U.S. patent application number 14/578081 was filed with the patent office on 2015-06-25 for aqueous dispersions for use as coatings with variable water vapor permeance ratings.
The applicant listed for this patent is CertainTeed Corporation. Invention is credited to Kevin J. Gallagher, Kenneth D. Knapp, Sharathkumar K. Mendon, James W. Rawlins, Murray S. Toas, Sam Yuan.
Application Number | 20150176211 14/578081 |
Document ID | / |
Family ID | 53399410 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150176211 |
Kind Code |
A1 |
Knapp; Kenneth D. ; et
al. |
June 25, 2015 |
AQUEOUS DISPERSIONS FOR USE AS COATINGS WITH VARIABLE WATER VAPOR
PERMEANCE RATINGS
Abstract
Certain embodiments described herein are directed articles that
include a cellulosic substrate (or a non-cellulosic substrate) and
an aqueous dispersion disposed on the substrate. In certain
examples, the dispersion is effective to provide a water vapor perm
rating of about 2 perms or less at 25% average RH as tested by ASTM
D1653, or about 2 perm or less at 25% average RH as tested by ASTM
E96, when the dispersion is cured as a coating on the substrate. In
some embodiments, the substrate can be (or can be part of) a
building substrate such as, for example, kraft paper placed on
insulation (e.g., fiberglass insulation) or oriented strand board.
In some instances, the aqueous dispersion can include a plant oil
macromonomer or a waterborne epoxy resin.
Inventors: |
Knapp; Kenneth D.;
(Norristown, PA) ; Gallagher; Kevin J.; (Plymouth
Meeting, PA) ; Toas; Murray S.; (Norristown, PA)
; Yuan; Sam; (Lansdale, PA) ; Mendon; Sharathkumar
K.; (Hattiesburg, MS) ; Rawlins; James W.;
(Hattiesburg, MS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CertainTeed Corporation |
Valley Forge |
PA |
US |
|
|
Family ID: |
53399410 |
Appl. No.: |
14/578081 |
Filed: |
December 19, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61918521 |
Dec 19, 2013 |
|
|
|
Current U.S.
Class: |
428/413 ;
428/499; 428/532 |
Current CPC
Class: |
D06N 2209/141 20130101;
C09D 5/00 20130101; D21H 19/58 20130101; D06N 3/123 20130101; D21H
19/14 20130101; D21H 19/24 20130101; Y10T 428/31851 20150401; D06N
2209/125 20130101; D06N 2211/06 20130101; D21H 19/60 20130101; D21H
19/62 20130101; D06N 3/10 20130101; Y10T 428/31511 20150401; C08L
63/00 20130101; D06N 3/04 20130101; D21H 19/12 20130101; Y10T
428/31971 20150401; D06N 2209/142 20130101; D21H 19/40 20130101;
D21H 19/72 20130101; C09D 5/022 20130101 |
International
Class: |
D21H 19/12 20060101
D21H019/12 |
Claims
1. An article comprising: a substrate selected from the group
consisting of cellulosic substrates, non-cellulosic substrates, and
combinations thereof; an aqueous dispersion disposed on the
substrate and effective to provide a variable water vapor perm
rating as a function of humidity, in which the water vapor perm
rating is about 2 perm or less at 25% average RH, as tested by ASTM
D1653; or 2 perm or less at 25% average RH, as tested by ASTM E96,
when the aqueous dispersion is cured as a coating on the
substrate.
2. The article of claim 1, in which the cured coating is further
effective to provide a water vapor perm rating of less than or
equal to 5 perms at 45% average RH as tested by ASTM D1653, or less
than or equal to 5 perms at 45% average RH as tested by ASTM
E96.
3. (canceled)
4. (canceled)
5. The article of claim 1, in which the aqueous dispersion
comprises a plant oil macromonomer dispersion.
6. (canceled)
7. (canceled)
8. The article of claim 1, further comprising a reactant added to
the aqueous dispersion.
9. (canceled)
10. (canceled)
11. The article of claim 8, in which the aqueous dispersion
comprises a waterborne epoxy resin dispersion and the reactant
comprises an amine.
