U.S. patent application number 09/785147 was filed with the patent office on 2002-02-07 for prepaints and methods of preparing paints from the prepaints.
Invention is credited to Friel, John Michael, Hook, John William III, Kelly, David Goodro, Lieser, Bernhard Helmut, Washel, Jerry William.
Application Number | 20020016405 09/785147 |
Document ID | / |
Family ID | 27391716 |
Filed Date | 2002-02-07 |
United States Patent
Application |
20020016405 |
Kind Code |
A1 |
Friel, John Michael ; et
al. |
February 7, 2002 |
Prepaints and methods of preparing paints from the prepaints
Abstract
The preparation of a paint line using sets of prepaints
containing a latex polymer binder. At least one of which contains a
latex polymeric binder, is also is described. The paints may be
applied to architectural coatings, and non-cementitious, aggregate
finish coating suitable for application on a wall directly or as a
topcoat.
Inventors: |
Friel, John Michael;
(Warminster, PA) ; Hook, John William III;
(Warminster, PA) ; Lieser, Bernhard Helmut; (San
Pedro, CA) ; Washel, Jerry William; (Harleysville,
PA) ; Kelly, David Goodro; (Ambler, PA) |
Correspondence
Address: |
Margaret B. Kelley, Esq.
Clifford Chance Rogers & Wells LLP
200 Park Avenue
New York
NY
10166
US
|
Family ID: |
27391716 |
Appl. No.: |
09/785147 |
Filed: |
February 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60183655 |
Feb 18, 2000 |
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60183656 |
Feb 18, 2000 |
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60247639 |
Nov 10, 2000 |
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Current U.S.
Class: |
524/501 ;
524/502; 524/515; 524/523; 524/524; 524/533 |
Current CPC
Class: |
B01F 35/2205 20220101;
B01F 33/8442 20220101; B44D 2/002 20130101; B01F 2101/30 20220101;
B01F 33/84 20220101; B44D 3/08 20130101; C09D 7/40 20180101; C09J
201/00 20130101; B44D 3/003 20130101; B01F 35/20 20220101; C09D
17/008 20130101; C09D 7/80 20180101 |
Class at
Publication: |
524/501 ;
524/502; 524/515; 524/523; 524/524; 524/533 |
International
Class: |
C08K 003/20; C08K
003/22; C08L 031/04 |
Claims
What is claimed:
1. A set of different, but mutually compatible, fluid prepaints
sufficient to formulate at least one paint line, which set
comprises: (i) at least one fluid opacifying prepaint comprising at
least one opacifying pigment; (ii) at least one extender prepaint
comprising at least one extender pigment; and (iii) at least one
binder prepaint comprising at least one latex polymeric binder.
2. The set of prepaints of claim 1, wherein the number of prepaints
is from 3 to 15.
3. The set of prepaints of claim 1, wherein the opacifying prepaint
further comprises at least one particulate polymeric binder
adsorbed onto the opacifying pigment.
4. The set of prepaints of claim 1, wherein the extender prepaint
further comprises at least one particulate polymeric binder
absorbed onto the extender pigment.
5. A method of forming at least one paint line, which method
comprises the steps of: (a) providing a set of prepaints, which set
comprises: (i) at least one opacifying prepaint comprising at least
one opacifying pigment; (ii) at least one extender prepaint
comprising at least one extender pigment, and (iii) at least one
binder prepaint comprising at least one latex polymeric binder; and
(b) dispensing a predetermined amount of the each of the prepaint
into containers or applicator(s) to form the paint line.
6. A method of forming a range of paints, the range comprising at
least two paint lines, which method comprises the steps of: (a)
providing a set of different, but mutually compatible, fluid
prepaints sufficient to formulate at least two paint lines, which
set comprises: (i) at least one opacifying prepaint comprising at
least one opacifying pigment; (ii) at least one extender prepaint
comprising at least one extender pigment; (iii) at least one binder
prepaint comprising at least one latex polymeric binder; and (iv)
at least one additional different prepaint selected from the group
consisting of prepaints (i), (ii), and (iii); and (b) dispensing a
predetermined amount of each prepaint into containers or
applicators to form the range of paints.
7. The method of claim 5 or claim 6, further comprising the step of
mixing the prepaints before, while, or after the prepaints are
dispensed into the containers.
8. The method of claim 5 or claim 6, further comprising the step of
mixing the prepaints before or while they are dispensed into the
applicator(s).
9. The method of claim 5 or claim 6, further comprising the step of
adjusting the viscosity of the dispensed prepaint(s) before, while,
or after the prepaints are dispensed into the containers.
10. The method of claim 5 or claim 6, further comprising the step
of adjusting the viscosity of the dispensed prepaints before or
while the prepaints are dispensed into the applicator(s).
11. The method of claim 5 or claim 6, wherein at least one additive
that enhances the application of the paint or final performance
properties of the paint is added to the prepaint(s).
12. The method of claim 11, wherein the additive is an aggregate
material.
13. The method of claim 11, wherein the additive is a
thickener.
14. The method of claim 5 or claim 6, wherein least one colorant is
added to the dispensed prepaints.
15. The method of claim 5 or claim 6, wherein the opacifying
prepaint further comprises at least one particulate polymeric
binder absorbed onto the opacifying pigment.
16. The method of claim 5 or claim 6, wherein the extender prepaint
further comprises at least one particulate polymeric binder
absorbed onto the extender pigment.
17. The method of claim 5 or claim 6, wherein the method is carried
out at a paint manufacturing facility.
18. The method of claim 5 or claim 6, wherein the method is carried
out at a point-of-sale.
19. The method of claim 5 or claim 6, wherein the method is carried
out at a point-of-use.
20. The method of claim 5 or claim 6, wherein the method is
controlled by a computer. .
21. The method of claim 5 or claim 6, wherein the number of
prepaints is from 4 to 15.
22. A fluid opacifying prepaint having a volume solids content of
about 30% to about 70% and a Stormer viscosity of about 50 to about
250 KU, which is useful for formulating a one pack, pigmented latex
paint containing other paint ingredients, which prepaint consists
essentially of: (i) at least one opacifying pigment, (ii) at least
one dispersant, (iii) at least one thickener, and (iv) water;
wherein the dispersant(s) and the thickener(s) are mutually
compatible with the pigment(s) and with the other paint
ingredients.
23. The prepaint of claim 22, wherein the volume solids content is
about 35% to about 50% and the Stormer viscosity is about 60 to
about 150 KU.
24. A fluid white opacifying prepaint having a volume solids
content of about 30% to about 70%, a pigment volume concentration
of about 35% to about 100%, and a Stormer viscosity of about 50 to
about 250 KU, which is useful for formulating a one pack, pigmented
latex paint containing other paint ingredients, which prepaint
consists essentially of (i) at least one opacifying pigment, (ii)
at least one dispersant, (iii) at least one thickener, (iv) at
least one film-forming or non-film-forming polymer, and (v) water;
wherein the dispersant(s), the thickener(s), and the polymer(s) are
compatible with the pigment(s) and with the other paint
ingredients; which prepaint is characterized in that it is stable
to sedimentation
25. The prepaint of claim 24, wherein the volume solids content is
about 35% to about 50%, the pigment volume concentration is about
50 to 100%, and the Stormer viscosity is about 60 to about 150
KU.
26. The prepaint of claim 24, wherein the polymer is adsorbed onto
the opacifying pigment.
27. The prepaint of claim 22 or 24, wherein the opacifying pigment
is titanium dioxide, zinc oxide, lead oxide, a synthetic polymer
pigment, or mixtures thereof.
28. The prepaint of claim 22 or 24, wherein the opacifying pigment
is rutile titanium dioxide.
29. The prepaint of claim 27, wherein the synthetic polymer pigment
is voided latex polymer particles.
30. The prepaint of claim 22 or 24, wherein the dispersant is
2-amino-2-methyl-1-propanol; dimethylaminoethanol; potassium
tripolyphosphate; trisodium polyphosphate; citric acid, polyacrylic
acid, diolefin/maleic anhydride adducts, hydrophobically-modified
polyacrylic acid, hydrophilically-modified polyacrylic acid, and
salts thereof; or mixtures thereof.
31. The prepaint of claim 22 or 24, wherein the thickener is a
hydrophobically-modified alkai-soluble or alkali-swellable emulsion
(HASE), a hydrophobically-modified, akali-soluble emulsion (ASE),
hydrophobically-modified ethylene oxide-urethane polymer,
cellulosic, hydrophobically-modified cellulosic,
hydrophobically-modified polyacrylamide, polyvinyl alcohol, fumed
silica, attapulgite clay, titanate chelating agent or mixtures
thereof.
32. The prepaint of claim 24, wherein the polymer is acrylic, vinyl
acetate, styrene-acrylic, styrene-butadiene, vinyl acetate-acrylic,
ethylene-vinyl acetate, vinyl acetate-vinyl versatate, vinyl
acetate-vinyl maleate, vinyl acetate-vinyl chloride-acrylic,
ethylene-vinyl acetate-acrylic polymers or mixtures thereof.
33. The prepaint of claim 32, wherein the polymer further
comprising up to 10% by weight of another monomer which is a
functional monomer, a non-functional monomer, or mixtures.
34. The prepaint of claim 22 or 24, further consists essentially of
at least one additive, selected from the group consisting of an
acid, a base, a defoamer, a coalescent, a cosolvent, a mildewcide,
a biocide and an antifreeze agent, the additive(s) being present in
an amount of less than about 10% by weight, based on the total
weight of the prepaint.
35. A fluid pigment extender prepaint, useful for formulating a one
pack, pigmented latex paint containing other paint ingredients,
which prepaint consists essentially of: (i) at least one mineral
extender having a volume solids content of about 30% to about 70%,
a pigment volume concentration of about 35% to about 100%, and a
Stormer viscosity of about 50 to about 250 KU; (ii) at least one
thickener; and (iii) water; wherein the mineral extender(s) and the
thickener(s) are compatible with each other and with the other
paint ingredients.
36. The prepaint of claim 35, further comprising a polymeric binder
compatible with the mineral extender(s) and the thickener(s).
37. A set of two different, but mutually compatible, fluid
prepaints which are useful for formulating a latex paint, which set
comprises: (i) the opacifying prepaint of claim 22 or 24 and (ii) a
latex polymeric binder prepaint having a volume solids content of
about 25% to about 70% and a Brookfield viscosity of less than
about 100,000 centipoise at a shear rate of 1.25 reciprocal
seconds, which binder prepaint consists essentially of a
water-borne latex polymeric binder having a Tg of about -40.degree.
C. to about 70.degree. C.; and (iii) water.
38. The set of prepaints of claim 37, wherein the binder prepaint
has a Tg of about -10.degree. C. to about 60.degree. C., a volume
solids content of about 30% to about 65%, and a Brookfield
viscosity of about 100 to about 50,000 centipoise at a shear rate
of 1.25 reciprocal seconds.
39. The set of prepaints of claim 37, wherein the binder prepaint
further consists essentially of at least one additive selected from
the group consisting of an acid, a base, a defoamer, a coalescent,
a cosolvent, a mildewcide, a biocide and an antifreeze agent; the
additive being present in an amount of less than about 10% by
weight, based on the total weight of the prepaint.
40. A set of three different, mutually compatible, fluid prepaints
which are useful for formulating a latex paint, which set
comprises: (i) the fluid opacifying prepaint and fluid latex
polymeric binder prepaint of claim 35; (ii) a fluid pigment
extender prepaint having a volume solids content of about 30% to
about 70%, a pigment volume concentration of about 35% to about
100%, and a Stormer viscosity of about 50 to about 250 KU, which
extender prepaint consists essentially of at least one mineral
extender, at least one thickener, and water.
41. The set of claim 40, wherein the fluid pigment extender
prepaint further consists essentially of a polymeric binder.
42. The set of prepaints of claim 40, wherein the volume solids
content is about 35% to about 65%, the pigment volume concentration
is about 40% to about 100% and the Stormer viscosity is about 60 to
about 150 KU.
43. The set of prepaints of claim 37, wherein the fluid pigment
extender prepaint further consists essentially of at least one
additive selected from the group consisting of an acid, a base, a
defoamer, a coalescent, a cosolvent, a mildewcide, a biocide and an
antifreeze, with the additive being present in an amount of less
than about 10% by weight, based on the total weight of the
prepaint.
44. A paint line produced by a process which comprises of steps of:
(a) providing a set of different, but mutually compatible, fluid
prepaints, which set comprises: (i) at least on opacifying prepaint
comprising, (ii) at least one opacifying pigment; (iii) at least
one extender prepaint comprising at least one extender pigment; and
(iv) at least one binder prepaint comprising at least one latex
polymeric binder, and b. dispensing a predetermined amount of each
of the prepaints into containers or applicator(s) produce the paint
line.
45. A set of different, but mutually compatible, fluid prepaints
sufficient to form at least one paint line useful as an elastomeric
coating, which set comprises: (i) at least one opacifying prepaint
comprising at least one opacifying pigment, (ii) at least one
extender prepaint comprising at least one extender pigment; and
(iii) at least one binder prepaint comprising at least one latex
polymeric binder; having a Tg less than about 0.degree. C.
46. A method of forming a paint line useful as an elastomeric
coating, which method comprises the steps of: (a) providing a set
of different, but mutually compatible, fluid prepaints comprising:
(i) at least one opacifying prepaint comprising at least one
opacifying pigment; (ii) at least one extender prepaint comprising
at least one extender pigment; and (iii) at least one binder
prepaint comprising at least one latex polymeric binder having a Tg
of less than about 0.degree. C.; and (b) dispensing a predetermined
amount of each of the prepaints into containers or applicator(s) to
form the paint line.
47. A method of forming a range of paints comprising at least two
paint lines useful as elastomeric coatings, which method comprises
the steps of: (a) providing a set of different, but mutually
compatible, fluid prepaints sufficient to formulate at least two
paint lines, which set comprises: (i) at least one opacifying
prepaint comprising at least one opacifying pigment, (ii) at least
one extender prepaint comprising at least one extender pigment,
(iii) at least one binder prepaint comprising at least one latex
polymeric binder having a Tg of less than about 0.degree. C., and
(iv) at least one additional different prepaint selected from the
group consisting of prepaints (i), (ii), and (iii); and b.
dispensing a predetermined amount of each of the prepaints into
containers or applicator(s) to form the paint lines.
48. A set of different, but mutually compatible, fluid prepaints
sufficient to form at least one paint line which is useful as a
non-cementitious, aggregate finish, which set comprises: (i) at
least one opacifying prepaint comprising at least one opacifying
pigment; (ii) at least one extender prepaint comprising at least
one extender pigment; (iii) at least one fluid binder prepaint
comprising at least one latex polymeric binder; and (iv) at least
one prepaint comprising an aggregate.
49. A method of forming at least one paint line which is useful as
a non-cementitious, aggregate finish, which method comprises the
steps of: (a) providing a set of different, but mutually
compatible, non-cementitious fluid prepaints, which set comprises:
(i) at least one opacifying prepaint comprising at least one
opacifying pigment, (ii) at least one extender prepaint comprising
at least one extender pigment, (iii) at least one binder prepaint
comprising at least one latex polymeric binder, and (iv) at least
one prepaint comprising an aggregate; and b. dispensing a
predetermined amount of each of the prepaints into containers or
applicator(s) to form the paint line.
50. A method of forming a range of paints, the range comprising at
least two paint lines which are useful as a non-cementitious,
aggregate finishing coating, which method comprises the steps of:
(a) providing a set of different, but mutually compatible, fluid
non-cementitious prepaints sufficient to formulate at least two
paint lines, which set comprises: (i) at least one opacifying
prepaint comprising at least one opacifying pigment; (ii) at least
one extender prepaint comprising at least one extender pigment;
(iii) at least one binder prepaint comprising at least one latex
polymeric binder; (iv) at least one prepaint comprising an
aggregate; and (v) at least one different additional prepaint
selected from the group consisting of prepaint (i), (ii), (iii),
and (iv); and (b) dispensing a predetermined amount of each of the
prepaints into containers or application(s) to form the paint
lines.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 60/183,655 filed Feb. 18, 2000, No. 60/183,656
filed Feb. 18, 2000 and No. 60/247,639 filed Nov. 10, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to sets of prepaints methods of
formulating paint lines using the sets of prepaints, useful as
architectural coatings, elastomeric coatings and non-cementitious,
aggregate finish coatings.
[0004] 2. Description of Related Art
[0005] For decades, professional painters/contractors and
do-it-yourself consumers have been able to purchase paints that are
tinted at the point-of-sale rather than at the manufacturing
facility. This postponement of product differentiation permits the
buyer to specify the desired color of the paint from a wide variety
of choices rather than a limited number of colors once produced by
the paint manufacturer.
[0006] While not practiced commercially, it is also theoretically
known in the paint industry to postpone product differentiation of
the paint components themselves as long as possible in the paint
manufacturing process. See, for example, Carola Grundfelt-Forsius'
paper in Faerg Lack Scand. 43(2), pages 5-6 (1997) which describes
the use of intermediaries, i.e., mixtures of several of the paint
raw material ingredients, that are mixed together with the tinting
pastes to yield different types of paints. Grundfelt-Forsius
provides an example of such a system employing a polyurethane
binder for a solution polymer system.
