose oil and pine oil, silicone oil, and mixtures thereof.
[0031] Examples of suitable non-drying oils include, without limitation, valeric acid, heptanoic acid, 2-ethyl hexanoic acid, pelargonic acid, isononanoic acid, lauric acid, stearic acid, hydrocarbon/mineral oils, such as paraffin oil, almond oil, babassu oil, baobab oil, coconut oil, macadamia oil, nahar seed oil, olive oil, peanut oil, and branched fatty acids containing 18 carbon atoms. The non-drying oil can include the oil commercially available under the trade name CALSOL P910 (R.E. Carroll, Inc., Ewing, NJ). Predominantly drying/semi-drying oils are often more appropriate for use in preparing the alkyd resin.
[0032] Suitable polyhydric alcohols that can be used in forming an alkyd resin present in the coating composition of the present disclosure include, without limitation, glycerol, neopentyl glycol, cyclohexanedimethanol, ethylene glycol, propylene glycol, pentaerythritol, di-pentaerythritol, neononyl glycol, diethylene glycol, dipropylene glycol, trimethylene glycol, trimethylolpropane, dipentaerythritol, tripentaerythritol, and mixtures thereof.
[0033] Suitable polybasic acids/anhydrides that can be used in forming such alkyd resins include, without limitation, polycarboxylic acids and anhydrides thereof. Nonlimiting examples of suitable polycarboxylic acids include phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, adipic acid, azelaic acid, glutaric acid, 3,3-diethylglutaric acid, malonic acid, pimelic acid, sebacic acid, suberic acid, succinic acid, 2,2-dimethylsuccinic acid, 2-methylsuccinic acid,
dodecenylsuccinic acid, itaconic acid, fumaric acid, maleic acid, citraconic acid, diethyl maleic acid, trimellitic acid, and mixtures thereof; the anhydrides of those polybasic acids are also suitable.
[0034] Alkyd resin may contain a compound comprising at least one hydroxy functionality and at least an acid functionality. Non-limiting examples of the compound include dimethylol alkane acids and trimethylol alkane acids. Further nonlimiting examples of the compound include dimethylol propionic acid, 3-hydroxy- 2,2-bis(hydroxymethyl)propanoic acid, dimethylol butyric acid, 5,5-dimethylol-6- hydroxyhexanoic acid, dihydroxybenzoic acid, and mixtures thereof.
[0035] The alkyd resin may have a high solid content. As used herein, the term “high solids” and like terms refer to those resin compositions having a total solids content of at least 50 percent by weight, such as at least 75 percent by weight, based on the total weight of the resin composition, whereby the solids content is defined as non-volatile solids content or non-volatile matter (or nvm). As used herein, the term “solids content” refers to the proportion of non-volatile material contained in the alkyd resin. It is the material left after the volatile solvent (which serves as a carrier or vehicle for the solid content) has vaporized. The solids content may be determined by evaporating to dryness a weighed sample of solution and determining the percent residue. The solids content can be measured as described in ISO 3251:2019.
[0036] In certain embodiments, the alkyd resin may be a pourable resin at one hundred percent solids. As used herein, “pourable” means that the viscosity of a material is such that the material is capable of flowing down the container in which it is stored, when the container is tipped over. The alkyd resin may preferably have low viscosity, wherein the low intrinsic viscosity of the alkyd resin means that less solvent is needed to reach an acceptable application viscosity. The alkyd resin can exhibit a viscosity, for example, within a range from 200 cP to 10,000 cP, from 200 cP to 8,000 cP, from 500 cP to 6,000 cP, from 500 cP to 5,000 cP, from 800 cP to 5,000 cP, or from 800 cP to 4,000 cP. The viscosity can be measured using a Brookfield RVDV-E viscometer, with a No. 2 spindle, at speed of 20 rpm, and a temperature of 25° C.
[0037] The alkyd resin may have a number average molecular weight (Mn) and/or weight average molecular weight (Mw) of at least 2,000, and in some cases at least 3,000. The alkyd resin may have a Mw. The alkyd resin may have a Mn and/or Mw
of up to 50,000, such as up to 40,000, or up to 30,000, or up to 20,000, or up to 15,000, or up to 10,000, or up to 9,000, or up to 8,000, or up to 7,000. The Mn of the alkyd resin can be at least 2,000, but not exceeding 30,000.. Such molecular weights can enable effective drying times of the alkyd due to relatively fewer oligomer species present. The Mn and/or Mw of the copolymer may vary in any range of values inclusive of those stated above. The Mn and Mw can be determined from gel permeation chromatography using polystyrene standards and have the unit g/mol.