12. (canceled)
13. The article of claim 8, further comprising at least one filler
added to the waterborne macromonomer dispersion and the
reactant.
14. The article of claim 13, further comprising a stain-resistance
additive in the dispersion.
15. The article of claim 1, in which the aqueous dispersion is
substantially free of polyamides.
16. An article comprising: a substrate selected from the group
consisting of cellulosic substrates, non-cellulosic substrates, and
combinations thereof; and a plant oil macromonomer dispersion
disposed on the substrate and effective to provide a variable water
vapor perm rating, as tested by ASTM D1653 or ASTM E96, when the
plant oil macromonomer dispersion is cured as a coating on the
substrate.
17. The article of claim 16, in which the variable water perm
rating is about 2 perms or less at 25% average RH, is less than or
equal to 5 perms at 45% average RH, is about 12 perms to about 24
perms at 75% average RH, and is greater than 25 perms at 95%
average RH as tested by ASTM D1653, or about 2 perm or less at 25%
average RH, is less than or equal to 5 perms at 45% average RH, is
about 6 perms to about 12 perms at 75% average RH, and is greater
than 11 perms at 95% average RH as tested by ASTM E96.
18. (canceled)
19. The article of claim 17, in which the plant oil macromonomer
dispersion is a vegetable oil macromonomer dispersion.
20. The article of claim 19, in which the vegetable oil
macromonomer dispersion further comprises a reactant.
21. (canceled)
22. The article of claim 20, further comprising a filler in the
dispersion.
23. (canceled)
24. The article of claim 22, further comprising a surfactant in the
dispersion.
25-31. (canceled)
32. The article of claim 16, in which the cellulosic substrate is
kraft paper.
33. (canceled)
34. The article of claim 16, further comprising a building material
coupled to the cellulosic substrate.
35. (canceled)
36. An article comprising: a substrate selected from the group
consisting of cellulosic substrates, non-cellulosic substrates, and
combinations thereof; and a waterborne epoxy resin dispersion
disposed on the substrate and effective to provide a variable water
vapor perm rating, as tested by ASTM D1653 or ASTM E96, when the
waterborne epoxy resin dispersion is cured as a coating on the
substrate.
37. The article of claim 36, in which the variable water perm
rating is about 2 perms or less at 25% average RH, is less than or
equal to 5 perms at 45% average RH, is about 12 perms to about 24
perms at 75% average RH, and is greater than 25 perms at 95%
average RH as tested by ASTM D1653, or about 2 perm or less at 25%
average RH, is less than or equal to 5 perms at 45% average RH, is
about 6 perms to about 12 perms at 75% average RH, and is greater
than 11 perms at 95% average RH as tested by ASTM E96.
38. The article of claim 3, in which the waterborne epoxy resin is
a waterborne solid epoxy resin.
39. (canceled)
40. The article of claim 38, further comprising a reactant added to
the aqueous dispersion.
41. (canceled)
42. The article of claim 40, further comprising a filler in the
dispersion.
43. (canceled)
44. (canceled)
45. The article of claim 42, further comprising a surfactant in the
dispersion.
46-54. (canceled)
55. The article of claim 46 36, further comprising a polyamide in
the dispersion.
56-153. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Patent Application No. 61/918,521 entitled
"Aqueous Dispersion For Use As Coatings With Variable Water Vapor
Permeance Ratings," by Kenneth D. Knapp, Kevin J. Gallagher, Murray
S. Toas, Sam Yuan, Sharathkumar K. Mendon and James W. Rawlins,
filed Dec. 19, 2013, which is assigned to the current assignee
hereof and incorporated herein by reference in its entirety.
TECHNOLOGICAL FIELD
[0002] This application is related to aqueous dispersions that are
effective for use as coatings. More particularly, certain
embodiments described herein are directed to aqueous dispersions
effective to provide a coating on a substrate to have variable
water vapor permeance values as a function of relative humidity
(RH).
BACKGROUND
[0003] Building materials can include films or facing materials
attached to them to provide desired physical properties for
insulation.