[0007] The postponement of product differentiation offers the buyer
the flexibility of selecting the desired final paint, whether it be
the color of the paint or the type of paint, while at the same time
permitting the paint manufacturer or seller (retail or wholesale or
distributor) to minimize inventories of raw materials,
intermediates and final products as well as stock outages.
[0008] Despite these benefits, paint manufacturers have only been
able to successfully employ the postponement in product
differentiation to paint systems based on solution polymers. Paint
manufacturers have not been successful in postponing product
differentiation in latex polymer-based paint systems. Since the
majority of paints used today are based on latex polymers, there is
a need for a practical method for postponing product
differentiation in a latex polymer -based system.
[0009] It is considerably more difficult to formulate a stable
paint when using latex emulsion polymers rather than solution
polymers because of latex instability. Emulsion polymers are very
sensitive to the solvents and surface active agents commonly found
in paint formulations, such as surfactants, dispersants, rheology
modifiers, and co-solvents. Solution polymers are by definition
soluble in the solvent they are supplied in, and there is no
thermodynamic driving force causing the polymer molecules to
agglomerate or become unstable. In contrast, latex polymers contain
the material in particles that are insoluble in water. These
particles require considerable surface modifications to render them
stable when supplied in an aqueous medium. If the surface
modification is inadequate, the latex particles attach to one
another forming a coagulated mass which then separates out of the
latex paint. Paint formulating with a latex system is very
difficult because the surface active materials in the formulation
disrupt the delicate balance of surface forces that stabilize the
latex particles in a water medium.
[0010] The difference between latex (also referred to herein as
"emulsion") and solution polymer systems is further explained in
Temple C. Patton's book entitled Paint Flow and Pigment Dispersion
(New York: John Wiley and Sons, Inc., 1979, pages 192-193). Here
the author describes the drying processes for the two systems. The
main difference lies in the time required for each to polymer reach
an irreversible state. Latex polymers reach this state much faster
than solution polymers and thus make paints based on latex polymers
more difficult to stabilize than paints based on solution polymers.
In discussing "solvent-type coatings" (which contain solution
polymers), the author writes " . . . the liquid vehicle flows
rather than deforms around the pigment particles on drying. This
flow assists the compaction process as the film shrinks because of
loss of volatile solvent. Although the vehicle becomes more viscous
as solvent evaporates, flow persists through most of the drying
cycle." As the author points out, the solution polymer is able to
flow though most of the drying cycle as the solvent evaporates.
This is not true for polymer emulsions. The same author notes: " .
. . there is a preliminary flow of the latex suspension. This takes
place before the time when the latex particles are first forced to
come into intimate contact because of initial water loss. However,
after this relatively short but very important initial flow,
pigment compaction to achieve a high critical pigment volume
concentration (CPVC) is achieved mainly by plastic deformation and
coalescence of the latex particles." Coalescence is the
irreversible contact between latex particles. Such irreversible
contact can occur in a liquid paint based on latex polymers, but
not in a liquid paint based on solution polymers. Thus, paints
based on latex polymers are more difficult to formulate.
[0011] There is a great need to develop a set of prepaints and a
method of formulating paints based on latex polymers using sets of
prepaints.
[0012] Paint formulating involves the process of selecting and
admixing appropriate paint ingredients in the correct proportions
to provide a paint with specific processing and handling
properties, as well as a final dry paint film with the desired
properties. The major ingredients of latex paint formulations are a
binder, an opacifying pigment, optional pigment extenders, and
water. Common optional additives include defoamers, coalescents,
plasticizers, thickeners, non-thickening rheology modifiers,
opacifying agents, driers, anti-skinning agents, surfactants,
mildewcides, biocides and dispersants. After the latex paint is
formulated and applied to a surface, the paint dries by evaporation
of the water, with or without the application of heat, and the
binder forms a film containing therein the pigment and the pigment
extender particles, if any.
SUMMARY OF THE INVENTION
[0013] A "paint line", as used herein, includes at least two
different paints which offer dried film properties which differ
materially from each other in at least one observable property such
as sheen, outdoor durability or color depth. A paint line may
include, for example, three paints the dried films of which have
different sheen levels, two paints the dried films of which have
suitable interior or exterior performance, or four paints the dried
films of which offer different quality or performance levels such
as may be evidenced, for example, by different levels of scrub
resistance.
[0014] A paint line could, more particularly, include four
different paints, the dried films of which have different sheen
levels, typically marketed as gloss; semi-gloss; eggshell, satin,
or low lustre; and flat. The sheen is determined by the volume and
type of the binder(s), pigment(s), and extender(s), if any, in the
paint.
[0015] As used herein, "paint" is term used in its broadest sense
which is intended to include any coating that may be applied to a
surface for decorative and/or protective purposes. Specifically
included are those paints employed for architectural coatings,
elastomeric coatings and non-cementitious, aggregate finish
coatings employed as topcoats over walls, and in an exterior
insulation and finishing system (referred to as "EIFS").
[0016] In addition to the various sheen levels, paints are commonly
formulated to be neutral or accent (no or very low level of
opacifying pigment), untinted (white) or tinted to a wide variety
of colors using different tint bases, including pastel or light
tones, medium or mid-tones, and deep tones. This capability
requires a paint line having as many as five paints. Also, paints
are formulated for exterior or interior use. And, paints are
formulated to provide certain levels of performance properties,
such as may be marketed as good/standard, better and
best/premium.
[0017] Paint manufacturers and retailers typically offer a range of
paints, which include at least two paint lines. By "the range
including at least two paint lines" herein is meant that the
discrete elected levels of the observable property defining a first
paint line are combined with the discrete elected levels of the
observable property defining a second paint line, etc. to define
the paints in the range of paints.
[0018] To prepare a range of paints which includes four paint lines
may require preparing paints four sheen levels, four tint bases,
interior and exterior use, and three quality levels. For all
combinations; 96 different paint formulations
(4.times.4.times.2.times.3) may be needed. Also encompassed,
however, is a range of paints in which certain of the defined
paints, certain proportion, including up to as high as 10-60%, of
the total number of paints, are selected to be omitted, for
example, for commercial reasons or because they are not stable as
defined herein. Further contemplated is a range of paints in which
the observable properties of the dried paint films substantially,
but not exactly, fulfill the standard definitions. For example, the
sheen of a dried outdoor mid-tone gloss paint in the standard,
better, and premium lines may differ by a few points without
departing from the meaning of a range of paints of this
invention.
[0019] Formulating the paints is complex--it is not simply a matter
of mixing a few paint ingredients in different ratios. Rather, it
involves the selection and mixing of different paint ingredients in
different ratios depending on the type of paint desired. This
requires paint manufacturers to store many different paint
ingredients and change paint ingredients during manufacture
depending on the specific paint type being prepared.
[0020] Furthermore, it requires those in the supply chain,
especially the paint retailers, to carry a large inventory of
paints in the warehouse and on the store shelves in order to offer
a range of paints, such as varying sheen levels, tint bases, paints
for exterior use, paints for interior use, and paints of various
quality. It would be desirable to make paints, either at a
relatively large-scale industrial plant or at a relatively
smaller-scale, point-of-sale or point-of-use location using a
limited number of paint ingredients to prepare all of these
different paint formulations, thus, minimizing the number and type
of paint ingredients needed to make a range of paints.
[0021] As used herein, "paint" is term used in its broadest sense
which is intended to include any coating that may be applied to a
surface for decorative and/or protective purposes. Specifically
included are those paints employed for architectural coatings,
elastomeric coatings and non-cementitious, aggregate finish
coatings employed as topcoats over walls, and in an exterior
insulation and finishing system (referred to as "EIFS").
[0022] As used herein, prepaints are "mutually compatible" if the
paints formed by admixing the prepaints do not evidence signs of
colloidal instability such as flocculation. Preferably, the paints
formed from the prepaints exhibit less than 5 g of residue (e.g.,
gel and/or grit per liter of paint when the paint is passed through
a 325 mesh screen. More preferably, the paints formed from the
prepaints exhibit less than 1 g of residue per liter of paint when
the paint is passed through a 325 mesh screen. If the prepaints,
optional additives included to enhance specific paint properties,
and colorants are fully compatible, i.e., they can be blended at
any ratio without inducing colloidal instability, then they can be
blended in any combination falling within the formulation space
needed to achieve the desired property profile in the final paint.
It is sufficient, however, for the prepaints, additives included to
enhance specific paint properties, and colorants to be compatible,
i.e., they can be blended at desired ratios without inducing
colloidal instability to achieve the desired property profile in
the range of paints.
[0023] In order to minimize the number of paint ingredients needed
to prepare a range of paints one needs to consider the extremes of
key properties required by the range of paints and formulate
prepaints which are capable of being blended in various
combinations to provide the key properties required, at their
extreme values and at intermediate points as well. Specific
properties may be improved by adding paint additives which enhance
the desired property.
[0024] The above goal is achieved by employing a set of different,
but mutually compatible, prepaints sufficient to formulate at least
one paint line, the set comprising: (i) at least one prepaint
comprising at least one opacifying pigment; (ii) at least one
prepaint comprising at least one extender pigment ; and (iii) at
least one prepaint comprising at least one latex polymeric binder.
The number of prepaints is preferably 3-15 and wherein the
prepaints are different from each other, but mutually
compatible.
[0025] Also provided is a method of forming at least one paint
line, which method comprises the steps of
[0026] (a) providing a set of different, but mutually compatible,
fluid prepaints sufficient to formulate at least one paint line,
which set comprises (i) at least one prepaint comprising at least
one opacifying pigment, (ii) at least one prepaint comprising at
least one extender pigment; and (iii) at least one prepaint
comprising at least one latex polymeric binder; and (iv) wherein
the total number of prepaints is preferably 3-15.
[0027] (b) dispensing a predetermined amount of the prepaints into
containers or applicator(s) to form the paint line.
[0028] Further provided is a method of forming a range of paints,
the range comprising at least two paint lines, which method
comprises the steps of:
[0029] (a) providing a set of different, but mutually compatible,
fluid prepaints sufficient to formulate the range of paints, which
set comprises (i) at least one prepaint comprising at least one
opacifying pigment, (ii) at least one prepaint comprising at least
one extender pigment; (iii) at least one prepaint comprising at
least one latex polymeric binder, and (iv) at least one additional
different prepaint selected from the group consisting of (i), (ii),
and (iii); and
[0030] (b) dispensing a predetermined amount of each of the
prepaints into containers or applicator(s) form the paints
lines.
[0031] The above methods may further include the step of mixing one
or more of the prepaints before, while, or after they are dispensed
into the containers or before or while they are dispensed into the
applicator(s) device. They also may include the step of adjusting
the viscosity of the dispensed prepaints before, while, or after
they are dispensed into the containers or before or while they are
dispensed into the applicator(s) using a compatible thickener,
water or a mixture thereof. They may further include the step of
adding at least one colorant to the dispensed prepaints.
[0032] Additives that enhance the application of the paint or the
final performance properties of the paint may be included in the
prepaints. Such additives include aggregate and thickeners.
[0033] The above methods may be carried out at a paint
manufacturing facility, a point-of-sale or a point-of-use and the
providing dispensing steps may be controlled by a computer.
[0034] A set of different, but mutually compatible, prepaints
sufficient to form at least one paint line useful as an elastomeric
coating comprises (i) at least one fluid prepaint comprising at
least one opacifying pigment; (ii) at least one fluid prepaint
comprising at least one extender pigment; and (iii) at least one
fluid prepaint comprising at least one latex polymeric binder
having a Tg less than about 0.degree. C.
[0035] Also provided is a method of forming at least one paint line
useful as an elastomeric coating, which method comprises the steps
of:
[0036] a. providing a set of prepaints comprising (i) at least one
prepaint comprising at least one opacifying pigment; (ii) at least
one prepaint comprising at least one extender pigment; and (iii) at
least one prepaint comprising at least one latex polymeric binder;
having a Tg of less than about 0.degree. C.; and
[0037] b. dispensing a predetermined amount of each of the
prepaints into containers or applicator(s) to form the paint
line.
[0038] A method of forming a range of paints is provided, the range
comprising at least two paint lines useful as an elastomeric
coating, which method comprises the steps of:
[0039] a. providing a set of prepaints sufficient to formulate the
two paint lines, which set comprises (i) at least one fluid
prepaint comprising at least one opacifying pigment, (ii) at least
one fluid prepaint comprising at least one extender pigment, (iii)
at least one fluid prepaint comprising at least one latex polymeric
binder having a Tg of less than about 0.degree. C., and (iv) at
least one additional different prepaint selected from the group
consisting of (i), (ii), and (iii) and wherein the prepaints are
different from each other, but mutually compatible; and
[0040] b. dispensing a predetermined amount of each of the
prepaints into containers or applicator(s) devices to form the
range of paints.
[0041] Also provided is a set of different, but mutually
compatible, fluid non-cementitious prepaints sufficient to form at
least one paint line useful as a non-cementitious, aggregate
finish, which set comprises: (i) at least one prepaint comprising
at least one opacifying pigment; (ii) at least one prepaint
comprising at least one extender pigment; (iii) at least one
prepaint comprising at least one latex polymeric binder, and (iv)
at least one prepaint comprising an aggregate.
[0042] Also provided is a method of forming at least one paint line
useful as a non-cementitious, aggregate finish, which method
comprises the steps of:
[0043] (a) providing a set of different, but mutually compatible,
fluid non-cementitious prepaints comprising (i) at least one
opacifying prepaint comprising at least one opacifying pigment,
(ii) at least one extender prepaint comprising at least one
extender pigment; (iii) at least one binder prepaint comprising at
least one latex polymeric binder; and (iv) at least one prepaint
comprising an aggregate; and
[0044] b. dispensing a predetermined amount of each of the
prepaints into containers or applicator(s) to form the paint
line.
[0045] A method of forming a range of paints is provided. The range
comprises at least two paint lines useful as a non-cementitious,
aggregate finishing coating. The method comprises the steps of:
[0046] (a) providing a set of different, but mutually compatible,
fluid non-cementitious prepaints sufficient to formulate at least
two paint lines, which set comprises (i) at least one opacifying
prepaint comprising at least one opacifying pigment; (ii) at least
one extender prepaint comprising at least one extender pigment;
(iii) at least one binder prepaint comprising at least one latex
polymeric binder; (iv) at least one prepaint comprising an
aggregate; and (v) at least one different prepaint selected from
the group consisting of (i), (ii), (iii), and (iv); and
[0047] b. dispensing a predetermined amount of each of the
prepaints into containers or applicator(s) to form the paint
lines.
[0048] If one paint line is desired, i.e., if one key property is
important (for example, sheen level, tint base, use paint type, or
quality type), then the complete paint line can be made from one
each of the opacifying, extender, and binder prepaints.
[0049] If a range of paints including two paint lines is desired,
i.e., if two key properties are to be varied (for example, if two
will be selected from the sheen level, tint base, use type, and/or
quality type), then at least one additional different opacifying,
extender, or binder prepaint, depending on which key properties are
to be varied must be added to the set which comprises at least one
each of prepaints. "Additional different prepaints refers to
prepaints which are different from the opacifying, extender, and
binder prepaints, respectively, but which otherwise meet the
limitations associated with the opacifying, extender, and binder
prepaints (i), (ii), and (iii).
[0050] If a range of paints including three paint lines is desired,
i.e., if three key properties are to be varied (for example, if
three will be selected from the sheen level, tint base, use type,
and/or quality type), then at least two additional different
prepaints, depending on which key properties are to be varied must
be added to the set which comprises at least one each of the
opacifying, extender, and binder prepaints (i), (ii), and
(iii).
[0051] If a range of paints including four paint lines is desired,
i. e., if four key properties are to be varied (for example, the
sheen level, tint base, use type, and/or quality type), then at
least three additional different opacifying, extender, and binder
prepaints, depending on which key properties are to be varied must
be added to the set which comprises at least one each of the
opacifying, extender, and binder prepaints (i), (ii), and
(iii).
[0052] This procedure of adding additional prepaints having the
desired paint property may be used to vary as many additional key
paint properties as desired.
[0053] As discussed above, "a paint line" includes two or more
different paints whose dried films differ materially in at least
one observable property. The paints are different from each other
and must meet at least one of the following criteria:
[0054] (1) the pigment volume concentration (PVC) of the paints
which are most different must differ by at least 2%; or
[0055] (2) the volume solids (VS) of the paints which are most
different must differ by at least 2%.
[0056] The pigment volume concentration (PVC) is a measure of how
"binder-rich" a formulation is. It is calculated using the
following formula: 1 PVC ( % ) = volume of pigment ( s ) + volume
extender ( s ) volume of pigment ( s ) + volume extender ( s ) +
volume binder ( s ) .times. 100
[0057] The volume solids (VS) is the dry volume of pigment(s) plus
the dry volume of extender(s) plus the dry volume of binder(s). It
is calculated using by the following formula: 2 VS ( % ) = dry
volume of pigment ( s ) + dry volume of extender ( s ) + dry volume
of binder ( s ) total volume of formulation .times. 100.
[0058] If additives are present, their volume is not included in
determining the total dry volume.
[0059] In each of the above embodiments, the prepaints are selected
so that they cover a wide formulation space so that the desired
final paint properties lie within the blend space defined by the
prepaints at the extremes. In many cases, the prepaints themselves
will not be practical paints. But, by pushing the prepaints to
these extremes one can maximize the blend space available for the
set. When the prepaints, additives, and colorants are all fully
compatible, they can be blended at desired ratios to achieve the
desired paint line(s) and range of paints without inducing
colloidal instability. It is possible to make a specific paint in
the paint line without utilizing each of the prepaints available in
the set of prepaints. For example, a deep tone paint does not
require the use of an opacifying pigment prepaint.