[0038] The polydispersity index (PDI) of the alkyd resin may be less than 10, such as less than 7.5, or less than 5. As used herein, “polydispersity index” is determined from the following equation: (weight average molecular weight (Mw)/number average molecular weight (Mn)). A monodisperse polymer has a PDI of 1.0.
[0039] The alkyd resin may have an acid value of less than 70 mg KOH/g, such as less than 50 mg KOH/g, or less than 20 mg KOH/g. The acid value is defined as mg of potassium hydroxide required to neutralize 1 g of resin. For alkyd resins 0.1 M KOH in ethanol may be employed.
[0040] The alkyd resin may be a long oil length alkyd with an oil content of between 60 and 75 percent by weight, a fatty acid content of 57 to 70 percent by weight, a number average molecular weight (Mn) from 2,000 to 10,000, an average molecular weight (Mw) from 15,000 to 30,000, an acid value of less than 20 mg KOH/g, a viscosity value from 500 cP to 5,000 cP, and/or may include from 65 to 80 % solids.
[0041] The alkyd resin may be a medium oil length alkyd with an oil content of between 45 and 60 percent by weight, a fatty acid content of 42 to 57 percent by weight, an acid value of less than 15 mg KOH/g, a viscosity value from 800 cP to 4,000 cP, and/or may include from 51 to 65 % solids.
[0042] The alkyd resin can be present in the coating composition of the present disclosure in an amount of 10 percent by weight or more, 15 percent by weight or more, 16 percent by weight or more, 17 percent by weight or more, 18 percent by weight or more, 19 percent by weight or more, or 20 percent by weight or more, including from 10 to 35 percent by weight, or from 15 to 30 percent by weight, from 15 to 25 percent by weight, or a range using any combination of the foregoing values
as endpoints, with weight percent being based on the total weight of the coating composition.
Drying & Non-Drying Oils
[0043] The coating composition of the present disclosure may comprise a drying oil and/or semi-drying oil and/or non-drying oil. The drying and/or semi-drying oil and/or non-drying oil can be a separate component from the alkyd resin and is in addition to the oil that is used to prepare the alkyd resin, as previously described. Any of the drying, semi -drying and non-drying oils previously described as being suitable for use in preparing the alkyd resin are also suitable for use in the present composition as the oil with which the alkyd resin is mixed.
[0044] The coating composition of the present disclosure may comprise at least one drying oil and/or at least one non-drying oil in addition to the oil that is used to prepare the alkyd resin. The at least one drying oil may be linseed oil, tung oil, fish oil, menhaden fish oil, safflower oil, castor oil, and mixtures thereof.
[0045] Such drying and/or semi-drying and/or non-drying oils can be present in the coating composition of the present disclosure in an amount of 5 to 55 percent by weight, or from 5 to 45 percent by weight, or from 7 to 42 percent by weight, with weight percent being based on the total weight of the coating composition.
Drying Agent
[0046] The coating composition of the present disclosure can also comprise a drying agent to promote the oxidative cure of binder components present in the composition. A drier compound can be employed for this purpose. The drying agent can comprise a primary drier, and at least one auxiliary drier. As used herein, the term “drier” (which is also referred to synonymously as “siccative” when in solution) refers to organometallic compounds that are soluble in organic solvents and binders. They can be added to unsaturated oils and binders in order to appreciably reduce their drying times, i.e., the transition of their films to the solid phase. Driers are available either as solids or in solution.
[0047] Non-limiting examples of suitable primary driers include, but are not limited to, various salts of cobalt, zirconium, cerium, calcium, zinc, and manganese. Metal salts of carboxylates having various chain lengths are particularly suitable. The primary drier may comprise an iron ligand complex and/or a manganese ligand
complex. The iron ligand complex and/or a manganese ligand complex may be substantially free of cobalt. The primary drier may be substantially free of cobalt. The primary drier can comprise the drier commercially available under the trade name BORCHI DRAGON (Borchers Americas Inc, Westlake, OH).