[0004] In many instances of manufacture, the facing materials used
are kraft paper with an asphalt or bituminous coating and other
polymeric materials to provide both support for the underlying
fibers and to provide a liquid water and/or water vapor
retarder.
[0005] A smart vapor retarder can be used as sheeting for covering
insulation materials installed in wall and ceiling cavities. A
build-up of excess moisture in the insulation is avoided by
allowing the excess moisture to escape by vapor diffusion through
the film thickness of the vapor retarder. A smart vapor retarder is
a coating or film formed by a material, a polyamide, for example,
that changes its water moisture vapor permeability in direct
relationship with increases and/or decreases of the ambient
humidity conditions. This transformation allows drying to occur
through the process of vapor diffusion, thereby improving the speed
of drying of the insulation and building materials. The film allows
trapped moisture to escape, thereby alleviating a consequent
formation of mold and water damage typically resulting from excess
trapped moisture
[0006] For example, U.S. Patent Application Publication No.
2004/0103603, which is incorporated by reference herein, describes
the attachment of a vapor retarder, such as polyamide films, to
insulation or other building materials such as gypsum board,
particle board, etc. This vapor retarder imparts a water vapor
diffusion resistance, permeance and/or transmission which depend on
the ambient humidity.
[0007] One disadvantage of a smart vapor retarder is that the
material cost may be higher than a conventional vapor retarder. For
example, a polyamide material cost may be approximately three times
the material cost of an inexpensive water vapor retarder material,
such as, polyethylene. The higher material cost is a disincentive
for the construction industry to use a smart vapor retarder,
instead of using a less costly, vapor barrier film of polyethylene
having little water vapor diffusion properties. Accordingly, it
would be advantageous for a smart vapor retarder to have a reduced
material content, which would reduce the material cost, and serve
as an incentive for the construction industry to use a smart vapor
retarder. One additional disadvantage is in the use of
polyethylene. Polyethylene is a commonly used vapor retarder in the
insulation industry, with a very low, but constant permeability
that does not allow for moisture transfer under varying levels of
humidity. However, for efficient moisture transfer, heightened
permeability is desired at higher humidity.
[0008] One further disadvantage is that the precursors of coatings
include chemicals that can have a detrimental environmental effect
due to high amounts of volatile organic compounds (VOCs). The film
or facing material typically includes petroleum products, which can
result in substantial off-gassing of volatile organic compounds
(VOCs) during preparation and/or use of the material. Other VOCs
can be co-reactants, such as copolymers of sheet material such as
disclosed in U.S. Pat. No. 8,852,749, which discloses compositions
comprising moisture barriers with variable permeances based on
compounds that are synthesized or polymerized from highly volatile
comonomers.
SUMMARY
[0009] In some aspects, the aqueous dispersions described herein
can be used in place of, or in addition to, petroleum based
products. For example, the aqueous dispersions can be used to
reduce the release of VOCs in manufacturing processes as well as
replace petroleum based products with those made from renewable
resources. In addition, the substantial absence of any VOCs
provides a more environmentally friendly coating. In other aspects,
the aqueous dispersion is substantially free of polyamide, e.g.,
nylon 6, whereas in other aspects, a polyamide can be included in
the aqueous dispersions.
[0010] In one aspect, an article comprising a cellulosic substrate
and an aqueous dispersion, disposed on the substrate, that is
effective to provide a water vapor perm rating as a function of RH
of about 2 perms or less at 25% average RH as tested by ASTM D1653,
or 1 perm or less at 25% average RH tested by ASTM E96 when the
aqueous dispersion is cured as a coating on the cellulosic
substrate.
[0011] Both methods, ASTM D1653 and ASTM E96 use a desiccant and
water procedure (Dry and Wet Cups) to provide a measure of the
permeance. The permeance is measured as the time rate of water
vapor transmission through a unit area of flat material or
construction induced by vapor pressure difference between two major
surfaces of the material or construction under specified
temperature and humidity conditions. The permeance is quantified in
perm, wherein 1 perm is 1 grain of water vapor per hour, per square
foot, per inch of mercury difference of water vapor partial
pressure above and below the area. ASTM E96 is typically used in
the insulation industry while ASTM D1653 is used for coatings such
as paints, varnish, lacquers, etc. Results between the two methods
typically correlate when tested under similar conditions.