[0060] This technique is similar to the design principles used in
statistical experimental design and analysis of mixture component
designs; however, instead of designing a mixture space to explore
the response surface within it, one is designing the boundaries of
the mixture space to maximize the flexibility of the paint system.
The key to success is to have mutual compatibility of the
individual prepaint ingredients and prepaints across the mixture
space.
[0061] Paint properties can be predicted in a number of ways. One
approach is to develop response surface models of the blend space
using standard Mixture Component experimental design statistical
tools. These simple statistical models can then be used by a linear
optimization program, by a massive grid search or by a graphical
analysis tool. Another approach is to simply use empirical methods
to determine which blends are needed for specific paint lines, then
incorporate those simple empirical recipes in the paint making
machine software.
[0062] An extension of the techniques is to have the paint machine
automatically pretest certain key properties (e.g., viscosity,
forced dry gloss or color) and make minor adjustments during the
formulating of a paint from the prepaints. Having feedback loops in
the paint machine can provide more precise matching of color,
gloss, and viscosity targets.
[0063] Compatible paint ingredients can be combined in the various
prepaints and the paints formed from the prepaints provide the
properties characteristic of the amount of ingredient used.
[0064] It is preferred that the all fluid prepaints employed in the
methods of the invention have the same or similar viscosities to
aid in mixing.
[0065] The water-resistance, including blister resistance, wet
adhesion, and scrub resistance of the paints prepared from the
prepaint sets, is expected to be improved because of the use of
lower amounts of stabilizing materials such as surfactants which
may be used relative to conventional formulating techniques.
Further, a line of pains or a range of paints prepared using the
prepaints may react more predictably to added-colorants, making
color matching easier and facilitating the use of software for
color matching. In addition, viscosity fluctuation in the final
paint formulation is expected to be reduced because of the prior
equilibration of ingredients in the prepaints.
[0066] The prepaints are formulated to maximize the flexibility of
paint manufacturing. Rather than purchasing individual paint
ingredients, paint manufacturers and even buyers at point-of-sale
and point-of-use (paint stores, paint departments, and
contractors), can purchase a set of prepaints to prepare a desired
range of paints. These sets of prepaints will contain at least one
each of prepaints x, y and z and possibly additional prepaints
depending upon the formulating flexibility desired. Optionally, the
above prepaints are mixed with an additional prepaint which
includes at least one colorant, such as a colored pigment or
dye.
[0067] The prepaint sets and formulating method of the present
invention is not limited to the preparation of only latex paints.
They may also be used to prepare any water-borne coating, or
related building products which require mixing ingredients,
including, architectural coatings, elastomeric wall and roof
coatings, topcoats and aggregate finish layers in EIFS, sealants,
caulks, mastics, adhesives and other building-related products.
DETAILED DESCRIPTION OF THE INVENTION
[0068] In one embodiment, the opacifying prepaint is a fluid
titanium dioxide prepaint which includes at least one opacifying
pigment, at least one dispersant, at least one thickener, and
water. The dispersant(s) and the thickener(s) are compatible with
the pigment(s) and with any other optional paint ingredients. The
prepaint has a volume solids content of about 30% to about 70%,
preferably about 35% to about 50%, and a Stormer viscosity of about
50 to about 250 KU, preferably about 60 to about 150 KU.
[0069] In an alternate embodiment, the opacifying prepaint is a
fluid titanium dioxide prepaint useful for formulating a one pack,
pigmented latex paint containing other paint ingredients. It
includes at least one opacifying pigment, at least one dispersant,
at least one thickener, at least one film-forming or
nonfilm-forming polymeric binder, and water. The dispersant(s), the
thickener(s), and the polymeric binder(s) are compatible with the
pigment(s) and with other optional paint ingredients. The prepaint
has a volume solids content of about 30% to about 70%, preferably
about 35% to about 50%, a PVC of about 35% to about 100%,
preferably about 50% to 100%, and a Stormer viscosity of about 50
to about 250 KU, preferably about 60 to about 150 KU. Preferably,
the prepaint is stable to sedimentation, which means that the
pigment does not settle out after 10 days at 25.degree. C.
Optionally, the polymeric binder is adsorbed onto the opacifying
pigment.
[0070] In one embodiment, the extender prepaint is a fluid pigment
extender prepaint which includes at least one mineral extender, at
least one thickener, an optional polymeric binder, and water. The
prepaint has a VS of about 30% to about 70%, preferably about 35%
to about 65%, a PVC of about 35% to 100%, preferably about 40% to
100%, and a Stormer viscosity of about 50 to about 250 KU,
preferably about 60 to about 150 KU. The prepaint ingredients are
compatible with each other and with the ingredients in the other
prepaints desired to be used therewith.
[0071] In one embodiment, the prepaint binder is a fluid latex
polymeric binder prepaint which includes a water-borne latex
polymeric binder having a Tg of about -40.degree. C. to about
70.degree. C., preferably about -10.degree. C. to about 60.degree.
C., and water. The binder prepaint has a volume solids content of
about 25% to about 70%, preferably about 30% to about 65%, and a
Brookfield viscosity of less than about 100,000 centipoise,
preferably about 100 to about 50,000 centipoise, at a shear rate of
1.25 reciprocal seconds. The prepaint ingredients are compatible
with each other and with the ingredients of the other prepaints
desired to be used therewith.
[0072] Minor amounts, i.e., less than about 10% by weight, based on
the total weight of the prepaint, of conventional paint additives
can be included in the above prepaints. Such additives include
acids, bases, defoamers, coalescents, cosolvents, mildewcides,
biocides, antifreeze agents and the like. The additives must be
compatible with the other paint ingredients in the prepaints.
[0073] Suitable opacifying pigments include white pigments which
impart white scattering power to the paint across all visible
wavelengths without a high degree of absorption. Pigment extenders
are inorganic solids or opaque polymers which do not impart the
primary color or hiding power to the paint although they may have
secondary influences on those properties. The tint bases used for
deep tone paints typically contain no or only very low levels of
opacifying pigments.
[0074] Suitable opacifying pigments include titanium dioxide
(TiO.sub.2) or a combination of titanium dioxide and auxiliary
hiding pigments such as synthetic polymer pigments, for example,
voided latex polymer particles, zinc oxide, lead oxide, and
mixtures thereof. Rutile and anatase grades of titanium dioxide are
suitable for use herein. Rutile titanium dioxide is preferred. The
surface of these titanium dioxides may be treated with various
organic surface treatments and/or inorganic surface treatments,
e.g., treatment with the oxides of silica, alumina, and zirconia.
Fumed titanium oxide is also useful herein.
[0075] Suitable voided latex particles have a diameter of about 100
nm to about 2,500 nm, preferably about 500 nm to about 1,100 nm and
a void fraction of about 10% to about 75%. The particles have at
least one void, but may have multiple voids, non-spherical voids,
interconnected voids, voids having channels connected to the
outside of the particles, and other structures described as
vesiculated and sponge-like. Preferably, the particles have a
single void. The particles have a glass transition temperature
(Tg), as measured by differential scanning calorimetry at a rate of
20.degree. C./min, of at least about 20.degree. C., preferably at
least about 50.degree. C. The higher the Tg, the harder the
particle is making it less likely to collapse. If the voided latex
particles collapse, they are unable to contribute to hiding. Voided
latex particles may be prepared by conventional polymerization
processes known in the art, such as those disclosed in U.S. Pat.
No. 3,784,391, U.S. Pat. No. 4,798,691, U.S. Pat. No. 4,908,271,
U.S. Pat. No. 4,972,000, U.S. Pat. No. 5,041,464, U.S. Pat. No.
5,157,084, U.S. Pat. No. 5,216,044 and U.S. Pat. No. 6,020,435, as
well as Japanese Patent Applications 60/223,873, 61/62510,
61/66710, 61/86941, 62/127336, 62/156387, 01/185311, and 02/140272.
Preferably, the voided latex particles are prepared according to
U.S. Pat. No. 4,427,836, U.S. Pat. No. 4,469,825, U.S. Pat. No.
4,594,363, U.S. Pat. No. 4,880,842, U.S. Pat. No. 5,494,971 and
U.S. Pat. No. 6,020,435.
[0076] Extender pigments useful herein include exterior and
interior extender pigments optimized for the intended end use.
Exterior extender pigments are not soluble in water and have a low
absorption number. They are optimized for exterior durability in
the particular market where the paint will be sold and they do not
detract from the desired non-cracking, non-chalking, and
non-dirt-retaining properties of the dried paint. They also provide
volume at a low cost. Interior extender pigments are optimized for
hiding, gloss, and low cost. Suitable extender pigments include
barium sulfate (1-15 microns), Blanc Fixe (0.5-5 microns), calcium
carbonate (0.05-35 microns), silica (0.001-14 microns), magnesium
silicate (0.5-15 microns), aluminum silicate (0.2-5 microns), mica,
bentonite, magnesium alumino-silicate, fumed allumina, colloidal
attapulgite, synthetic amorphous sodium alumino-silicate, sodium
potassium alumino-silicate, and the like.
[0077] Latex polymeric binders are polymers or prepolymers which
form the primary paint film. They bind the pigment and/or extender,
provide the required paint flow, and determine the gloss and
hardness of the final paint film. The binders selected for the
prepaints will depend upon the final use of the formulated paints.
Binders suitable for exterior paints are generally suitable for
interior paints, but binders suitable for interior paints may not
be suitable for exterior paints.
[0078] Suitable latex polymeric binders include, but are not
limited to, homopolymers, copolymers or terpolymers such as, for
example, acrylic and/or methacrylic, polymers or copolymers,
polyvinyl acetate, styrene-acrylic copolymers, styrene-butadiene
copolymers, vinyl acetate-acrylic copolymers, ethylene-vinyl
acetate copolymers, vinyl acetate-vinyl versatate copolymers, vinyl
acetate-vinyl maleate copolymers, vinyl acetate-vinyl
chloride-acrylic terpolymers, ethylene-vinyl acetate-acrylic
terpolymer, and urethane polymers. The polymers may contain up to
about 10% by weight of monomers containing functional groups, for
example, but not limited to, carboxylic acid, phosphate, sulfate,
sulfonate and amide groups, other monomers, and mixtures thereof.
Latex polymer binders optionally incorporated in prepaints x, y,
x', y', or other prepaints may be the same as or different from the
latex polymeric binder of prepaint z.
[0079] Thickener is a general term used to describe any material
added to a paint to modify its Theological profile. Preferred
thickeners are associative thickeners. Suitable thickeners for use
herein include polyvinyl alcohol (PVA), hydrophobically-modified,
alkali-soluble emulsions known in the art as HASE emulsions,
alkali-soluble or alkali-swellable emulsions known in the art as
ASE emulsion, hydrophobically-modified ethylene oxide-urethane
polymers known in the art as HEUR thickeners; and cellulosic
thickeners such as hydroxymethyl cellulose (HMC), hydroxyethyl
cellulose (HEC), hydrophobically-modified hydroxy ethyl cellulose
(HMHEC), sodium carboxymethyl cellulose (SCMC), sodium
carboxymethyl 2-hydroxyethyl cellulose, 2-hydroxypropyl methyl
cellulose, 2-hydroxyethyl methyl cellulose, 2-hydroxybutyl methyl
cellulose, 2-hydroxyethyl ethyl cellulose, 2-hydoxypropyl
cellulose, and the like. Also useful as thickeners are fumed
silica, attapulgite clay and other types of clay, titanate
chelating agents, and the like.
[0080] Suitable dispersants for use herein include non-ionic,
anionic and cationic dispersants such as 2-amino 2-methyl
1-propanol (AMP), dimethyl amino ethanol (DMAE), potassium
tripolyphosphate (KTPP), trisodium polyphosphate (TSPP), citric
acid and other carboxylic acids, and the like. Also, suitable for
use as dispersant are anionic polymers such as homopolymers and
copolymers based on polycarboxylic acids, including those that have
been hydrophobically- or hydrophilically-modified, e.g.,
polyacrylic acid or polymethacrylic acid or maleic anhydride with
monomers such as styrene, acrylate or methacrylate, diisobutylene,
and other hydrophilic or hydrophobic comonomers as well as the
salts of the aforementioned dispersants, and mixtures thereof.
[0081] Suitable defoamers include silicone-based and mineral
oil-based defoamers, and the like.
[0082] Coalescents are not necessary if solvent-free latex polymer
binders are used in the binder prepaints. Solvent-free binders
typically have a low Tg and low minimum film-forming temperature so
that they are film-forming at ambient temperatures, (about
20.degree. C.). If a coalescent is required, preferably it is
incorporated in prepaint z and any other prepaints containing latex
polymeric binders.
[0083] Suitable coalescents, plasticizers, and other optional
solvents include ethylene glycol, propylene glycol, hexylene
glycol, 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate
(TEXANOL.TM.), glycol ethers, mineral spirits, methyl carbitol,
butyl carbitol, phthalates, adipates, and the like.
[0084] Suitable mildewcides and biocides include zinc oxide,
isothiazolones, triazoles, and the like.
[0085] Suitable surfactants include cationic, anionic, and
non-ionic surfactants.
[0086] Suitable aggregates include small (typically 40 mesh and
higher), intermediate (typically 20-40 mesh), and large (typically
20 mesh and lower) aggregates such as sand, large particle size
carbonates (limestone), ceramics, glass, fibers, coal, granite,
talc, multicolored quartz, crushed sea shells, recycled asphalt
products, fiberglass, vermiculite, perlite, XO aggregate and the
like.
[0087] In another preferred embodiment, the prepaints may be used
in the formulation to make elastomeric coatings suitable for either
wall or roof applications. These prepaints may be mixed in various
ratios to obtain elastomeric coatings of different quality,
flexibility, mildew protection, and substrate adhesion suitable for
either application on walls or roofs. What distinguishing the
present elastomeric coatings from typical architectural coatings is
the inclusion of binders having low temperature (<0.degree. C.)
flexibility and the thickness at which the elastomeric coating is
applied, which is typically a dry coating thickness of 6-20 mil for
wall applications and 15-40 mil for roof applications. Low
temperature flexibility is particularly desirable for elastomeric
coatings that are being used over walls that may develop cracks,
such as masonry walls, or roofing substrates that have a high
degree of dimensional variance with climate. In addition to coating
flexibility, it is desirable to have a paint line with different
qualities with different degrees of low temperature flexibility,
with the ability to adhere to different substrates, and with
variations in appearance.
[0088] The following formulation properties influence both low
temperature flexibility and coating durability:
[0089] For climates that experiences freezing temperatures through
the winter, the following table shows the effect of the PVC,
TiO.sub.2 PVC, and temperature the paint quality:
1 Paint Description PVC TiO.sub.2 PVC Flexibility Temperature high
quality <40 >5 <0.degree. F. medium <40 4-5
<0.degree. F. medium >40 >5 <0.degree. F. low >40
<4 <0.degree. F.
[0090] For a climate that has few days of freezing temperatures
through the winter the following chart shows the effect of PVC,
TiO.sub.2 PVC, and temperatures on the paint quality:
2 Paint Description PVC TiO.sub.2 PVC Flexibility Temperature high
quality <40 >5 <0.degree. F. medium <40 4-5
<32.degree. F. medium >40 >5 <32.degree. F. low >40
<4 <32.degree. F. poor >40 >4 <40.degree. F.
[0091] The quality of the elastomeric coating also depends on the
absence or presence of zinc oxide (ZnO) in the formulation, because
zinc oxide changes the mechanical properties of the coating.
[0092] Finally, the elastomeric coating may be further varied
through the addition of colorants. Typically, these colorants are
dry ground and made in the coating grind portion.
[0093] For elastomeric coatings, the properties which may be varied
to make different elastomeric coatings which include coating
flexibility, coating quality (durability), substrate adhesion, and
appearance.
[0094] To vary the flexibility of the elastomeric coating, one may
adjust the Tg of the binder, the PVC of the coating, and presence
and level of zinc oxide. To vary the durability of the elastomeric
coating, one may adjust the level of TiO.sub.2. To vary the
substrate adhesion of the elastomeric coating, one may formulate to
coat a wall or a roof by varying the binder composition and level.
To vary the appearance of the elastomeric coating, one may adjust
the level and type of colorant. To obtain these different
properties one may prepare a set of prepaints using the procedure
set forth in Examples 36-41, and mix the prepaints in quantities
appropriate to make elastomeric coatings that vary the above
properties.
[0095] In another preferred embodiment, sets of prepaints and may
be used to make non-cementitious, aggregate finish coatings
suitable for application directly on a wall or as a topcoat in
EIFS. The prepaints or preformulated components may be mixed in
varying ratios to obtain coatings of different flexibility, quality
(durability), color and texture.
[0096] The following formulation properties provide an example of
how one may influence the durability of non-cementitious, aggregate
finish coatings used in specifically for EIFS. Other types of
aggregate finishes may have different ranges of PVC that correspond
to different qualities. Therefore, the description below is only
meant to be an example for aggregate finish coatings used in EIFS,
and is not meant to define PVC levels used in other
non-cementitious, aggregate finish coatings.