[0048] The primary drier may comprise less than 0.001 percent by weight of cobalt, such as less than 0.0001 percent by weight of cobalt, such as less than 0.00001, 0.000001 or 0.0000001 percent by weight of cobalt based on the total solid weight of the oxidatively drying binder. The primary drier may be completely free of cobalt.
[0049] Non-limiting examples of suitable auxiliary driers include calcium, barium, potassium, and lithium metal soaps. As used herein, the term “metal soap” refers to a metal salt of an organic acid such as a calcium salt or a zirconium salt of an organic acid. Examples of suitable calcium (Ca) salts of an organic acid include, but are not limited to, calcium carboxylates such as calcium neodecanoates, calcium octoates, calcium tallates, calcium linoleates, calcium naphthenates, and mixtures thereof. Examples of suitable zirconium (Zr) salts of an organic acid include, but are not limited to, zirconium carboxylates such as zirconium propionate, zirconium neodecanoates, zirconium octoates, zirconium naphthenates, and mixtures thereof.
[0050] The drier may comprise a mixture of iron ligand complex and/or a manganese ligand complex as a primary drier and a calcium carboxylate as an auxiliary drier.
[0051] Any suitable amount of such primary drier may be employed. For example, the primary drier can be present an amount ranging of 0.01 to 5.0 percent by weight, such as 0.1 to 3.0 percent by weight, such as 0.5 to 2.0 percent by weight with weight percent being based on total weight of the coating composition.
[0052] Any suitable amount of such at least one auxiliary drier may be employed. For example, the at least one auxiliary drier can be present an amount ranging of 0.01 to 5.0 percent by weight, such as 0.5 to 3.0 percent by weight, such as 1.0 to 2.0 percent by weight with weight percent being based on total weight of the coating composition.
Additional Components
[0053] The coating composition may comprise an anti-skinning compound. Nonlimiting examples of suitable anti-skinning compound include methyl ethyl ketoxime,
n-butyl ketoxime, cyclohexane ketoxime, methyl isobutyl ketoxime, di-methyl ketoxime, 2-cyclohexylphenol, 4-cyclohexylphenol, mono-tertiary butylhydroquinone, diethyl hydroxylamine, 2-[(l-methylpropyl)amino]ethanol, 3- methoxybutyl acetate, triphenyl phosphite, tocopherol, hydroxy acetone, tin octoate, isoascorbic acid, and 2,4-pentadione and the like, and mixtures thereof.
[0054] Any suitable amount of such anti-skinning compound may be employed. For example, the anti-skinning compound is present an amount of 0.01 to 5.0 percent by weight, such as 0.05 to 3.0 percent by weight, such as 0.1 to 2.0 percent by weight, such as 0.1 to 1.0 percent by weight with weight percent being based on total weight of the coating composition.
[0055] The coating composition of the present disclosure may comprise a UV absorber compound. As used herein, the term “UV absorber” refers to compositions which absorb wavelengths typically associated with binder degradation, for example, wavelengths of from 250 to 400 nm. The UV absorber can avoid absorbing, or absorbs an insignificant amount of, visible light, e.g., wavelengths of from 400 to 700 nm, and can be non-opacifying.
[0056] The coating composition of the present disclosure may comprise at least one UV absorber such as a benzotriazole (including derivatives thereof), triazine (including derivatives thereof), triazole (including derivatives thereof), hindered amine light stabilizer (HALS, including derivatives thereof), oxanilide (including derivatives thereof), benzophenone (including derivatives thereof), and mixtures thereof.
[0057] Non-limiting examples of suitable benzotriazole UV absorbers include 2- (2'-hydroxy-5'-methylphenyl)-benzotriazole, 2-(3',5'-di-tert-butyl-2'- hydroxyphenyl)-5-chlorobenzotriazole, 2(2'-hydroxy-3',5'-di-tert- amylphenyl)benzotriazole, benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(l,l- dimethylethyl)-4-hydroxy-,C7-9-branched alkyl esters, 2-(3',5'-bis(l-methyl-l- phenylethyl)-2'-hydroxyphenyl)benzotriazole, 2-(2-hydroxy-3- dimethylbenzylphenyl-5-(l,l,3,3-tetramethylbutyl))-2H-benzotriazole, iso-octyl-3- (3-(2H-benzotriazol-2-yl)-5-tert-butyl-) 4-hydroxyphenyl-proprionate, and poly(oxy- 1 ,2-ethanediyl), a-(3-(3-(2H-benzotriazol-2-yl)-5-(l ,l-dimethylethyl)-4- hydroxyphenyl)-l-oxopropyl)-co-hydroxy poly(oxy-l ,2-ethanediyl), a-(3-(3-(2H-
benzotriazol-2-yl)-5-(l,l-dimethylethyl)-4-hydroxyphenyl)-l-oxopropyl)-co-(3-(3- (2H-benzotriazol-2-yl)-5-( 1 , 1 -dimethylethyl)-4-hydroxyphenyl)- 1 -oxopropyl). The benzotriazole UV absorber may be Benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)- 5-(l,l-dimethylethyl)-4-hydroxy-, methyl ester. The UV absorber can comprise the composition commercially available under the trade name TINUVIN 1130 (BASF, Ludwigshafen, Germany).