[0012] In some embodiments, the cellulosic substrate can be a
building substrate such as, for example, kraft paper placed on
insulation (e.g., fiberglass insulation) or oriented strand board.
In other embodiments, the substrate can include non-woven sheeting
material, gypsum wallboard, or other building substrates.
[0013] In certain embodiments, the cured coating can be further
effective to provide a water vapor perm rating of less than or
equal to 5 perms at 45% average RH as tested by ASTM D1653, or less
than 5 perms at 45% average RH as tested by ASTM E96. In other
embodiments, the cured coating is further effective to provide a
water vapor perm rating of about 12 perms to about 24 perms at 75%
average RH as tested by ASTM D1653, or about 6 perms to about 12
perms at 75% average RH as tested by ASTM E96. In some examples,
the cured coating is further effective to provide a water vapor
perm rating of greater than 25 perms at 95% average RH as tested by
ASTM D1653, or greater than 17 perms at 95% average RH as tested by
ASTM E96. In certain examples, the aqueous dispersion comprises a
plant oil macromonomer dispersion, e.g., a seed oil macromonomer
dispersion, a vegetable oil macromonomer dispersion, a seed oil
macromonomer emulsion, a vegetable oil macromonomer emulsion, etc.
In other embodiments, the dispersion can include a reactant added
to the aqueous dispersion. In some examples, the aqueous dispersion
comprises a plant oil macromonomer dispersion, e.g., a vegetable
oil macromonomer dispersion, and the reactant comprises a free
radically polymerized monomer, e.g., a derivatized benzene
comprising an unsaturated moiety such as, for example, styrene. In
other examples, the aqueous dispersion comprises a waterborne epoxy
resin dispersion and the reactant comprises an amine, e.g., an
aliphatic amine or a non-aliphatic amine. In some instances, the
waterborne epoxy resin dispersion comprises a waterborne solid
epoxy resin dispersion, e.g., an aqueous dispersion of the solid
epoxy resin, and a nonionic surfactant. In certain embodiments, the
aqueous dispersion can include at least one filler, a
stain-resistance additive or other additives.
[0014] In another aspect, an article comprising a cellulosic
substrate and a plant oil macromonomer dispersion disposed on the
cellulosic substrate and effective to provide a variable water
vapor perm rating, as tested by ASTM D1653 (or ASTM E96), when the
plant oil macromonomer dispersion is cured as a coating on the
cellulosic substrate is provided. In some embodiments, the variable
water vapor perm rating as tested by ASTM D1653 is about 2 perm or
less at 25% average RH, is less than or equal to 5 perms at 45%
average RH, is about 12 perms to about 24 perms at 75% average RH,
and is greater than 25 perms at 95% average RH; or as tested by
ASTM E96 is about 2.5 perm or less at 25% average RH, is less than
or equal to 5 perms at 45% average RH, is about 6 perms to about 12
perms at 75% average RH, and is greater than 11 perms at 95%
average RH In some embodiments, the dispersion can include one or
more of a filler, a flame retardant, a surfactant, a
stain-resistance additive, and a biocide. In certain embodiments,
the cellulosic substrate can be kraft paper, oriented strand board,
gypsum wallboard, or other substrates used in the building
industry.
[0015] In an additional aspect, an article comprising a cellulosic
substrate and a waterborne epoxy resin dispersion, e.g., an aqueous
epoxy resin dispersion, disposed on the cellulosic substrate and
effective to provide a variable water vapor perm rating, as tested
by ASTM D1653 is about 2 perm or less at 25% average RH, is less
than or equal to 5 perms at 45% average RH, is about 12 perms to
about 24 perms at 75% average RH, and is greater than 25 perms at
95% average RH; or as tested by ASTM E96 is about 2 perm or less at
25% average RH, is less than or equal to 5 perms at 45% average RH,
is about 6 perms to about 12 perms at 75% average RH, and is
greater than 17 perms at 95% average RH. In some instances, the
waterborne epoxy resin is a waterborne solid epoxy resin, e.g., a
waterborne solid epoxy resin comprising a diglycidyl ether of
bisphenol-A. In other embodiments, one or more reactants, fillers,
surfactants, stain-resistance additives, biocide, or other
additives can be present in the dispersion. In certain embodiments,
the cellulosic substrate can be kraft paper, oriented strand board,
gypsum wallboard, or other substrates used in the building
industry.