3 Quality Description PVC high quality <72 medium 72-77 low
>77
[0097] In addition, one may define the following formulation
properties that affect color strength. Other types of aggregate
finishes may have different ranges of TiO.sub.2 levels that
correspond to different color strengths. Therefore, the description
below is only meant to be an example for aggregate finish coatings
used in EIFS, and is not meant to define TiO.sub.2 levels used in
other aggregate finishes.
4 Quality Description TiO.sub.2 PVC (%) white, pastels >1.5
midtones 0.5-1.5 deep tones <0.5
[0098] Finally, one may also define the aggregate size and amount
which affect coating's texture.
5 Description Small Aggregate Large Aggregate fine >90%
.ltoreq.10% coarse .ltoreq.90% >10%
[0099] Further variations in the performance of aggregate finish
can be achieved by varying the flexibility or Tg of the binder.
[0100] In the formulation of non-cementitious, aggregate finish
coatings, one may vary the PVC level, the TiO.sub.2 level, the
aggregate ratio, and the binder Tg to make different coatings.
[0101] To differentiate based on the flexibility of
non-cementitious, aggregate finish coatings, one may adjust the Tg.
To differentiate based on the durability of non-cementitious,
binder's aggregate finish coatings, one may adjust the PVC. To
differentiate based on the color of the non-cementitious, aggregate
finish coatings, one may adjust the level of TiO.sub.2 and the type
and level of colorant. To differentiate based on the texture of the
non-cementitious, aggregate finish coatings, one may adjust the
size and level of the large aggregate and ratio of the large
aggregates to small aggregates. To obtain coating that have these
different properties one may prepare the prepaint set as set forth
in Examples 54-58 a set of prepaints which can be formulated into
and mix the prepaints in appropriate quantities to make
non-cementitious, aggregate finish coatings that vary in the
properties.
[0102] In the following examples, all ranges are inclusive and the
minimums and maximums of the nested ranges are combinable.
[0103] Test Procedures
[0104] The Stormer viscosity of the prepaints is measured using
ASTM method D562. The Brookfield viscosity of the binder prepaints
and final paints is measured using spindle #4 of a Brookfield
viscometer at 6 rpm. The ICI viscosity of the prepaints and paints
is measured using ASTM method D3205-77.
EXAMPLES
Example 1
[0105] This example describes the preparation of a white prepaint
which was prepared by combining the following ingredients:
6 Amount Ingredient (lbs./100 gallons) Pigment - Titanium Dioxide
Slurry (76.5% solids) 1152.25 (Ti-Pure .TM. R-746 -- DuPont)
Dispersant 7.06 (Tamol .TM. 1124 - Rohm and Haas) Defoamer 1.00
(Drewplus .TM. L-475) Binder Acrylic (50% solids - Tg 28.degree. C.
166.32 (Rhoplex .TM. SG-10M - Rohm and Haas) Opacifer - Voided
Latex Particles 151.80 (Ropaque .TM. OP-96 - Rohm and Haas)
Coalescent 12.95 (Texanol .TM.) Rheology Modifier 12.76 (Acrysol
.TM. RM-8W - Rohm and Haas) Base - Ammonia (28%) 1.65
[0106] The prepaint was prepared using a laboratory mixer having a
45.degree. pitch stirring blade. The water, dispersant, and
defoamer, were combined and mixed. The titanium dioxide slurry was
slowly added and the mixture was stirred for 15-20 minutes. The
binder, coalescent, rheology modifier, ammonia, and additional
water if necessary were then added.
[0107] The resulting prepaint had a total volume of 100 gallons,
total weight of 1,505.8 lbs., total PVC of 80.0%, volume solids of
44.0%, weight solids of 67.1%, density of 15.058 lbs./gallon, 0.40%
dispersant on pigment solids, and 10.0% coalescent on latex solids.
Its initial and equilibrated Stormer viscosities were 88 and 90 KU.
Its initial and equilibrated pH values were 8.8and8.6.
Example 2
[0108] This example describes the preparation of an exterior
pigment extender prepaint. It was prepared as above by combining
the following ingredients:
7 Ingredient Amount (lbs./100 gallons) Pigment - Nephilene Syenite
(7.5.mu.) 784.30 (Minex .TM. 4) Dispersant 7.84 (Tamol .TM. 1124 -
Rohm and Haas) Defoamer 2.00 (Drewplus .TM. L-475) Binder Acrylic
(53.5% solids - Tg 18.degree. C.) 157.49 (Rhoplex .TM. ML-200 -
Rohm and Haas) Coalescent 5.90 (Texanol .TM.) Rheology Modifier
2.55 (Acrysol .TM. RM-8W - Rohm and Haas) Water 368.86
[0109] The resulting prepaint had a total volume of 100 gallons,
total weight of 1,328.9 lbs., total PVC of 80.0%, volume solids of
45.0%, weight solids of 65.4%, density of 13.29 lbs./gallon, 0.50%
total dispersant on pigment solids and 7.0% total coalescent on
binder solids. The initial and equilibrated Stormer viscosities
were 90 and 93. The initial and equilibrated pH values were 8.9 and
8.7.
Example 3
[0110] This example describes the preparation of an interior
pigment extender prepaint which was prepared as described above by
combining the following ingredients:
8 Amount (lbs./ Ingredient 100 gallons) Pigment - Calcium Carbonate
(12.mu.) 405.67 (Omyacarb .TM. 12) Pigment - Calcium Carbonate
(3.2.mu.) 203.59 (Vicron .TM. 15-15) Pigment - Aluminum Silicate
(1.4.mu.) 165.41 (Optiwhite .TM.) Dispersant 7.75 (Tamol .TM. 1124
-Rohm and Haas) Defoamer 1.00 (Drewplus .TM. L-475) Binder - Vinyl
Acetate/Acrylic (55% solids - Tg 14 .degree. C.) 157.61 (RES .TM.
3803- Rohm and Haas) Coalescent (Texanol .TM.) 6.07 Rheology
Modifier - HEUR (Acrysol .TM. RM-2020-NPR) 17.53 Base - Ammonia
(28%) 0.87 Water 356.59
[0111] The resulting prepaint had a total volume of 100 gallons,
total weight of 1,322.1 lbs., total PVC of 80%, volume solids of
45%, weight solids of 65.15%, density of 13.2210 lbs./gallon, 0.50%
dispersant on pigment solids, and 7.00% coalescent on binder
solids, Its initial and equilibrated Stormer viscosities were 94
and 97. Its initial and equilibrated pH values were both 9.2.
Example 4
[0112] This example describes a vinyl acetate/acrylic latex polymer
binder prepaint which was prepared as described above except that
the binder, defoamer, coalescent, ammonia, water, and rheology
modifier were combined and mixed. The ingredients and amounts were
as follows:
9 Amount (lbs./ Ingredient 100 gallons) Defoamer 8.00 (Drewplus
.TM. L-475) Binder - Vinyl Acetate/Acrylic (55% solids - Tg
14.degree. C.) 788.06 (RES .TM. 3803- Rohm and Haas) Coalescent
30.34 (Texanol .TM.) Rheology Modifier -HEUR 3.02 (Acrysol .TM.
SCT-275 - Rohm and Haas) Base - Ammonia (28%) 1.95 Water 60.08
[0113] The resulting prepaint had a total volume of 100 gallons,
total weight of 891.5 lbs., volume solids of 45.0%, a weight solids
of 48.6%, a density of 8.91 lbs./gallon and 7.0% coalescent on
binder solids. Its initial and equilibrated Stormer viscosities
were 88 and 90. Its initial and equilibrated pH values were 8.6 and
8.4. Its equilibrated Brookfield viscosity should be less than
10,000 cps.
Example 5
[0114] This example describes a flat acrylic binder prepaint which
was prepared as above by combining the following ingredients:
10 Ingredient Amount (lbs./100 gallons) Defoamer 8.00 (Drewplus
.TM. L-475) Binder - Acrylic (53.5% solids - Tg 18.degree. C.)
769.96 (Rhoplex .TM. ML-200 - Rohm and Haas) Coalescent 28.83
(Texanol .TM.) Rheology Modifier (HEUR) 1.15 (Acrysol .TM. RM-8W -
Rohm and Hans) Base - Ammonia (28%) .57 Solvent - Propylene Glycol
60.00 Water 12.84
[0115] The resulting prepaint had a total volume of 100 gallons,
total weight of 881.4 lbs., volume solids of 44.0%, weight solids
of 46.7%, density of 8.81 lbs./gallon, and 7.0% coalescent on
binder solids. Its initial and equilibrated Stormer viscosities
were 91 and 89. Its initial and final pH values were both 8.9/9.0.
Its equilibrated Brookfield viscosity should be less than 10,000
cps.
Example 6
[0116] This example describes a gloss acrylic binder prepaint which
was prepared as described above by combining the following
ingredients:
11 Ingredient Amount (lbs./100 gallons) Defoamer 8.00 (Drewplus
.TM. L-475) Binder - Acrylic (50% solids - Tg 28.degree. C.) 737.08
(Rhoplex .TM. SG-10M - Rohm and Haas) Coalescent 36.85 (Texanol
.TM. ) Rheology Modifier - HEUR 11.62 (Acrysol .TM. RM 8W - Rohm
and Haas) Base - Ammonia (28%) .35 Solvent - Propylene Glycol 60.00
Water 21.26
[0117] The resulting prepaint had a total volume of 100 gallons, a
total weight of 875.2 lbs., volume solids of 39.0%, a weight solids
of 42.11%, a density of 8.75 lbs./gallon and 10.0% coalescent on
binder solids. Its initial and equilibrated Stormer viscosities
were 97 and 98. The initial and equilibrated pH values were 9.0.
Its equilibrated Brookfield viscosity should be less than 10,000
cps.
Example 7
[0118] This example describes the preparation of a white pigment
prepaint including a solvent-free acrylic binder and without the
use of a coalescent. The ingredients are mixed as described in
Example 1 using the ingredients and amounts set out below.
12 Amount Ingredient (lbs./100 gallons) Pigment-Titanium Dioxide
734.49 (Ti-Pure .TM. R-706 - DuPont) Opacifier - Voided Latex
Particles 164.43 (Ropaque .TM. OP-96 - Rohm and Haas) Dispersant
29.38 (Tamol .TM. 731 - Rohm and Haas) Non-ionic Surfactant 2.00
(Triton .TM. CF-10) Biocide 2.00 (Kathon .TM. LX (1.5%) - Rohm and
Haas) Defoamer 3.00 (Foamaster .TM. VL) Binder - Acrylic copolymer
(43.5% solids - 165.96 Tg -2.degree. C.) (Rhoplex .TM. SF-012 -
Rohm and Haas) Rheology Modifier - HEUR 5.00 (Acrysol .TM. RM-825 -
Rohm and Haas) Rheology Modifier - HEUR 42.69 (Acrysol .TM. RM-2020
NPR - Rohm and Haas) Base - Ammonia (28%) .49 Water 250.13
[0119] The resulting prepaint should have a total volume of 100
gallons, total weight of 1,401.3 lbs., total PVC of 80.0%, volume
solids of 40.0%, weight solids of 61.1% density of 14.01
lbs./gallon, and 1.0% dispersant on pigment solids. Its estimated
Stormer viscosity is 102 KU. Its pH should be 8.5-9.0.
Example 8
[0120] This example describes the preparation of an exterior
pigment extender prepaint with a solvent-free acrylic binder
without the use of a coalescent. The ingredients are mixed as
described in Example 1 using the ingredient amounts set out
below.
13 Ingredient Amount (lbs./100 gallons) Pigment - Nephiline Syenite
(7.5.mu.) 697.16 (Minex .TM. 4) Dispersant 27.89 (Tamol .TM. 731 -
Rohm and Haas) Non-ionic Surfactant 2.00 (Triton .TM. CF-10)
Biocide 2.00 (Kathon .TM. LX (1.5%) - Rohm and Haas) Defoamer 3.00
(Foamaster .TM. VL) Binder - Acrylic (46.5% solids - Tg 1.degree.
C.) 160.84 (Primal .TM. SF-015 Rohm and Haas) Rheology Modifier
HEUR 101.80 (Acrysol .TM. RM-2020 NPR - Rohm and Haas) Water
284.47
[0121] The resulting prepaint should have a total volume of 100
gallons, total weight of 1,280.9 lbs., total PVC of 80.0%, volume
solids of 40.0%, weight solids of 60.27%, density of 12.81
lbs./gallon, and 1.0% dispersant on pigment solids. Its Stormer
viscosity should be 95 KU. Its pH should be 8.5-9.0. If not, the pH
is adjusted as described in Example 7.
Example 9
[0122] This example describes the preparation of an interior
pigment extender prepaint including a solvent-free vinyl
acetate/acrylic binder without the use of a coalescent. The
ingredients are mixed as described in Example 1 using the
ingredient amounts set out below.
14 Ingredient Amount (lbs./100 gallons) Pigment - Calcium Carbonate
(3.2.mu.) 451.20 (Snowflake .TM. ) Pigment - Aluminum Silicate
(1.4.mu.) 220.37 (Optiwhite .TM. ) Dispersant 19.19 (Tamol .TM.
1254 - Rohm and Haas) Non-ionic Surfactant 2.00 (Triton .TM. CF-10)
Biocide 2.00 (Kathon .TM. LX (1.5%)) Defoamer 3.00 (Foamaster .TM.
VL) Binder - Vinyl Acetate/Acrylic (55% solids) 139.86 (Rovace .TM.
9900) Rheology Modifier HASE 9.00 (Acrysol .TM. DR-3) Base -
Ammonia (28%) 0.86 Water 405.69
[0123] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,254.9 lbs., total PVC of 80.0%, volume
solids of 40.0%, weight solids of 59.65%, density of 12.55
lbs./gallon, and 1.0% dispersant on pigment solids. Its Stormer
viscosity should be 95 KU. Its pH should be 8.5-9.0.
Example 10
[0124] This example describes the preparation of a vinyl
acetate/acrylic latex polymer binder prepaint including a
solvent-free vinyl acetate/acrylic binder without a coalescent. The
ingredients are mixed as described in Example 4 using the
ingredient amounts set out below.
15 Ingredient Amount (lbs./100 gallons) Binder - Vinyl
Acetate/Acrylic (55% solids - 699.25 Tg 10.degree. C.) (Rovace .TM.
9900 - Rohm and Haas) Defoamer 3.00 (Foamaster .TM. VL) Rheology
Modifier HASE 12.96 (Acrysol .TM. DR-3 - Rohm and Haas) Base -
Ammonia (28%) 2.90 Water 405.69
[0125] The resulting prepaint should have a total volume of 100
gallons, total weight of 885.2 lbs., volume solids of 40.0%, a
weight solids of 43.5%, and density of 8.85 lbs./gallon. Its
Stormer viscosity should be 99 KU. Its Brookfield viscosity should
be less than 10,000 cps. Its pH should be 8.5-9.0.
Example 11
[0126] This example describes the preparation of a flat latex
polymer binder prepaint including a solvent-free acrylic binder and
no coalescent. The ingredients are mixed as described in Example 4
using the ingredient amounts set out below.
16 Amount Ingredient (lbs./100 gallons) Defoamer 8.00 (Foamaster
.TM. VL) Binder - Acrylic Copolymer (43.5% solids - 723.77 Tg
-2.degree. C.) (Rhoplex .TM. SF-012 - Rohm and Haas) Rheology
Modifier - HEUR 3.00 (Acrysol .TM. RM - 2020 NPR - Rohm and Haas)
Water 133.75
[0127] The resulting prepaint should have a total volume of 100
gallons, a total weight of 868.5 lbs., volume solids of 36.0%,
weight solids of 38.8% and density of 8.69 lbs./gallon. Its Stormer
viscosity should be 99 KU. Its Brookfield viscosity should be less
than 10,000 cps. Its pH should be 8.5-9.0 and, if not, it is
adjusted as discussed above.
Example 12
[0128] This example describes the preparation of a gloss latex
polymer binder prepaint using a solvent-free acrylic binder and no
coalescent. The ingredients are mixed as described in Example 4
using the ingredient amounts set out below.
17 Amount Ingredient (lbs./100 gallons) Defoamer 8.00 (Foamaster
.TM. VL) Binder - Acrylic Copolymer (43.5% solids - 767.57 Tg
-2.degree. C.) (Rhoplex .TM. SF-012 - Rohm and Haas) Rheology
Modifier - HEUR 23.00 (Acrysol .TM. RM-2020 NPR - Rohm and Haas)
Water 61.62
[0129] The resulting prepaint should have a total volume of 100.0
gallons, total weight of 860.4 lbs., volume solids of 37.0%, a
weight solids of 38.8% and a density of 8.60 lbs./gallon. Its
Stormer viscosity should be 99 KU. Its Brookfield viscosity should
be less than 10,000 cps. Its pH should be 8.5-9.0 and, if not, it
should be adjusted as described above.
Example 13
[0130] This example describes the preparation of a white pigment
prepaint using an interior gloss grade titanium dioxide which was
prepared by combining the following ingredients:
18 Amount Ingredient (lbs./100 gallons) Pigment - Titanium Dioxide
734.49 (Ti-Pure .TM. R-900 - DuPont) Opacifier - Voided Latex
Particles (30.5% solids) 164.43 (Ropaque .TM. Ultra-Rohm and Haas)
Dispersant 20.99 (Tamol .TM. 1254 - Rohm and Haas) Non-ionic
Surfactant 2.00 (Triton .TM. CF-10) Biocide 2.00 (Kathon .TM. LX
(1.5%) - Rohm and Haas) Defoamer 3.00 (Foamaster .TM. VL - source)
Binder - Vinyl Acetate/Acrylic (55% solids - 140.10 Tg 14.degree.