[0058] Non-limiting examples of suitable hindered amine light stabilizer (HALS) include Bis-(l-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate, Bis-(N- methyl,2,2,6,6-tetramethyl-4-piperidinyl) sebacate, Methyl-(N-methyl,2,2,6,6- tetramethyl-4- piperidinyl) sebacate, Methyl l,2,2,6,6-pentamethyl-4-piperidyl sebacate, Bis(l,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis (2,2,6,6-tetramethyl-l- (octyloxy)-4-piperidinyl) ester, Bis (1, 2, 2, 6, 6-pentamethyl-4-piperidinyl)-[[3, 5-bis (1, 1 -dimethylethyl) -4- hydroxyphenyl] methyl] butyl malonate, bis(2, 2,6,6- tetramethyl-4-piperdinyl)decanedioate; l-acetyl-4-(3-dodecyl-2,5-dioxo-l- pyrrolidinyl)-2,2,6,6-tetramethyl-piperidine, hindered amine light stabilizers disclosed in U.S. Pat. No. 5,260,135 (see, e.g., the compounds disclosed in column 2, line 61 to column 4, line 2), which is incorporated herein by reference, and mixtures thereof.
[0059] Non-limiting examples of suitable triazine UV absorbers include 2-(4-(2- hydroxy-3-tridecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6-bis (2,4,dimethylphenyl)- 1 ,3,5-triazine, 2-(4-(2-hydroxy-3 -dodecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6- bis(2,4-dimethylphenyl)-l ,3,5-triazine, and 2-(4-(2-hydroxy-3-(2'-ethyl)hexyl)oxy)- 2-hydroxyphenyl)-4,6-bis(2,4-dimethylphenyl)-l,3,5-triazine. Triazine UV absorbers can include a mixture of 2-(4-(2-hydroxy-3-tridecyl oxypropyl)oxy)-2- hydroxyphenyl)-4,6-bis (2, 4, dimethylphenyl)- 1, 3, 5-triazine and 2-(4-(2-hydroxy-3- dodecyl oxypropyl)oxy)-2-hydroxyphenyl)-4,6-bis(2,4-dimethylphenyl)-l,3,5- triazine.
[0060] The UV absorber may be provided in a suitable carrier, such as an organic solvent. The organic solvent can include ketones, acetates, esters, glycol ethers, aliphatic hydrocarbons, aromatic hydrocarbons, and mixtures thereof.
[0061] Non-limiting examples of suitable UV stabilizers include products under the tradenames CYASORB (Solvay, Butte, MT), UVINUL (BASF, Ludwigshafen, Germany), and TINUVIN (BASF, Ludwigshafen, Germany).
[0062] The UV absorber can be present in the coating compositions of the present invention in an amount of 0.01 to 9.0 percent by weight, such as 0.1 to 6.0 percent by weight, such as 0.5 to 5.0 percent by weight, with weight percent being based on the total weight of the coating composition.
[0063] The coating composition of the present disclosure can comprise at least one biocide compound. A biocide can be added as a precautionary measure to preclude potential problems associated with yeast, mold, aerobic bacteria, and other biological products. The biocide can provide antimicrobial protection of the coating composition in its "dry film" form after use. Examples of suitable biocides include, but are not limited to, organotin biocides; methylene thiocyanate biocides; isothiazolinones biocides; nitro-biocides; carbamate biocides, chlorinated and brominated compounds; hydrazine derivatives; and combinations thereof.
[0064] The biocide can be present in the coating composition of the present disclosure in an amount of 0.01 to 4 percent by weight, such as 0.05 to 3.0 percent by weight, such as 0.1 to 2.0 percent by weight, such as 0.5 to 1.5, with weight percent being based on the total weight of the coating composition.