[0016] In another aspect, a method of providing a coating that has
variable water vapor perm ratings as tested by ASTM D1653 (or ASTM
E96), the method comprising disposing an aqueous dispersion on a
substrate, and curing the disposed aqueous dispersion on the
substrate to provide a coating comprising a variable water vapor
perm rating as tested by ASTM D1653 (or ASTM E96) is described. In
some embodiments, the variable water perm rating as tested by ASTM
D1653 is about 2 perm or less at 25% average RH, is less than or
equal to 5 perms at 45% average RH, is about 12 perms to about 24
perms at 75% average RH, and is greater than 25 perms at 95%
average RH; or as tested by ASTM E96 is about 1 perm or less at 25%
average RH, is less than or equal to 5 perms at 45% average RH, is
about 6 perms to about 12 perms at 75% average RH, and is greater
than 17 perms at 95% average RH.
[0017] In certain instances, the method can include co-spraying the
aqueous dispersion and a reactant on the substrate. In some
embodiments, the method can include adding a reactant to the
aqueous dispersion prior to disposal of the aqueous dispersion on
the substrate. In additional embodiments, the method can include
co-spraying the aqueous dispersion and a surfactant on the
substrate. In some examples, the method can include adding a
surfactant to the aqueous dispersion prior to disposal of the
aqueous dispersion on the substrate. In other embodiments, the
method can include co-spraying the aqueous dispersion, a reactant
and a surfactant on the substrate. In some examples, the method can
include adding a surfactant and a reactant to the aqueous
dispersion prior to disposal of the aqueous dispersion on the
substrate. In further examples, the method can include rolling the
aqueous dispersion onto the substrate. If desired one or more
thickening agents, surfactants or other materials can be added to
facilitate the rolling process. In some embodiments, the aqueous
dispersion can be co-sprayed with a polyamide onto the substrate or
a polyamide can be added to the dispersion prior to disposal. In
certain examples, one or more biocidal agents can be added to or
co-sprayed with the aqueous dispersion.
[0018] In another aspect, a kit comprising an aqueous dispersion, a
reactant and instructions for using the aqueous dispersion and the
reactant is provided. In some embodiments, the reactant is
effective to mix with the aqueous dispersion to provide a cured
coating on a substrate, in which the cured coating provides a
variable water vapor perm rating as tested by ASTM D1653/E96, in
which the cured coating has a water vapor perm rating of about 2
perm or less at 25% average RH as tested by ASTM D1653, or less
than 1 perm at 25% average RH as tested by ASTM E96 when the
aqueous dispersion is cured as a coating on the substrate.
[0019] In certain embodiments, the aqueous dispersion and the
reactant of the kit are configured for co-spraying onto the
substrate. In some embodiments, the kit can include an aqueous
carrier effective to disperse a vegetable oil macromonomer, a
waterborne epoxy resin or both. In some instances, the kit may also
include one or more of a nonionic surfactant, a biocidal agent, a
building substrate, and a spraying device.
[0020] In another aspect, a method of facilitating use of a
building substrate is provided. In some examples, the method
comprises providing an aqueous dispersion effective to provide a
cured coating on a substrate, in which the cured coating provides a
variable water vapor perm rating as tested by ASTM D1653 (or ASTM
E96), in which the cured coating has a water vapor perm rating of
about 1 perm or less at 25% average RH as tested by ASTM D1653 (or
ASTM E96) when the aqueous dispersion is cured as a coating on the
substrate, and providing instructions for using the aqueous
dispersion to form the coating.
[0021] In certain embodiments, the method comprises providing a
reactant for use with the aqueous dispersion to provide the cured
coating. In other embodiments, the method comprises providing one
or more of a surfactant, a biocidal agent, a filler and
combinations thereof for use with the reactant and the aqueous
dispersion to provide the cured coating.