C.) (RES 3083 - Rohm and Haas) Coalescent 11.37 (Texanol .TM. )
Rheology Modifier - HASE 11.47 (Acrysol .TM. DR-3) Base - Ammonia
(28%) 1.20 Solvent - Propylene Glycol 50.00 Water 264.38
[0131] The resulting prepaint had a total volume of 100 gallons, a
total weight of 1405.4 lbs., total PVC of 80%, volume solids of
40%, weight solids of 61.25%, density of 14.05 lbs./gallon, 1.0%
dispersant on pigment solids, and 9.0% coalescent on binder solids.
The Stormer viscosity was 100 KU. The Brookfield viscosity was
15,300 cps. The pH was 8.8.
Example 14
[0132] This example describes the preparation of a white pigment
prepaint using an exterior gloss grade titanium dioxide which was
prepared by combining the following ingredients:
19 Amount Ingredient (lbs./100 gallons) Pigment-Titanium Dioxide
734.56 (Ti-Pure .TM. R-706-DuPont) Opacifier - Voided Latex
Particles (30.5% solids) 164.44 (Ropaque .TM. Ultra-Rohm and Haas)
Dispersant 29.38 (Tamol .TM. 731 - Rohm and Haas)) Non-ionic
Surfactant 2.00 (Triton .TM. CF-10) Biocide 2.00 (Kathon .TM. LX
(1.5%) - Rohm and Haas) Defoamer 3.00 (Foamaster .TM. VL) Binder -
Acrylic Copolymer (50% solids - 151.20 Tg 28.degree. C.) (Rhoplex
.TM. SG-10 - Rohm and Haas) Coalescent 12.49 (Texanol .TM. )
Rheology Modifier)HEUR 42.69 (Acrysol .TM. RM-2020 NPR - Rohm and
Haas) Base - Ammonia (28%) .49 Solvent - Propylene Glycol 50.00
Water 211.34
[0133] The resulting prepaint had a total volume of 100 gallons, a
total weight of 1403.6 lbs., total PVC of 80%, volume solids of
40%, weight solids of 61.2%, density of 14.04 lbs./gallon, 1.0%
dispersant on pigment solids, and 9.0% coalescent on binder solids.
The Stormer viscosity was 100 KU. The Brookfield viscosity was
4,010 cps. The pH was 8.8.
Example 15
[0134] This example describes the preparation of an exterior
pigment extender prepaint. It was prepared by combining the
following ingredients:
20 Ingredient Amount (lbs./100 gallons) Pigment - Nephilene Syenite
(7.5.mu.) 697.16 (Minex .TM. 4) Dispersant 27.89 (Tamol .TM. 731 -
Rohm and Haas) Non-ionic Surfactant 2.00 (Triton .TM. CF-10)
Biocide 2.00 Kathon .TM. LX (1.5%) - Rohm and Haas) Defoamer 3.00
(Foamaster .TM. VL) Binder-Acrylic (53.5% solids - Tg 18.degree.
C.) 139.98 (Rhoplex .TM. Multilobe 200 - Rohm and Haas) Coalescent
5.24 (Texanol .TM. ) Rheology Modifier - HEUR 101.80 (Acrysol .TM.
RM - 2020 - Rohm and Haas) Solvent-Propylene Glycol 50.00 Water
254.40
[0135] The resulting prepaint had a total volume of 100 gallons, a
total weight of 1281.5 lbs., total PVC of 80.0%, volume solids of
40.0%, weight solids of 60.3%, density of 12.81 lbs./gallon, 1.0%
dispersant on pigment solids, and 7.0% total coalescent on binder
solids. The Stormer viscosity was 96 KU. The Brookfield viscosity
was 7,210 cps. The pH was 9.8.
Example 16
[0136] This example describes the preparation of an interior
pigment extender prepaint. It was prepared by combining the
following ingredients:
21 Amounts (lbs./ Ingredients 100 gallons) Pigment - Calcium
Carbonate (5 .mu.) 451.20 (Snowflake .TM.) Pigment - Aluminum
Silicate (1.4 .mu.) 220.37 (Optiwhite .upsilon.) Dispersant 19.19
(Tamol .TM. 1254 - Rohm and Haas) Non-ionic Surfactant 2.00 (Triton
.TM. CF-10) Biocide 2.00 (Kalthon .TM. LX (1.5%) - Rohm and Haas)
Defoamer 3.00 (Foamaster .upsilon. VL) Binder - Vinyl
Acetate/Acrylic (55% solids - Tg 14.degree. C.) 140.10 (RES 3083 -
Rohm and Haas) Coalescent 6.93 (Texanol .TM.) Rheology Modifier -
HASE 11.00 (Acrysol .TM. DR-3 - Rohm and Haas) Base - Ammonia (28%)
0.86 Solvent - Propylene Glycol 50.00 Water 348.48
[0137] The resulting prepaint had a total volume of 100 gallons, a
total weight of 1255.1 lbs., total PVC of 80.0%, volume solids of
40.0%, a weight solids of 59.7%, density of 12.55 lbs./gallon, 1.0%
dispersant on pigment solids, and 9.0% total coalescent on binder
solids. The Stormer viscosity was 102 KU. The Brookfield viscosity
was 3,410 cps. The pH was 8.9.
Example 17
[0138] This describes the preparation of a vinyl acetate/acrylic
binder prepaint. It was prepared by combining the following
ingredients:
22 Amounts (lbs./ Ingredients 100 gallons) Defoamer 3.00 (Foamaster
VL) Binder - Vinyl Acetate/Acrylic (55% solids - Tg 14.degree. C.)
700.48 (RES 3083 - Rohm and Haas) Coalescent 34.67 (Texanol .TM.)
Rheology Modifier - HASE 12.96 (Acrysol .TM. DR-3 - Rohm and Haas)
Base - Ammonia (28%) 2.90 Solvent - Propylene Glycol 50.00 Water
83.48
[0139] The resulting prepaint had a total volume of 100 gallons, a
total weight of 887.5 lbs., volume solids of 40.0%, a weight solids
of 43.4%, a density of 8.88 lbs./gallon, 9.0% coalescent on binder
solids. Its Stormer viscosity was 98.0. The Brookfield viscosity
was 13,600 cps. Its pH was 9.0.
Example 18
[0140] This example describes the preparation of a flat acrylic
binder prepaint. It was prepared by combining the following
ingredients:
23 Amounts Ingredients (lbs./100 gallons) Defoamer 3.00 (Foamaster
.TM. VL) Binder - Acrylic (53.5% solids - Tg 18.degree. C.) 699.92
(Rhoplex .TM. Multilobe 200 - Rohm and Haas) Coalescent 26.21
(Texanol .TM.) Rheology Modifier - HEUR 1.44 (Acrysol .TM. RM-2020
NPR - Rohm and Haas) Base - Ammonia (28%) 0.35 Solvent - Propylene
Glycol 50.00 Water 96.59
[0141] The resulting prepaint had a total volume of 100 gallons, a
total weight of 877.5 lbs., volume solids of 40.0%, weight solids
of 42.7%, density of 8.78 lbs./gallon, 7.0% coalescent on binder
solids. Its Stormer viscosity was 94.0. The Brookfield viscosity
was 4,900 cps. Its pH was 8.9.
Example 19
[0142] This example describes the preparation of a gloss acrylic
binder prepaint. It was prepared by combining the following
ingredients:
24 Amounts Ingredients (lbs./100 gallons) Defoamer 3.00 (Foamaster
.TM. VL) Binder - Acrylic Copolymer (50% solids - Tg 28.degree. C.)
755.99 (Rhoplex .TM. SG-10M - Rohm and Haas) Coalescent 37.80
(Texanol .TM.) Rheology Modifier - HEUR 11.62 (Acrysol .TM. RM-2020
NPR - Rohm and Haas) Base - Ammonia (28%) 0.35 Solvent - Propylene
Glycol 50.00 Water 17.68
[0143] The resulting prepaint had a total volume of 100 gallons, a
total weight of 876.4 lbs., volume solids of 40.0%, weight solids
of 43.1%, a density of 8.76 lbs./gallon, 10.0% coalescent on binder
solids. Its Stormer viscosity was 96. The Brookfield viscosity was
5,000 cps. Its pH was 8.8.
Example 20
[0144] This example describes the preparation of a white prepaint
by combining the following ingredients:
25 Ingredient Amount (lbs./100 gallons) Pigment - Titanium Dioxide
1001.66 (Ti-Pure .TM. R-706 -- DuPont) Dispersant 20.03 (Tamol .TM.
1124 - Rohm and Haas) Defoamer 1.00 (Drewplus .TM. L-475) Binder
Acrylic (50% solids - Tg 28.degree. C. 189.00 (Rhoplex .TM. SG -
10M - Rohm and Haas) Opacifer - Voided Latex Particles 172.50
(Ropaque .TM. OP-96 - Rohm and Haas) Coalescent 14.72 (Texanol
.TM.) Rheology Modifier 2.00 (Acrysol .TM. RM-8W - Rohm and Haas)
Base - Ammonia (28%) 1.65 Water 200.44
[0145] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,603.0 lbs., total PVC of 80.0%, volume
solids of 50.0%, weight solids of 71.7%, a density of 16.03
lbs./gallon, 1% dispersant on pigment solids, and 10.0% coalescent
on latex solids.
Example 21
[0146] This example describes the preparation of a white pigment
prepaint with pigmented vesiculated polymeric bead. The pigmented
vesiculated polymeric bead has a particle size of 12.5 microns,
approximately 7% (s/s) titanium dioxide, and a void volume of
approximately 77%. The ingredients are mixed as described in
Example 1 using the ingredient amounts set out below.
26 Ingredient Amount (lbs./100 gallons) Pigmented Vesiculated
Polymeric Bead 733.00 (Spindrift .TM. 25) Dispersant 0 (Tamol .TM.
1124 - Rohm and Haas) Defoamer 2.00 (Drewplus .TM. L-475) Binder
Acrylic (53.5% solids - Tg 18.degree. C.) 154 (Rhoplex .TM. ML-200
- Rohm and Haas) Coalescent 5.90 (Texanol .TM.) Rheology Modifier
2.55 (Acrysol .TM. RM-8W - Rohm and Haas) Water 15.89
[0147] The resulting prepaint should have a total volume of 100
gallons, total weight of 913.3 lbs., total PVC of 80.0%, volume
solids of 44.0%, weight solids of 28.28%, and density of 9.13
lbs./gallon. Its Stormer viscosity should be 91 KU. Its pH should
be 8.5-9.0. If not, the pH is adjusted as described in Example
7.
Example 22
[0148] This example describes the preparation of an exterior
pigment extender prepaint by combining the following
ingredients:
27 Ingredient Amount (lbs./100 gallons) Pigment - Nephilene Syenite
(7.5 .mu.) 871.44 (Minex .TM. 4) Dispersant 8.71 (Tamol .TM. 1124 -
Rohm and Haas) Defoamer 2.00 (Drewplus .TM. L-475) Binder Acrylic
(60.5% solids - Tg 16.degree. C.) 154.74 (Rhoplex .TM. AC-264 -
Rohm and Haas) Coalescent 6.56 (Texanol .TM.) Rheology Modifier
3.00 (Acrysol .TM. RM-8W - Rohm and Haas) Water 326.08
[0149] The resulting prepaint should have a total volume of 100
gallons, total weight of 1,382.5 lbs., total PVC of 80.0%, volume
solids of 50.0%, weight solids of 69.8%, density of 13.82
lbs./gallon, 0.5% dispersant on pigment solids, and 7.0% coalescent
on latex solids.
Example 23
[0150] This example describes the preparation of an interior
pigment extender prepaint by combining the following
ingredients:
28 Amount (lbs./ Ingredient 100 gallons) Pigment - Calcium
Carbonate (12 .mu.) 450.67 (Omyacarb .TM. 12) Pigment - Calcium
Carbonate (3.2 .mu.) 226.17 (Vicron .TM. 15-15) Pigment - Aluminum
Silicate (1.4 .mu.) 183.76 (Optiwhite .TM.) Dispersant 8.61 (Tamol
.TM. 1124 - Rohm and Haas) Defoamer 1.00 (Drewplus .TM. L-475)
Binder - Vinyl Acetate/Acrylic (55% solids - Tg 14.degree. C.)
175.09 (RES 3803) Coalescent (Texanol .TM.) 6.74 Rheology Modifier
- HEUR (Acrysol .TM. SCT-275) 15.00 Base - Ammonia (28%) 0.87 Water
308.13
[0151] The resulting prepaint should have a total volume of 100
gallons, total weight of 1376.0 lbs., total PVC of 80.0%, volume
solids of 50.0%, weight solids of 69.5%, density of 13.76
lbs./gallon, 0.5% dispersant on pigment solids, and 7.0% coalescent
on latex solids. Example 24 This example describes the preparation
of a vinyl acetate/acrylic binder prepaint by combining the
following ingredients:
29 Amount (lbs./ Ingredient 100 gallons Defoamer 2.00 (Drewplus
.TM. L-475) Binder - Vinyl Acetate/Acrylic (55% solids - Tg
14.degree. C.) 875.62 (RES 3803) Coalescent 13.00 (Texanol .TM.)
Rheology Modifier - HEUR 9.29 (Acrysol .TM. SCT-275 - Rohm and
Haas)
[0152] The resulting prepaint should have a total volume of 100
gallons, total weight of 899.9 lbs., a total PVC of 0.0%, volume
solids of 50.0%, weight solids of 53.2%, density of 8.99
lbs./gallon, and 10.0% coalescent on latex solids.
Example 25
[0153] This example describes the preparation of a flat acrylic
prepaint by combining the following ingredients:
30 Ingredient Amount (lbs./100 gallons) Defoamer 8.00 (Drewplus
.TM. L-475) Binder Acrylic (60.5% solids - Tg 16.degree. C.) 773.67
(Rhoplex .TM. AC-264 - Rohm and Haas) Coalescent 23.40 (Texanol
.TM.) Rheology Modifier (HEUR) 13 (Acrysol .TM. RM-8W - Rohm and
Haas) Base - Ammonia (28%) 0.50 Solvent - Propylene Glycol 60.00
Water 1.84
[0154] The resulting prepaint should have a total volume of 100
gallons, total weight of 880.4 lbs., total PVC of 0.0%, volume
solids of 50.0%, weight solids of 53.2%, density of 8.80
lbs./gallon, and 5.0% coalescent on latex solids.
Example 26
[0155] This example describes the preparation of a gloss acrylic
binder prepaint by combining the following ingredients:
31 Ingredient Amount (lbs./100 gallons) Binder - Acrylic (50%
solids - Tg 28.degree. C.) 836.85 (Rhoplex .TM. SG-10M - Rohm and
Haas) Coalescent 41.84 (Texanol .TM.)
[0156] The resulting prepaint should have a total volume of 100
gallons, a total weight of 878.7 lbs., total PVC of 0.0%, volume
solids of 44.3%, weight solids of 47.4%, density of 8.78
lbs./gallon, and 10.0% coalescent on latex solids.
Example 27
[0157] This example describes the preparation of nine exterior flat
latex paints of varying quality and tone using different
combinations of the white pigment prepaint of Example 14, the
exterior pigment extender prepaint of Example 15, the vinyl
acetate-acrylic (PVA) binder prepaint of Example 17, and the flat
acrylic binder prepaint of Example 18. The paints are formulated by
adding the white pigment prepaint and exterior pigment extender
prepaint to the binder prepaints and mixing well.
32 Prepaints (wt.) Paint Flat Volume Exterior PVA Acrylic PVC
Solids White Extender Binder Binder Water No. (%) (%) (Ex 14) (Ex
15) (Ex 17) (Ex 18) (wt.) 27-1 45.0 35.0 395.53 269.60 -- 335.92
104.34 27-2 50.0 30.0 317.19 311.10 -- 246.80 208.68 27-3 50.0 30.0
263.69 359.94 197.64 51.38 208.68 27-4 42.5 35.0 197.77 415.12 --
359.92 104.34 27-5 47.5 30.0 158.60 425.86 -- 267.37 208.68 27-6
47.5 30.0 131.84 450.28 214.11 55.67 208.68 27-7 40.0 35.0 --
560.64 -- 383.91 104.34 27-8 45.0 30.0 -- 540.62 -- 287.93 208.68
27-9 45.0 30.0 -- 540.62 230.58 59.95 208.68 Paints 27-1, 27-4 and
27-7 are premium quality light, mid and deep tone paints; paints
27-2, 27-5 and 27-8 are first quality light, mid and deep tone
paints; and paints 27-3, 27-6 and 27-9 are second quality light,
mid and deep tone paints.
Example 28
[0158] This example describes the preparation of nine exterior
satin latex paints of varying quality and tone using different
combinations of the white pigment prepaint and exterior pigment
extender prepaint of Examples 14 and 15, respectively, and the
vinyl acetate/acrylic binder (PVA) and flat acrylic binder
prepaints of Examples 17 and 18. The paints are formulated as
described above.