[0065] The coating composition may include other additives, such as catalysts, other pigments and pigment pastes, dyes, fillers, stabilizers, thixotropic agents, antisagging agents, anti- oxidants, antifouling agents, anti-gelling agents, bactericides, fungicides, algaecides, insecticides, anti-settling agents, antifoaming agents, slip agents, flow and levelling agents, rheological modifiers, photo-initiators, corrosion inhibitors, matting agents, waxes, flame retardants, anti-static agents, loss of dry inhibitors, optical brighteners, adhesion promoters, diluents, elastomers, plasticizers, air release agents, desiccants, anti-crater additives, reinforcing agents, dispersing aids, substrate wetting agents, odorants, corrosion-inhibitive pigments, additional hardeners, and/or additional curable compounds. The coating composition may include surface active agents, such as an anionic, cationic or nonionic surfactant or dispersing agent. Other resinous materials can be utilized in conjunction with the aforementioned alkyd resins. The metal drier combinations and optionally colorants,
pigments and extenders and optionally other additives may be formulated into the coating compositions by mixing and, if appropriate, dispersing and grinding with the liquid binder. Various additives, when used, can comprise no more than about 30 percent by weight, such as no more than about 10 percent by weight, of the present coating composition.
[0066] The coating composition may comprise further components, such as colorants. The colorant component may comprise an inorganic or organic, transparent or nontransparent pigment. Non-limiting examples of such pigments include titanium dioxide, iron oxides, mixed metal oxides, bismuth vanadate, chromium oxide green, ultramarine blue, carbon black, lampblack, monoazo and disazo pigments, anthraquinones, isoindolinones, isoindolines, quinophthalones, phthalocyanine blues and greens, dioxazines, quinacridones and diketo-pyrrolopyrroles; and extender pigments including silica, barium sulfate, magnesium silicate, calcium silicate, mica, micaceous iron oxide, calcium carbonate, zinc oxide, aluminium hydroxide and aluminium silicate, gypsum, feldspar, talcum, kaolin, and mixtures thereof. The amount of pigment that can be used to form the coating composition can vary depending on the particular composition application, and can be zero when a clear composition is desired.
[0067] The colorant can be present in the coating composition of the present disclosure in an amount of 0.01 to 10 percent by weight, such as 0. 1 to 8.0 percent by weight, such as 0.5 to 5.0 percent by weight, with weight percent being based on the total weight of the coating composition.
Example Formulations & Substrates
[0068] The coating composition may be formulated as a one package coating composition, also referred herein as a one-component (I K) coating composition. A "1 K" or "one package" composition refers to a composition wherein all of the components are maintained in the same container after manufacture, during storage, etcetera.
[0069] The coating composition can be formulated as varnish, lacquer, paint, stain, enamel, printing ink, or floor covering and similar compositions which contain auto-oxidizable alkyd resins.
[0070] The components of the coating composition of the present disclosure can be blended together to form the coating compositionby any means known in the art. For example, the components may be blended together using a Cowles blade or any known blade or a Hockmeyer mill or any known mill in the coating industry.
[0071] The coating composition of the present disclosure is suitable for application to, for example, porous substrates, such as paper, cardboard, particle board, fiber board, concrete, cement, brick, wood and wood products. Wood substrates are particularly suitable. Various woods can be stained with the present coating composition, including, for example, oak, cedar, maple, pine, or any known wood substrate. These types of woods are often used in the preparation of, for example, kitchen cabinets, bath cabinets, tables, desks, dressers, and other furniture or floors.
[0072] The present disclosure also relates to a porous substrate coated at least in part with the coating composition. The coating composition may also color the substrate, while allowing some of the substrate’s natural color and grain to show through. The porous substrate may be wood.
[0073] The coating composition of the present disclosure can be applied to the substrate by any known method in the art. Non-limiting examples of such application methods include spreading (e.g. with paint pad or doctor blade, or by brushing or rolling, or wiping), spraying (e.g. air-fed spray, airless spray, hot spray, and electrostatic spray), and flow coating (e.g. dipping, curtain coating, roller coating, and reverse roller coating). Multiple layers can be applied. The present coating composition can then be cured by initiating oxidative cure of the binder components. Such oxidative cure can be accomplished by allowing the coated substrate to be exposed to ambient or elevated temperature conditions.