33 Prepaints (wt.) Paint Flat Volume Exterior PVA Acrylic PVC
Solids White Extender Binder Binder Water No. (%) (%) (Ex 14) (Ex
15) (Ex 17) (Ex 18) (wt.) 28-1 35.0 35.0 395.53 129.44 -- 431.90
104.34 28-2 37.0 30.0 351.59 123.51 -- 353.75 208.68 28-3 40.0 26.0
263.69 175.73 228.35 59.41 292.15 28-4 32.5 36.0 197.77 287.98 --
468.92 83.47 28-5 34.5 30.0 175.75 253.98 -- 374.31 208.68 28-6
37.5 26.0 131.84 270.07 242.63 63.12 292.12 28-7 30.0 36.0 --
432.50 -- 493.60 83.47 28-8 32.0 30.0 -- 384.44 -- 394.88 208.68
28-9 35.0 26.0 -- 364.42 256.87 66.86 292.15
[0159] Paints 28-1, 28-4 and 28-7 are premium quality light, mid
and deep tone paints; paints 28-2, 28-5 and 28-8 are first quality
light, mid and deep tone paints; and paints 28-3, 28-6 and 28-9 are
second quality light, mid and deep tone paints.
Example 29
[0160] This example describes the preparation of nine exterior
gloss latex paints of using different combinations of the white
pigment and exterior extender prepaints of Examples 14 and 15 and
vinyl acetate/acrylic binder (PVA) and gloss acrylic binder
prepaints of Examples 17 and 19. The paints are formulated as
described above.
34 Prepaints (wt.) Paint Gloss Volume PVA Acrylic PVC Solids White
Binder Binder Water No. (%) (%) (Ex 14) (Ex 17) (Ex 19) (wt.) 29-1
26.0 35.0 435.66 -- 494.85 104.34 29-2 30.0 30.0 460.50 -- 413.60
166.94 29-3 30.0 30.0 429.93 304.15 88.51 208.68 29-4 13.0 35.0
217.83 -- 630.87 104.34 29-5 15.0 30.0 230.25 -- 557.38 166.94 29-6
15.0 30.0 214.96 409.14 119.06 208.68 29-7 -- 35.0 -- -- 766.89
104.34 29-8 -- 30.0 -- -- 701.15 166.94 29-9 -- 30.0 -- 514.12
149.61 208.68
[0161] Paints 29-1, 29-4 and 29-7 are premium quality light, mid
and deep tone paints; paints 29-2, 29-5 and 29-8 are first quality
light, mid and deep tone paints; and paints 29-3, 29-6 and 29-9 are
second quality light, mid and deep tone paints.
Example 30
[0162] This example describes the preparation of nine interior flat
latex paints using different combinations of the white pigment and
interior extender prepaints of Examples 14 and 16 and the vinyl
acetate/acrylic (PVA) and flat acrylic binder prepaints of Examples
17 and 18. The paints are formulated as described above.
35 Prepaints (wt.) Paint Flat Volume Interior PVA Acrylic PVC
Solids White Extender Binder Binder Water No. (%) (%) (Ex 14) (Ex
15) (Ex 17) (Ex 18) (wt.) 30-1 50.0 30.0 351.59 273.94 197.64 51.38
208.68 30-2 60.0 30.0 263.69 470.21 166.40 -- 208.68 30-3 75.0 25.0
128.02 620.95 34.67 -- 313.02 30-4 47.5 15.0 175.79 401.73 214.11
55.67 208.68 30-5 57.5 30.0 131.84 558.69 187.20 -- 208.68 30-6
72.5 25.0 64.01 653.67 52.00 -- 313.02 30-7 45.0 30.0 -- 529.51
230.58 59.95 208.68 30-8 55.0 30.0 -- 647.18 208.01 -- 208.68 30-9
70.0 25.0 -- 686.40 69.34 -- 313.02
[0163] Paints 30-1, 30-4 and 30-7 are premium quality light, mid
and deep tone paints; paints 30-2, 30-5 and 30-8 are first quality
light, mid and deep tone paints; and paints 30-3, 30-6 and 30-9 are
second quality light, mid and deep tone paints.
Example 31
[0164] This example describes the preparation of nine interior
satin latex paints using the white pigment and interior extender
prepaints of Examples 14 and 16 and the vinyl acetate/acrylic (PVA)
and flat acrylic binder prepaints of Examples 17 and 18. The paints
are formulated as described above.
36 Prepaints (wt.) Paint Flat Volume Interior PVA Acrylic PVC
Solids White Extender Binder Binder Water No. (%) (%) (Ex 14) (Ex
15) (Ex 17) (Ex 18) (wt.) 31-1 35.0 36.0 395.53 140.51 355.75 92.49
83.47 31-2 37.0 30.0 351.59 120.98 357.77 -- 208.68 31-3 40.0 20.0
263.69 172.12 288.43 -- 292.15 31-4 32.5 36.0 197.77 282.06 375.51
97.96 83.47 31-5 34.5 30.0 175.79 248.76 378.57 -- 208.68 31-6 37.5
26.0 131.84 264.52 306.46 -- 292.15 31-7 30.0 36.0 -- 423.61 395.28
102.77 83.47 31-8 32.0 30.0 -- 376,54 399.37 -- 208.68 31-9 35.0
26.0 -- 356.93 324.49 -- 292.15
[0165] Paints 31-1, 31-4 and 31-7 are premium quality light, mid
and deep tone paints; paints 31-2, 31-5 and 31-8 are first quality
light, mid and deep tone paints; and paints 31-3, 31-6 and 31-9 are
second quality light, mid and deep tone paints.
Example 32
[0166] This example describes the preparation of nine interior
gloss latex paints using the white pigment prepaint of Example 14
and the vinyl acetate/acrylic (PVA) and gloss acrylic binder
prepaints of Examples 17 and 19. The paints are formulated as
described above.
37 Prepaints (wt.) Paint Gloss Volume PVA Acrylic PVC Solids White
Binder Binder Water No. (%) (%) (Ex 14) (Ex 17) (Ex 19) (wt.) 32-1
26.0 35.0 435.66 -- 494.85 104.34 32-2 30.0 38.0 429.93 304.15
88.51 208.68 32-3 30.1 28.0 403.18 366.31 -- 250.42 32-4 13.0 35.0
217.83 -- 630.87 104.34 32-5 15.0 30.0 214.96 409.14 119.06 208.68
32-6 15.0 28.0 201.59 493.78 -- 250.42 32-7 -- 35.0 -- -- 766.89
104.34 32-8 -- 30.0 -- 514.12 149.61 208.68 32-9 -- 28.0 -- 621.24
-- 250.42
[0167] Paints 32-1, 32-4 and 32-7 are premium quality light, mid
and deep tone paints; paints 32-2, 32-5 and 32-8 are first quality
light, mid and deep tone paints; and paints 32-3, 32-6 and 32-9 are
second quality light, mid and deep tone paints.
Example 33
[0168] This example describes the preparation of a latex paint
useful for architectural coatings which can be prepared using the
white pigment prepaint of Example 20, the exterior pigment extender
of Example 22, and the flat acrylic binder prepaint of Example 25.
The paint is formulated as described above.
38 Prepaints (wt.) Paint Flat Volume Exterior Acrylic PVC Solids
White Extender Binder Water (%) (%) (Ex 20) (Ex 21) (Ex 24) (wt.)
35 48 331.27 294.95 475.42 33.39
[0169] The resulting paint should be a premium paint having a satin
finish and a light tone.
Example 34
[0170] This example describes the preparation of a low solids
interior flat paint using the white pigment prepaint of Example 20,
the interior pigment extender of Example 23, and the vinyl
acetate/acrylic (PVA) binder prepaint of Example 24.
39 Paint Prepaints (wt.) Volume Interior PVA PVC Solids White
Extender Binder Water (%) (%) (Ex 20) (Ex 22) (Ex 23) (wt.) 75 15
107.22 294.97 16.87 584.31
Example 35
[0171] This example describes the preparation of paints using the
prepaints of Examples 1 to 6. The paints were prepared by mixing
the pigment prepaint(s) with the binder prepaint(s), then adding
the thickeners, water and colorants and mixing well. The Stormer
viscosity, ICI viscosity, and pH were the equilibrated measured
values.
40 Part A - Exterior Flat Paints (Best and Good) Prepaint (lbs.)
Exterior Flat Thickener (lbs.) White Extender PVA Acrylic Acrysol
Paint Pigment Pigment Binder Binder Acrysol RM 2020 Water Colorant
No. (Ex 1) (Ex 2) (Ex 4) (Ex 6) SCT-275 NPR (lbs.) (lbs.)
35-1.sup.a 353.86 278.01 -- 306.97 10.40 14.00 149.68 -- 35-2.sup.b
235.96 351.50 177.30 46.09 26.40 11.20 237.06 -- 35-3.sup.a --
516.00 -- 351.00 32.68 -- 146.45 162 35-4.sup.b -- 500.00 206.58
53.70 48.48 -- 237.06 162 .sup.aBest light tone and deep tone
paints .sup.bGood light tone and deep tone paints Measured
Equilibrated Values Calculated Properties Stormer ICI Volume Weight
Paint Viscosity Viscosity Volume.sup.A Weight* PVC Solids Solids
Density No. (KU) (cp) pH (gallons) (lbs.) (%) (%) (%) (b/gal)
35-1.sup.c 102 1.15 8.76 100 1112.92 45.05 35.08 50.66 11.13
35-2.sup.b 101 0.87 8.30 100 1085.52 50.04 30.05 45.68 10.86
35-3.sup.e 110 1.90 9.02 100 1046.13 39.94 35.00 47.92 10.46
35-4.sup.f 121 1.80 8.70 100 1045.82 45.09 29.76 43.25 10.36
.sup.cThere was 0.44% dispersant based on dry pigment and 7.48%
coalescent based on dry polymer. .sup.dThere was 0.46% dispersant
based on dry pigment and 7.40% coalescent based on dry polymer.
.sup.eThere was 0.50% dispersant based on dry pigment and 7.00%
coalescent based on dry polymer. .sup.fThere was 0.50% dispersant
based on dry pigment and 7.00% coalescent based on dry polymer.
Part B - Exterior Satin Paint (Better) Prepaint (lbs.) Exterior
Flat Thickener (lbs.) White Extender PVA Acrylic Acrysol Paint
Pigment Pigment Binder Binder Acrysol RM 2020 Water Colorant No.
(Ex 1) (Ex 2) (Ex 4) (Ex 6) SCT-275 NPR (lbs.) (lbs.) 35-5 314.56
137.00 -- 323.00 17.82 17.58 234.22 -- Measured Equilibrated Values
Calculated Properties Stormer ICI Volume Weight Paint Viscosity
Viscosity Volume.sup.A Weight* PVC Solids Solids Density No. (KU)
(cp) pH (gallons) (lbs.) (%) (%) (%) (b/gal) 35-5 104 1.19 8.95
100.00 1044.18 36.94 29.96 43.26 10.44 There was 0.43% dispersant
based on dry pigment and 7.43% coalescent based on dry polymer.
Part C - Exterior Semigloss (Best and Good) Prepaint (lbs.)
Exterior Gloss Thickener (lbs.) White Extender PVA Acrylic Acrysol
Paint Pigment Pigment Binder Binder Acrysol RM 2020 Water Colorant
No. (Ex 1) (Ex 2) (Ex 4) (Ex 5) SCT-275 NPR (lbs.) (lbs.)
35-6.sup.a 389.40 -- -- 530.37 -- 15.20 98.44 -- 35-7.sup.b 383.98
-- 85.33 294.89 22.40 26.00 217.67 -- .sup.aBest .sup.bGood
Measured Equilibrated Values Calculated Properties Stormer ICI
Volume Weight Paint Viscosity Viscosity Volume Weight PVC Solids
Solids Density No. (KU) (cp) pH (gallons) (lbs.) (%) (%) (%)
(b/gal) 35-6.sup.c 99 1.19 8.54 100.00 1033.41 26.00 35.00 46.91
10.33 35-7.sup.d 102 1.05 8.20 100.00 1030.27 30.00 29.90 42.43
10.30 .sup.cThere was a 0.40% dispersant based on dry pigment
solids and a 10.00% coalescent base on dry polymer .sup.dThere was
a 0.40% dispersant based on dry pigment solids and a 7.97%
coalescent base on dry polymer Part D - Interior Flat Prepaint
(lbs.) Interior Flat Thickener (lbs.) White Extender PVA Acrylic
Acrysol Paint Pigment Pigment Binder Binder Acrysol RM 2020 Water
Colorant No. (Ex 1) (Ex 2) (Ex 4) (Ex 5) SCT-275 NPR (lbs.) (lbs.)
35-8.sup.a 314.56 280.69 177.31 46.09 24.00 20.80 230.22 -- 35-9
115.95 590.05 30.04 -- 34.60 -- 336.19 -- 35-10.sup.a -- 496.07
206.55 53.67 41.92 -- 236.60 162 35-11 -- 643.99 62.04 -- 51.36 --
320.17 162 .sup.aPaints 35-8 and 35-10 were best light and deep
tone paints. Paints 35-9 and 35-11 were good light and deep tone
paints. Measured Equilibrated Values Calculated Properties Stormer
ICI Volume Weight Paint Viscosity Viscosity Volume Weight PVC
Solids Solids Density No. (KU) (cp) pH (gallons) (lbs.) (%) (%) (%)
(b/gal) 35-8 99 1.05 8.45 100.00 1093.67 50.00 30.00 45.88 10.94
35-9 84 0.70 8.50 100.00 1106.83 75.15 24.99 43.08 11.07 35-10 120
1.90 8.60 100.00 1034.81 45.04 29.99 43.36 10.35 35-11 108 1.88
8.80 100.00 1077.56 70.00 25.05 41.74 10.78 The percentage
dispersant on dry pigment was 0.45%, 0.48%, 0.50%, and 0.50% for
paint nos. 34-8 to 34-11, respectively. The percentages of
Coalescent was 7.53%, 47%, 7.00% and 7.00% for paint nos. 34-8 to
34-11, respectively. Part E - Interior Satin Paint Prepaint (lbs.)
Interior Flat Thickener (lbs.) White Extender PVA Acrylic Acrysol
Paint Pigment Pigment Binder Binder Acrysol RM 2020 Water Colorant
No. (Ex 1) (Ex 2) (Ex 4) (Ex 5) SCT-275 NPR (lbs.) (lbs.) 35-12
314.56 138.00 319.00 -- 24.96 21.40 229.76 -- The paint was a
better light tone paint. Measured Equilibrated Values Calculated
Properties Stormer ICI Volume Weight Paint Viscosity Viscosity
Volume Weight PVC Solids Solids Density No. (KU) (cp) pH (gallons)
(lbs.) (%) (%) (%) (b/gal) 35-12 93 0.91 8.37 100.00 1047.68 37.05
29.99 43.54 10.48 The dispersant in dry pigment was 0.43%. The
coalescent in dry polymer was 7.42%. Part F - Semi-Gloss Paint
Prepaint (lbs.) Interior Gloss Thickener (lbs.) White Extender PVA
Acrylic Acrysol Paint Pigment Pigment Binder Binder Acrysol RM 2020
Water Colorant No. (Ex 1) (Ex 3) (Ex 4) (Ex 6) SCT-275 NPR (lbs.)
(lbs.) 35-13 383.98 -- 294.89 85.33 22.40 26.00 217.67 -- 35-14
359.89 -- 347.58 -- 28.80 28.00 255.70 -- Paint nos. 35-13 were
better and good light tone paints. Measured Equilibrated Values
Calculated Properties Stormer ICI Volume Weight Paint Viscosity
Viscosity Volume Weight PVC Solids Solids Density No. (KU) (cp) pH
(gallons) (lbs.) (%) (%) (%) (b/gal) 35-13 102 1.05 8.20 100.00
1030.27 30.01 29.91 42.43 10.30 35-14 101 1.19 7.90 100.00 1019.97
30.02 28.02 40.22 10.20 The dispersant was 0.40% on dry pigment for
paints 35-13 and 35-14. The coalescents were 7.97% and 7.47%,
respectively for paints 35-13 and 35-14.
Example 36
[0172] This example describes the preparation of a white opacifying
pigment prepaint for use in an elastomeric coating. The prepaint
can be prepared by combining the following ingredients:
41 Amount Ingredient (lbs./100 gal.) Binder Acrylic (50.5% solids,
T.sub.g = -16.degree. C. 177.11 Rhoplex .RTM. 2438 - Rohm and Haas)
Water 257.90 Dispersant (Tamol .RTM. 165A - Rohm and Haas) 49.24
Defoamer (Nopco NXZ) 12.44 Base - Ammonia (28%) 3.94 Coalescent
(Texanol) 2.68 Rheology Modifier (Acrysol .RTM. SCT-275) 5.00
Pigment - Titanium Dioxide (Ti-Pure R-960 - DuPont) 1292.48
[0173] The prepaint is prepared using a high speed disperser. The
water, dispersant, acrylic binder, defoamer, base, and rheology
modifier are combined and mixed briefly and at low speed and then
the dry pigment is added. After all the dry pigment is added, the
mixture should be dispersed at high speed for 15-20 minutes, as is
known to those skilled in the art.
[0174] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,800.80 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 76.74%, a density of
18.008 lbs./gal., 0.80% dispersant on pigment solids, and 3.0%
coalescent on latex solids.
Example 37
[0175] This example describes the preparation of a white opacifying
pigment prepaint containing zinc oxide for use in an elastomeric
coating. The prepaint can be prepared as above by combining the
following ingredients:
42 Amount Ingredient (lbs./100 gal.) Binder Acrylic (50.5% solids,
T.sub.g = -16.degree. C. 177.11 Rhoplex .RTM. 2438 - Rohm and Haas)
Water 278.10 Dispersant (Tamol .RTM. 2001 - Rohm and Haas) 26.99
Surfactant (Triton .RTM. X-405 - Union Carbide) 10.00 Defoamer
(Nopco NXZ) 5.00 Base - Ammonia (28%) 3.94 Coalescent (Texanol)
2.68 Rheology Modifier (Acrysol .RTM. SCT-275) 5.00 Pigment - Zinc
Oxide 283.26 (XX-503 - Zinc Corporation of America) Pigment -
Titanium Dioxide (Ti-Pure R-706 - DuPont) 1133.50
[0176] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,925.58 lbs., a total PVC of 80.00%, a
titanium dioxide PVC of 67.90%, a volume solids of 50.00%, a weight
solids of 78.22%, a density of 19.2558 lbs./gal., 0.80% dispersant
on pigment solids, and 3.0% coalescent on latex solids.
Example 38
[0177] This example describes the preparation of an extender
pigment prepaint for use in an elastomeric coating. The prepaint is
prepared as described above by combining the following
ingredients:
43 Amount Ingredient (lbs./100 gal.) Water 295.80 Dispersant (Tamol
731A - Rohm and Haas) 10.82 Defoamer (Nopco NXZ) 13.36 Base -
Ammonia (28%) 6.68 Coalescent (Texanol) 1.79 Rheology Modifier
(Natrosol 250 HR) 1.00 Binder Acrylic (50.5% solids, T.sub.g =
-16.degree. C., 177.11 Rhoplex 2438 - Rohm and Haas) Pigment -
Calcium Carbonate 901.50 (Duramite)
[0178] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,408.05 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 70.38%, a density of
14.0805 lbs./gal., 0.30% dispersant on pigment solids, and 2.0%
coalescent on latex solids.
Example 39
[0179] This example describes the preparation of a low Tg acrylic
binder prepaint with good low temperature flexibility. The prepaint
is prepared using a laboratory mixer having a 45.degree. pitch
stirring blade.
44 Amount Ingredient (lbs./100 gal.) Binder Acrylic (50.5% solids,
T.sub.g = -16.degree. C. 814.71 Rhoplex .RTM. 2438 - Rohm and Haas)
Defoamer (Nopco NXZ) 1.33 Rheology Modifier (Natrosol 250 HR) 5.32
Solvent - Propylene Glycol 26.62 Base - Ammonia (28%) 2.66
Coalescent (Texanol) 8.23 Water 6.06
[0180] The resulting prepaint should have a total volume of 100
gallons, a total weight of 864.93 lbs., a volume solids of 46.00%,
a weight solids of 47.57%, a density of 8.6493 lbs./gal., and 2.0%
coalescent on latex solids.
Example 40
[0181] This example describes the preparation of a mid-range Tg
stryene/acrylic binder prepaint with low temperature flexibility
only down to -5.degree. C. The prepaint is prepared using a
laboratory mixer having a 45.degree. pitch stirring blade.
45 Amount Ingredient (lbs./100 gal.) Binder Styrene/Acrylic (55.0%
solids, T.sub.g = -5.degree. C. 803.91 Rhoplex .RTM. 2019R - Rohm
and Haas) Defoamer (Nopco NXZ) 1.33 Rheology Modifier (Natrosol 250
HR) 5.32 Solvent - Propylene Glycol 26.62 Base - Ammonia (28%) 2.66
Coalescent (Texanol) 8.84 Water 10.99
[0182] The resulting prepaint should have a total volume of 100
gallons, a total weight of 859.69 lbs., a volume solids of 50.00%,
a weight solids of 51.43%, a density of 8.5969 lbs./gal., and 2.0%
coalescent on latex solids.
Example 41
[0183] This example describes the preparation of a high T.sub.g
(14.degree. C.) 100% acrylic binder prepaint with poor low
temperature flexibility. The prepaint is prepared using a
laboratory mixer having a 45.degree. pitch stirring blade.
46 Ingredient Amount (lbs./100 gal.) Binder Acrylic (53.5% solids,
T.sub.g = 14.degree. C. 822.40 Multilobe .TM. 200-Rohm and Haas
Defoamer (Nopco NXZ) 1.33 Rheology Modifier (Natrosol 250 HR) 5.32
Solvent-Propylene Glycol 26.62 Base-Ammonia (28%) 2.66 Coalescent
(Texanol) 26.40 Water 0.36
[0184] The resulting prepaint should have a total volume of 100
gallons, a total weight of 885.11 lbs., a volume solids of 47.00%,
a weight solids of 49.71%, a density of 8.8511 lbs./gal., and 6.0%
coalescent on latex solids.
Example 42
[0185] This example describes the preparation of 11 elastomeric
wall coating formulations of varying quality and mildew resistance,
using different combinations of the white pigment prepaints of
Examples 36 and 37, the extender prepaints of Example 38, and the
binder prepaints of Examples 39, 40 and 41. The paints are
formulated by adding the white pigment prepaint and extender
prepaint to the binder prepaints and mixing well.
[0186] The prepaint amounts mixed together are those given below.
All weights are in lbs., the total volume of each elastomeric
coating is 100 gallons, formulated to 45% volume solids.
47 Weight of Example Prepaints Paint 36 37 38 39 40 41 Water Total
41-1 70.9 0.0 419.8 528.8 0.0 0.0 42.4 1061.9 42-2 0.0 89.3 409.9
528.8 0.0 0.0 42.4 1070.5 42-3 70.9 0.0 657.4 370.2 0.0 0.0 54.6
1153.1 42-4 0.0 89.3 647.5 370.2 0.0 0.0 54.6 1161.6 42-5 131.7 0.0
372.3 528.8 0.0 0.0 42.4 1075.2 42-6 0.0 165.9 353.9 528.8 0.0 0.0
42.4 1091.0 42-7 131.7 0.0 609.9 370.2 0.0 0.0 54.6 1166.3 42-8 0.0
165.9 591.5 370.2 0.0 0.0 54.6 1182.2 42-9 70.9 0.0 419.8 0.0 483.6
0.0 83.0 1057.3 42-10 0.0 89.3 647.5 0.0 338.5 0.0 83.0 1158.3
42-11 70.9 0.0 657.4 227.5 0.0 141.6 58.7 1014.5
[0187] The expected PVC, TiO2 level, low temperature flexibility,
and quality of the resulting elastomeric coatings are shown
below.
48 Zno TiO.sub.2 Paint PVC presence PVC Flex Quality 42-1 30 no 3.5
0.degree. F. medium 42-2 30 yes 3.5 0.degree. F. medium 42-3 45 no
3.5 0.degree. F. low 42-4 45 yes 3.5 0.degree. F. low 42-5 30 no
6.5 0.degree. F. high 42-6 30 yes 6.5 0.degree. F. high 42-7 45 no
6.5 0.degree. F. medium 42-8 45 yes 6.5 0.degree. F. medium 42-9 30
no 3.5 20.degree. F. medium 42-10 45 yes 3.5 20.degree. F. low
42-11 45 no 3.5 40.degree. F. poor
[0188] The elastomeric coating preparations shown above represent a
range of qualities that depend upon the durability and the
flexibility at low temperature. These examples are not intended to
be limiting. For instance, all the pigment and extender prepaints
can be formulated with or without binders, and the binders may have
a higher T.sub.g than the one used in these examples. In addition,
the extender prepaint is not meant to limited to the use of calcium
carbonate, but to show an example that could also include other
commonly used extenders such as, clays, silicas, magnesium
silicates, and the like.
[0189] Elastomeric coatings for use for roofs can be differentiated
in the same manner as elastomeric coatings for walls, with two
additional variations, the use of functional extenders such as
aluminum trihydrate to promote flame retardency, and enhanced
adhesion to specific roofing substrates. The examples that follow
are intended to show the capabilities of the prepaint concept when
applied to elastomeric roof coatings, and are not intended to
limit.
Example 43
[0190] This example describes the preparation of a white pigment
prepaint. The prepaint is prepared by combining the following
ingredients:
49 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = 29.degree. C. 159.75 Rhoplex .RTM. EC-1791-Robm and Haas)
Water 268.95 Dispersant (Tamol .RTM. 165A-Rohm and Haas) 49.24
Defoamer (Nopco NXZ) 12.44 Base-Ammonia (28%) 3.94 Coalescent
(Texanol) 2.64 Rheology Modifier (Acrysol .RTM. SCT-275) 10.00
Pigment-Titanium Dioxide 1292.48 (Ti-Pure R-960-DuPont)
[0191] The prepaint can be prepared using a high speed disperser.
The water, dispersant, acrylic binder, defoamer, base, and rheology
modifier are combined and mixed briefly at low speed and then the
dry pigment is added. After all the dry pigment is added, the
mixture is dispersed at high speed, for 15-20 minutes as is known
to those skilled in the art.
[0192] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,799.45 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 76.71%, a density of
17.9945 lbs./gal., 0.80% dispersant on pigment solids, and 3.0%
coalescent on latex solids.
Example 44
[0193] This example describes the preparation of a white pigment
prepaint for use in preparing coatings which have good adhesion to
asphalt roofing materials. The prepaint is prepared by combining
the following ingredients:
50 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = 8.degree. C. 160.69 Lipacryl .RTM. MB-3640-Robm and Haas)
Water 268.12 Dispersant (Tamol .RTM. 165A-Rohm and Haas) 49.24
Defoamer (Nopco NXZ) 12.44 Base-Ammonia (28%) 3.94 Coalescent
(Texanol) 2.65 Rheology Modifier (Acrysol .RTM. SCT-275) 10.00
Pigment-Titanium Dioxide 1292.48 (Ti-Pure R-960-DuPont)
[0194] The prepaint is prepared using a high speed disperser, as
illustrated in Example 43. The resulting prepaint should have a
total volume of 100 gallons, a total weight of 1,799.56 lbs., a
total PVC of 80.00%, a volume solids of 50.00%, a weight solids of
76.73%, a density of 17.9956 lbs./gal., 0.80% dispersant on pigment
solids, and 3.0% coalescent on latex solids. This prepared is
designed to work best in coatings for asphalt substrates.
Example 45
[0195] This example describes the preparation of a white opacifying
prepaint containing zinc oxide. The prepaint is prepared as above
by combining the following ingredients:
51 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = -29.degree. C. 159.75 Rhoplex .RTM. EC-1791-Robm and
Haas) Water 272.67 Dispersant (Tamol .RTM. 731A-Rohm and Haas)
44.09 Surfactant (Triton .RTM. X-405-Union Carbide) 10.00 Defoamer
(Nopco NXZ) 5.00 Base-Ammonia (28%) 3.94 Coalescent (Texanol) 2.64
Rheology Modifier (Acrysol .RTM. SCT-275) 12.00 Pigment-Zinc
Dioxide 275.47 (XX-503-Zinc Corporation of America)
Pigment-Titanium Dioxide 1102.32 (Ti-Pure R-960-DuPont)
[0196] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,887.88 lbs., a total PVC of 80.00%, a
titanium oxide PVC of 68.23%, a volume solids of 50.00%, a weight
solids of 77.63%, a density of 18.8788 lbs./gal., 0.80% dispersant
on pigment solids, and 3.0% coalescent on latex solids.
Example 46
[0197] This example describes the preparation of an extender
pigment prepaint. The prepaint is prepared as above by combining
the following ingredients:
52 Ingredient Amount (lbs./100 gal.) Water 310.92 Dispersant (Tamol
.RTM. 731A-Rohm and Haas) 10.82 Defoamer (Nopco NXZ) 13.36
Base-Ammonia (28%) 6.68 Coalescent (Texanol) 1.76 Rheology Modifier
(Natrosol 250 HR) 2.00 Binder Acrylic (55.0% solids, T.sub.g =
-29.degree. C. 159.75 Rhoplex .RTM. EC-1791-Robm and Haas)
Pigment-Calcium Carbonate (Duramite) 901.50
[0198] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,406.78 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 70.33%, a density of
14.0678 lbs./gal., 0.30% dispersant on pigment solids, and 2.0%
coalescent on latex solids.
Example 47
[0199] This example describes the preparation of an extender
pigment prepaint for use in preparing coatings which have good
adhesion to asphalt roofing materials. The prepaint is prepared as
above by combining the following ingredients:
53 Ingredient Amount (lbs./100 gal.) Water 310.09 Dispersant (Tamol
.RTM. 731A-Rohm and Haas) 10.82 Defoamer (Nopco NXZ) 13.36
Base-Ammonia (28%) 6.68 Coalescent (Texanol) 1.77 Rheology Modifier
(Natrosol 250 HR) 2.00 Binder Acrylic (55.0% solids, T.sub.g =
-8.degree. C. 160.69 Lipacryl .RTM. MB3640-Robm and Haas)
Pigment-Calcium Carbonate (Duramite) 901.50
[0200] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,406.90 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 70.36%, a density of
14.0690 lbs./gal., 0.30% dispersant on pigment solids, and 2.0%
coalescent on latex solids.
Example 48
[0201] This example describes the preparation of an extender
pigment prepaint using aluminum trihydrate, which is known to
impart flame retardant properties. It is prepared as described
above by combining the following ingredients:
54 Ingredient Amount (lbs./100 gal.) Water 311.61 Dispersant (Tamol
.RTM. 731A-Rohm and Haas) 9.70 Defoamer (Nopco NXZ) 13.36
Base-Ammonia (28%) 6.68 Coalescent (Texanol) 1.76 Rheology Modifier
(Natrosol 250 HR) 2.00 Binder Acrylic (55.0% solids, T.sub.g =
-29.degree. C. 159.75 Rhoplex .RTM. EC-1791-Robm and Haas)
Pigment-Aluminum Trihydrate 807.94 (Solem SB-432 Huber)
[0202] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,312.79 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 68.24%, a density of
13.1279 lbs./gal., 0.30% dispersant on pigment solids, and 2.0%
coalescent on latex solids.
Example 49
[0203] This example describes the preparation of low Tg acrylic
binder prepaint which should have good low temperature flexibility
and good adhesion to a variety of roofing substrates. The prepaint
is prepared using a laboratory mixer having a 45.degree. pitch
stirring blade.
55 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = -29.degree. C. 798.75 Rhoplex .RTM. EC-1791-Robm and
Haas) Defoamer (Nopco NXZ) 1.33 Rheology Modifier (Natrosol 250 HR)
5.32 Pigment-Propylene Glycol 26.62 Base-Ammonia (28%) 2.66
Coalescent (Texanol) 8.79 Water 16.45
[0204] The resulting prepaint should have a total volume of 100
gallons, a total weight of 859.93 lbs., a volume solids of 50.00%,
a weight solids of 51.09%, a density of 8.5993 lbs./gal., and 2.0%
coalescent on latex solids.
Example 50
[0205] This example describes the preparation of a mid-range Tg
acrylic binder prepaint which should have good adhesion to asphalt
roofing materials. The prepaint prepared using a laboratory mixer
having a 45.degree. pitch stirring blade.
56 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = -8.degree. C. 803.45 Lipacryl .RTM. MB-3640 - Rohm and
Haas) Defoamer (Nopco NXZ) 1.33 Rheology Modifier (Natrosol 250 HR)
5.32 Solvent - Propylene Glycol 26.62 Base - Ammonia (28%) 2.66
Coalescent (Texanol) 8.84 Water 12.29
[0206] The resulting prepaint should have a total volume of 100
gallons, a total weight of 860.52 lbs., a volume solids of 50.00%,
a weight solids of 51.35%, a density of 8.6052 lbs./gal., and 2.0%
coalescent on latex solids.
Example 51
[0207] This example describes the preparation of a tan pigment
prepaint with zinc oxide. The prepaint is prepared as in example 46
by combining the following ingredients.
57 Ingredient Amount (lbs./100 gal.) Binder Acrylic (55.0% solids,
T.sub.g = -29.degree. C. 143.78 Rhoplex .RTM. EC-1791 - Rohm and
Haas) Water 307.35 Dispersant (Tamol .RTM. 731A - Rohm and Haas)
30.07 Surfactant (Triton .RTM. X-405 - Union Carbide) 10.00
Defoamer (Nopco NXZ) 5.00 Base - Ammonia (28%) 3.94 Coalescent
(Texanol) 2.37 Rheology Modifier (Acrysol .RTM. SCT-275) 40.00
Pigment - Zinc Oxide 480.33 (XX-503 - Zinc Corporation of America)
Pigment - Tan Iron Oxide (Mapico 422) 1023.06
[0208] The resulting prepaint should have a total volume of 100
gallons, a total weight of 2,045.89 lbs., a total PVC of 80.00%, a
volume solids of 45.00%, a weight solids of 77.35%, a density of
20.4589 lbs./gal., 0.50% dispersant on pigment solids, and 3.0%
coalescent on latex solids.