[0074] A substrate partially or fully coated with a coating composition of the present disclosure may be pre -treated before application of the coating composition. The substrate may additionally or alternatively be post-treated after application of the coating composition, for example with any other compositions.
[0075] The coating composition can be applied and cured at ambient temperature conditions in the range of from -10°C to 50°C. Curing of the coating compositions can proceed rapidly, and in general can take place at a temperature within the range
of from -10°C to +50°C, such as from 0°C to 40 °C, such as from 3 to 25°C. However, the coating compositions may be cured by additional heating.
[0076] The coating composition may be used as a single coating, a top coating, a base coating in a two-layered system, as a layer of a multi-layered system including a clear top coating composition, colorant layer, and base coating composition, and/or as a primer layer.
[0077] The present disclosure also relates to the use of the coating compositions as a coating for porous substrates in a varnish, lacquer, paint, stain, enamel, printing ink or floor covering.
EXAMPLES
[0078] Example coating compositions were formulated within the parameters shown in Tables 1A - 1C. Component amounts are listed by % wt. The Mw values for the alkyd resins were determined via gel permeation chromatography using polystyrene standards. The example coating compositions also included a hydroxyphenyl benzotriazole UV absorber component (included at 0.1 to 4.5 % wt.) and a hindered amine light stabilizer (HALS) (included at 0.1 to 4.5 % wt.).
* Solvent comprised naphtha, toluene, and/or xylene.
** Other Components comprised fungicide, anti-skinning compound, wetting and/or dispersing additives.
** Other Components comprised fungicide, anti-skinning compound, wetting and/or dispersing additives.
* Solvent comprised naphtha, toluene, and/or xylene.
** Other Components comprised fungicide, anti-skinning compound, wetting and/or dispersing additives.
[0079] Examples 1 and 5 did not include a drying oil component. Example 8 included an acrylic resin (an IB MA resin commercially available under the trade name PARALOID B67 (100%) (Dow Chemical Company, Midland, MI)) rather than an alkyd resin.
[0080] The example coating compositions were applied to cumaru wood and subjected to a weather resistance test (according to EN 927-3:2012), a drying test (according to ASTM D 1640-03(09)), a wood absorption test (based on scanning electron microscopy evaluation of cross sections of treated wood substrate), and natural appearance testing (according to ASTM D 3964-10(2020)). The results are summarized in Tables 2A and 2B. Negative/f ailed results are shown in italics.
Table 2B
[0081] As shown, Example 1 failed to be adequately absorbed by the wood substrate and produced a glossy film appearance rather than a desired natural wood appearance. Example 5 failed to dry during the drying test, failed the absorption test, and produced a semi-gloss film appearance rather than a desired natural wood appearance. Similarly, Example 8 failed to dry during the drying test, failed the absorption test, and produced a semi-gloss film appearance rather than a desired natural wood appearance.
[0082] Examples 1 and 5 did not include a drying oil component. Example 8 did include a drying oil component, but included an acrylic resin rather than an alkyd resin. The Examples that included both a drying oil and an alkyd resin exhibited effective weather resistance, drying times, and wood absorption, and also resulted in a natural appearance when applied to a wood substrate.
[0083] While Examples 3 and 4 exhibited effective weather resistance, Examples 2, 6, and 7 exhibited superior weather resistance. This may be due to the relatively higher alkyd resin allowances of Examples 2, 6, and 7 relative to Examples 3 and 4. Thus, a coating composition with an alkyd resin content of 17 percent by weight or more, 18 percent by weight or more, 19 percent by weight or more, or 20 percent by weight or more can exhibit particularly effective weather resistance.
Claims
1. A solvent-based coating composition, comprising:
(i) a binder component comprising an alkyd resin;
(ii) a drying oil separate from the alkyd resin; and
(iii) a non-drying oil separate from the alkyd resin; optionally, further comprising:
(iv) a drier compound;
(v) an anti-skinning compound;
(vi) a UV absorber compound; and/or
(vii) a biocide compound.
2. The coating composition of claim 1, wherein the alkyd resin has a number average molecular weight (Mw) up to 50,000 g/mol, such as up to 40,000 g/mol, or up to 30,000 g/mol, or up to 20,000 g/mol, or up to 15,000 g/mol, or up to 10,000 g/mol, or up to 9,000 g/mol, or up to 8,000 g/mol, or up to 7,000 g/mol, as determined by gel permeation chromatography using polystyrene standards.