Example 52
[0209] This example describes the preparation of an extender
pigment prepaint using crystalline silica. Silica extenders are
known to provide good durability and abrasion resistance. It is
prepared as above by combining the following ingredients:
58 Ingredient Amount (lbs./100 gal.) Water 296.22 Dispersant (Tamol
.RTM. 731A - Rohm and Haas) 26.54 Defoamer (Nopco NXZ) 13.36 Base -
Ammonia (28%) 6.68 Coalescent (Texanol) 1.76 Thickener (Natrosol
250 HR) 2.00 Binder Acrylic (55.0% solids, T.sub.g = -29.degree. C.
159.75 Rhoplex .RTM. EC-1791 - Rohm and Haas) Silica Extender
(Silver Bond B) 884.81
[0210] The resulting prepaint should have a total volume of 100
gallons, a total weight of 1,391.11 lbs., a total PVC of 80.00%, a
volume solids of 50.00%, a weight solids of 69.92%, a density of
13.9111 lbs./gal., 0.75% dispersant on pigment solids, and 2.0%
coalescent on latex solids.
Example 53
[0211] This example describes the preparation of 15 elastomeric
roof coating formulations of varying quality, flexibility, adhesion
and flame retardency. The coatings are formulated using different
combinations of the white prepaints of Examples 43, 44, and 45, the
non-white pigment prepaint of Example 51, the extender prepaints of
Examples 46, 47, 48, and 52, and the binder prepaints of Examples
40, 49 and 50. The paints are formulated by adding the pigment
prepaint and extender prepaint to the binder prepaints and mixing
well. The amounts mixed are those cited below. All weights are in
lbs., and the total volume of each elastomeric coating is 100
gallons. The volume solids is 45%.
59 Weight in lbs. of example prepaints Paint 43 44 45 51 46 47 48
52 40 49 50 Water Total 53-1 70.9 -- -- -- 419.4 -- -- -- -- 483.7
-- 83 1057.0 53-2 -- -- 87.2 -- 409.8 -- -- -- -- 483.7 -- 83
1063.7 53-3 70.9 -- -- -- 656.8 -- -- -- -- 338.6 -- 83 1149.2 53-4
-- -- 87.2 -- 647.2 -- -- -- -- 338.6 -- 83 1156.0 53-5 131.6 -- --
-- 371.9 -- -- -- -- 483.7 -- 83 1070.2 53-6 -- -- 161.9 -- 354.2
-- -- -- -- 483.7 -- 83 1082.7 53-7 131.6 -- -- -- 609.3 -- -- --
-- 338.6 -- 83 1162.5 53-8 -- -- 161.9 -- 591.6 -- -- -- -- 338.6
-- 83 1175.0 53-9 70.9 -- -- -- -- -- 391.4 -- -- 483.7 -- 83
1028.9 53-10 -- -- 88.9 -- -- -- 647.8 -- -- 338.5 -- 83 1158.2
53-11 91.1 -- -- -- 403.6 -- -- -- 483.6 -- -- 83 1061.2 53-12 --
-- 112.1 -- 628.7 -- -- -- 338.5 -- -- 83 1162.2 53-13 -- 131.6 --
-- -- 530.2 -- -- -- -- 387.2 83 1132.1 53-14 131.6 -- -- -- 530.2
-- -- 387.2 -- -- 83 1132.0 53-15 -- -- -- 179.0 -- -- -- 548.0 --
368.0 -- 76 1171.0
[0212] The expected PVC, TiO2 level, low temperature flexibility,
extender type, and presence of special adhesion and quality of the
resulting elastomeric coating mixtures are shown below.
60 TiO2 Flex Paint PVC ZnO PVC Color Extender Temp Special adhesion
Quality 53-1 30 no 3.5 white CaCO.sub.3 -15.degree. F. variety
medium 53-2 30 yes 3.5 white CaCO.sub.3 -15.degree. F. variety
medium 53-3 45 no 3.5 white CaCO.sub.3 -15.degree. F. variety low
53-4 45 yes 3.5 white CaCO.sub.3 -15.degree. F. variety low 53-5 30
no 6.5 white CaCO.sub.3 -15.degree. F. variety high 53-6 30 yes 6.5
white CaCO.sub.3 -15.degree. F. variety high 53-7 45 no 6.5 white
CaCO.sub.3 -15.degree. F. variety medium 53-8 45 yes 6.5 white
CaCO.sub.3 -15.degree. F. variety medium 53-9 30 no 3.5 white ATH
-15.degree. F. variety medium 53-10 45 yes 3.5 white ATH
-15.degree. F. variety low 53-11 30 no 4.5 white CaCO.sub.3
20.degree. F. variety medium 53-12 45 yes 4.5 white CaCO.sub.3
20.degree. F. variety low 53-13 40 no 6.5 white CaCO.sub.3
20.degree. F. asphalt medium 53-14 40 no 6.5 white CaCO.sub.3
20.degree. F. asphalt blend medium 53-15 42 yes 0 tan silica
-15.degree. F. variety medium
[0213] The elastomeric coatings prepared shown above represent a
range of qualities that depend upon the durability and the
flexibility of the coating at low temperature. Different extender
prepaints are used to promote flame retardency in the dried
coatings. Included are prepaints prepared using dry ground
colorants and no TiO.sub.2 to develop tinted paints. These examples
are not intended to be limiting. For instance, all the pigment and
extender prepaints can be formulated with or without binders, and
the binders may have a higher Tg than the one used in the example.
In addition, the extender prepaint is not meant to be limited to
calcium carbonate, but to show an example that could also include
other commonly used extenders such as, clays, silicas, magnesium
silicates, etc.
Example 54
[0214] This example describes the preparation of a white pigment
prepaint/preformulated component.
61 Ingredient Amount (lbs./100 gal.) Water 275.83 Solvent -
Propylene Glycol 50.00 Dispersant (Tamol .RTM. 731A - Rohm and
Haas) 26.71 Defoamer (Nopco NXZ) 1.50 Surfactant(Triton CF-10) 1.00
Pigment - Titanium Dioxide (Ti-Pure R-902 - 1335.56 DuPont) Base
(Ammonia - 28%) 4.00 Defoamer (Nopco NXZ) 1.50 Thickener (Acrysol
.RTM. RM-2020 NPR - Rohm 50.00 and Haas) Water 93.45
[0215] The water, glycol, defoamer, dispersant and surfactant are
combined and mixed briefly at low speed. The dry pigment is then
added. After all the dry pigment is added, the mixture is mixed at
high shear for 15-20 minutes as is known to those skilled in the
art.
[0216] The resulting white pigment prepaint/preformulation should
have a total volume of 100 gallons, a total weight of 1,839.55
lbs., a total PVC of 100.00%, a volume solids of 40.12%, a weight
solids of 72.60%, a density of 18.4495 lbs./gal., and 0.50%
dispersant on pigment solids.
Example 55
[0217] This example describes the preparation of a small particle
size extender prepaint/preformulated component:
62 Ingredient Amount (lbs./100 gal.) Binder Acrylic (46.5% solids,
T.sub.g = 17.degree. C. 201.32 Rhoplex .RTM. EI-2000 - Rohm and
Haas) Solvent - Propylene Glycol 5.00 Dispersant (Tamol .RTM. 731A
- Rohm and Haas) 10.42 Defoamer (Nopco NXZ) 2.00 Thickener #1
(Attagel 50) 27.96 Small particle size extender (Minex 4) 840.53
Coalescent (Texanol) 3.28 Base (Ammonia - 28%) 2.00 Water 283.42
Thickener #2 (Acrysol .RTM. ASE-60 - Rohm and 4.00 Haas)
[0218] The water, acrylic binder, defoamer, base, and glycol are
combined and mixed briefly at low speed. The dry extender is then
added. After all the dry extender is added, the mixture is mixed at
high shear for 15-20 minutes as is known to those skilled in the
art.
[0219] The resulting small particle size extender
prepaint/preformulation should have a total volume of 100 gallons,
a total weight of 1,379.93 lbs., a total PVC of 80.00%, a volume
solids of 50.00%, a weight solids of 69.72%, a density of 13.7993
lbs./gal., 0.30% dispersant on pigment solids, and 3.50% coalescent
on latex solids.
Example 56
[0220] This example describes the preparation of binder
prepaint/preformulation. It is prepared using a laboratory mixer
having a 45.degree. pitch stirring blade.
63 Ingredient Amount (lbs./100 gal.) Binder Acrylic (46.5% solids,
T.sub.g = 17.degree. C. 805.28 Rhoplex .RTM. EI-2000 - Rohm and
Haas) Defoamer (Nopco NXZ) 1.33 Thickener (Acrysol .RTM. ASE-60 -
Rohm and Haas) 20.00 Solvent - Propylene Glycol 10.00 Base -
Ammonia (28%) 2.66 Coalescent (Texanol) 13.11 Water 21.92
[0221] The resulting binder prepaint/preformulation package should
have a total volume of 100 gallons, a total weight of 874.31 lbs.,
a volume solids of 40.00%, a weight solids of 42.83%, a density of
8.7431 lbs./gal., and 3.50% coalescent on latex solids.
Example 57
[0222] This example describes the preparation of binder
prepaint/preformulation which should have good low temperature
flexibility. It is prepared using a laboratory mixer having a
45.degree. pitch stirring blade.
64 Ingredient Amount (lbs./100 gal.) Binder Acrylic (61% solids,
T.sub.g = -29.degree. C. 584.20 Rhoplex .RTM. EC-2848 - Rohm and
Haas) Defoamer (Nopco NXZ) 1.33 Thickener (Acrysol .RTM. ASE-60 -
Rohm and Haas) 20.00 Solvent - Propylene Glycol 10.00 Base -
Ammonia (28%) 2.66 Coalescent (Texanol) 12.47 Water 226.92
[0223] The resulting preformulated binder package should have a
total volume of 100 gallons, a total weight of 857.59 lbs., a
volume solids of 40.00%, a weight solids of 41.55%, a density of
8.5759 lbs./gal., and 3.50% coalescent on latex solids.
Example 58
[0224] This example describes a small particle size aggregate for
use in giving the aggregate finish a fine texture.
65 Ingredient Amount (lbs./100 gal.) Sand - Small Particle Size
2,211.18 (Sand #90)
[0225] The resulting preformulated aggregate should have a total
volume of 100 gallons, a total weight of 2,211.18 lbs., a volume
solids of 100.00%, a weight solids of 100.00%, a density of 22.1118
lbs./gal.
Example 59
[0226] This example describes the preparation of preformulated
large particle size aggregate that gives coarse texture. It can be
prepared using a ribbon mixer.
66 Ingredient Amount (lbs./100 gal.) Sand - Large Particle Size
442.24 (Sand #15)
[0227]
67 Sand - Small Particle Size 1768.94 (Sand #90)
[0228] The resulting preformulated aggregate should have a total
volume of 100 gallons, a total weight of 2,211.18 lbs., a volume
solids of 100.00%, a weight solids of 100.00%, a density of 22.1118
lbs./gal.
Example 60
[0229] This example describes the preparation of 19 aggregate
finish formulations of varying quality, color intensity, and
texture. To make these different aggregate finishes different
combinations of the small particle size extender preformulation of
Example 55, the binder preformulations of Examples 56 and 57, the
white pigment prepaint of Example 54, and the large particle size
aggregate of Examples 58 and 59 are used. The aggregate finishes
are formulated by adding the small particle size extender
preformulation to the binder preformulation and then adding the
white pigment prepaint, if needed, and finally adding the water and
large particle size aggregate. The components thoroughly mixed
using a ribbon mixer. The amounts mixed are those shown below. All
weights are in lbs., the total volume of each aggregate finish is
100 gallons, formulated to 67% volume solids.
68 Weight of Example Prepaints Paint 55 56 57 58 59 54 Water Total
60-1 64.72 429.09 995.56 0.00 10.03 1499.40 60-2 41.60 432.75
995.56 30.90 6.55 1507.11 60-3 6.93 438.24 995.56 77.26 1.34
1518.66 60-4 180.29 337.56 995.56 0.00 27.41 1540.82 60-5 157.17
341.22 995.56 30.90 23.93 1548.52 60-6 122.50 346.71 995.56 77.26
18.72 1560.08 60-7 295.86 246.03 995.56 0.00 44.79 1582.24 60-8
272.74 249.69 995.56 30.90 41.31 1589.94 60-9 238.07 255.18 995.56
77.26 36.10 1601.50 60-10 122.50 340.08 995.56 77.26 18.72 1553.45
60-11 64.72 429.09 995.56 0.00 10.03 1499.40 60-12 41.60 432.75
995.56 30.90 6.55 1507.11 60-13 6.93 438.24 995.56 77.26 1.34
1518.66 60-14 180.29 337.56 995.56 0.00 27.41 1540.82 60-15 157.17
341.22 995.56 30.90 23.93 1548.52 60-16 122.50 346.71 995.56 77.26
18.72 1560.08 60-17 295.86 246.03 995.56 0.00 44.79 1582.24 60-18
272.74 249.69 995.56 30.90 41.31 1589.94 60-19 238.07 255.18 995.56
77.26 36.10 1601.50
[0230] The PVC, TiO2 level, expected color intensity, texture, and
low temperature flexibility of the resulting aggregate finish
coatings are shown below.
69 Paint PVC TiO.sub.2 PVC Texture Flex Color tone Quality 60-1 70
0 fine 40.degree. F. deep high 60-2 70 1 fine 40.degree. F.
mid-tone high 60-3 70 2.5 fine 40.degree. F. pastel high 60-4 75 0
fine 40.degree. F. deep medium 60-5 75 1 fine 40.degree. F.
mid-tone medium 60-6 75 2.5 fine 40.degree. F. pastel medium 60-7
80 0 fine 40.degree. F. deep low 60-8 80 1 fine 40.degree. F.
mid-tone low 60-9 80 2.5 fine 40.degree. F. pastel low 60-10 75 2.5
fine 0.degree. F. pastel medium 60-11 70 0 coarse 40.degree. F.
deep high 60-12 70 1 coarse 40.degree. F. mid-tone high 60-13 70
2.5 coarse 40.degree. F. pastel high 60-14 75 0 coarse 40.degree.
F. deep medium 60-15 75 1 coarse 40.degree. F. mid-tone medium
60-16 75 2.5 coarse 40.degree. F. pastel medium 60-17 80 0 coarse
40.degree. F. deep low 60-18 80 1 coarse 40.degree. F. mid-tone low
60-19 80 2.5 coarse 40.degree. F. pastel low
[0231] The aggregate finish coatings shown above represent a range
of qualities, textures, and coloring abilities that depend upon the
PVC, TiO.sub.2 level, and particle size ratio of large particle
size extender. These formulations are not intended to be limited by
the example. For instance, all the extender
prepaints/preformulation could be formulated without binder. In
addition, the extender prepaint/preformulation is not meant to be
limited to the use of nepheline syenite, but to show an example
that could also include other commonly used extenders such as,
clays, silicas, magnesium silicates, calcium carbonates, etc.
[0232] The following list gives no more information than in
examples.
70 Supplier Information Material Name Description Supplier Tamol
.TM. 1124 Dispersant Rohm and Haas Company (Philadelphia, PA) Tamol
.TM. 1254 Dispersant Rohm and Haas Company (Philadelphia, PA) Tamol
.TM. 731 Dispersant Rohm and Haas Company (Philadelphia, PA)
Acrysol .TM. DR-3 HASE Thickener/Rheology Rohm and Haas Company
Modifier (Philadelphia, PA) Acrysol .TM. RM-2020 NPR HEUR
Thickener/Rheology Rohm and Haas Company Modifier (Philadelphia,
PA) Acrysol .TM. RM-8W HEUR Thickener/Rheology Rohm and Haas
Company Modifier (Philadelphia, PA) Acrysol .TM. RM-825 HEUR
Thickener/Rheology Rohm and Haas Company Modifier (Philadelphia,
PA) Rhoplex .TM. Multilobe 200 Emulsion Polymer Binder Rohm and
Haas Company (Philadelphia, PA) Rhoplex .TM. SG-10M Emulsion
Polymer Binder Rohm and Haas Company (Philadelphia, PA) RES 3083
Emulsion Polymer Binder Rohm and Haas Company (Philadelphia, PA)
Kathon .TM. LX 1.5% Biocide Rohm and Haas Company (Philadelphia,
PA) Triton .TM. CF-10 Surfactant Union Carbide Corporation
(Danbury, CT) Foamaster .TM. VL Defoamer Henkel Corporation (King
of Prussia, PA) Drewplus .TM. L-475 Defoamer Drew Chemical
Corporation (Kearny, NJ) Ti-Pure .TM. R-746 Titanium Dioxide E.I.
Dupont de Nemours and Co., Inc. (Wilmington, DE) Ti-Pure .TM. R-706
Titanium Dioxide E.I. Dupont de Nemours and Co., Inc. (Wilmington,
DE) Ti-Pure .TM. R-900 Titanium Dioxide E.I. Dupont de Nemours and
Co., Inc. (Wilmington, DE) Ti-Pure .TM. R-902 Titanium Dioxide E.I.
Dupont de Nemours and Co., Inc. (Wilmington, DE) Minex .TM. 4
Mineral Extender Inimin Corp. (Dividing Creek, NJ) Optiwhite .TM.
Clay Extender Burgess Pigment Company (Sandersville, GA) Snowflake
.TM. Calcium Carbonate Extender ECC International Imerya
(Sylacauga, AL) Vicron .TM. 15-15 Calcium Carbonate Extender Pfizer
(New York, NY) Omyacarb .TM. Calcium Carbonate Extender Omya
(Proctor, VI) Texanol .TM. Coalescent Eastman Chemical (Kings Port,
TN)
* * * * *