3. The coating composition of any preceding claim, wherein the alkyd resin has a viscosity from 200 cP to 10,000 cP, such as from 200 cP to 8,000 cP, from 500 cP to 6,000 cP, from 500 cP to 5,000 cP, from 800 cP to 5,000 cP, or from 800 cP to 4,000 cP, measured using a Brookfield RVDV-E viscometer, with a No. 2 spindle, at speed of 20 rpm, and a temperature of 25° C.
4. The coating composition of any preceding claim, wherein the alkyd resin is a high solids resin, having a total solids content of at least 50 percent by weight, such as at least 75 percent by weight, measured according to ISO 3251:2019.
5. The coating composition of any preceding claim, wherein the alkyd resin is present in an amount of 15 percent by weight or more, 16 percent by weight or more, 17 percent by weight or more, 18 percent by weight or more, 19 percent by weight or more, or 20 percent by weight or more, such as 10 to 35 percent by weight, based on the total weight of the coating composition.
6. The coating composition of any preceding claim, wherein the drying oil and/or non-drying oil is present in an amount 5 to 55 percent by weight, such as 5 to 45 percent by weight or 7 to 42 percent by weight, based on the total weight of the coating composition.
7. The coating composition of any preceding claim, wherein the drier compound comprises a mixture of a primary drier in an amount of 0.01 to 5.0 percent by weight and an auxiliary drier in an amount of 0.01 to 5.0 percent by weight, with weight percent being based on the total weight of the coating composition.
8. The coating composition of any preceding claim, wherein the drier compound is substantially free of cobalt.
9. The coating composition of any preceding claim, wherein the anti-skinning compound is present an amount of 0.01 to 5 percent by weight, with weight percent being based on the total weight of the coating composition.
10. The coating composition of any preceding claim, wherein the UV absorber compound is present in an amount of 0.01 to 9.0 percent by weight, with weight percent being based on the total weight of the coating composition.
11. The coating composition of any preceding claim, wherein the biocide is present in an amount of 0.01 to 4.0 percent by weight, with weight percent being based on the total weight of the coating composition.
12. The coating composition of any preceding claim, further comprising one or more additives.
13. The coating composition of any preceding claim, further comprising a colorant in an amount of 0.01 to 10 percent by weight, with weight percent being based on the total weight of the coating composition.
14. The coating composition of any preceding claim, wherein the composition is substantially free of water.
15. The coating composition of any preceding claim, wherein the coating composition, when cured, exhibits: weather resistance of 3 months or more according to EN 927-3:2012; and/or a drying time within 24 hours according to ASTM D 1640-03(09).
16. A porous substrate coated at least in part with the coating composition of any preceding claim.
17. The porous substrate of claim 16, wherein the porous substrate comprises wood and exhibits a natural wood appearance according to ASTM D 3964-10(2020).
18. Use of the coating composition of any preceding claim as a coating for porous substrates in a varnish, lacquer, paint, stain, enamel, printing ink, or floor covering.
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US5260135A (en) | 1991-07-26 | 1993-11-09 | Ppg Industries, Inc. | Photodegradation-resistant electrodepositable primer compositions |
WO2007075296A1 (en) * | 2005-12-20 | 2007-07-05 | Ppg Industries Ohio, Inc. | Stain compositions and related coated substrates |
WO2012005645A1 (en) * | 2010-07-07 | 2012-01-12 | Perstorp Ab | Alkyd resin |
WO2021108507A1 (en) * | 2019-11-27 | 2021-06-03 | Swimc Llc | Low voc coatings including hyper-branched alkylated polymers |
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2023
- 2023-07-25 WO PCT/IB2023/057540 patent/WO2024023704A1/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US5260135A (en) | 1991-07-26 | 1993-11-09 | Ppg Industries, Inc. | Photodegradation-resistant electrodepositable primer compositions |
WO2007075296A1 (en) * | 2005-12-20 | 2007-07-05 | Ppg Industries Ohio, Inc. | Stain compositions and related coated substrates |
WO2012005645A1 (en) * | 2010-07-07 | 2012-01-12 | Perstorp Ab | Alkyd resin |
WO2021108507A1 (en) * | 2019-11-27 | 2021-06-03 | Swimc Llc | Low voc coatings including hyper-branched alkylated polymers |
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