[0022] In an additional aspect, a composition effective to provide
a cured coating on a substrate, in which the cured coating has a
water perm rating as tested by ASTM D1653 is about 2 perm or less
at 25% average RH, is less than or equal to 5 perms at 45% average
RH, is about 12 perms to about 24 perms at 75% average RH, and is
greater than 25 perms at 95% average RH; or as tested by ASTM E96
is about 2 perm or less at 25% average RH, is less than or equal to
5 perms at 45% average RH, is about 6 perms to about 12 perms at
75% average RH, and is greater than 11 perms at 95% average RH is
described. In some embodiments, the composition comprises an
aqueous dispersion, a surfactant and a reactant effective to react
with the dispersed material in the aqueous dispersion to provide
the cured coating.
[0023] In certain examples, the dispersed material comprises a
plant oil macromonomer, e.g., a vegetable oil macromonomer. In
other examples, the reactant is a derivatized benzene comprising an
unsaturated moiety. In some examples, the dispersed material
comprises a waterborne solid epoxy resin. In further examples, the
reactant is an amine, e.g., an aliphatic amine or a non-aliphatic
amine. In certain embodiments, the composition can include one or
more of a surfactant, a biocidal agent, a filler or other
materials.
[0024] In other configurations, an article comprising a
non-cellulosic substrate, and an aqueous dispersion disposed on the
substrate and effective to provide a variable water vapor perm
rating as a function of humidity, in which the water vapor perm
rating is about 2 perms or less at 25% average RH as tested by ASTM
D1653, or about 1 perm or less at 25% average RH as tested by ASTM
E96, when the aqueous dispersion is cured as a coating on the
non-cellulosic substrate is provided.
[0025] In some aspects, an article comprising a non-cellulosic
substrate, and a plant oil macromonomer dispersion disposed on the
non-cellulosic substrate and effective to provide a variable water
vapor perm rating, as tested by ASTM D1653 (or ASTM E96), when the
plant oil macromonomer dispersion is cured as a coating on the
non-cellulosic substrate is described.
[0026] In other aspects, an article comprising a non-cellulosic
substrate, and a waterborne epoxy resin dispersion disposed on the
non-cellulosic substrate and effective to provide a variable water
vapor perm rating, as tested by ASTM D1653 (or ASTM E96), when the
waterborne epoxy resin dispersion is cured as a coating on the
non-cellulosic substrate is disclosed.
[0027] Additional features, aspects, examples and embodiments are
described in more details below.
BRIEF DESCRIPTION OF THE FIGURES
[0028] Certain embodiments are described with reference to the
accompanying figures in which:
[0029] FIGS. 1A and 1B are articles (100) comprising a substrate
(110) with a coating (120) disposed thereon or coatings (1202) and
(1204) disposed on opposite surfaces;
[0030] FIG. 2 is a graph showing water vapor perm values as a
function of RH for three test compositions and a nylon 6 control;
and
[0031] FIG. 3 is a graph showing water perm values for a nylon 6
control and an epoxy resin based coating.
[0032] FIGS. 4 and 5 are graphs showing water perm values for
samples according to the present disclosure.
[0033] It will be recognized by the person of ordinary skill in the
art, given the benefit of this disclosure, that certain dimensions
or features in the figures may have been enlarged, distorted or
shown in an otherwise unconventional or non-proportional manner to
provide a more user-friendly version of the figures. Where
dimensions or values are specified in the description below, the
dimensions or values are provided for illustrative purposes only.
Reference to front, back, top and bottom are provided for exemplary
purposes and are not limiting.
DETAILED DESCRIPTION
[0034] Certain embodiments are described below with reference to
singular and plural terms in order to provide a user friendly
description of the technology disclosed herein. These terms are
used for convenience purposes only and are not intended to limit
the materials and articles described herein as including or
excluding certain features unless otherwise noted as being present
in a particular embodiment described herein.
[0035] In certain examples, the articles, compositions and methods
described herein can provide desirable attributes and physical
properties including, for example, variable water vapor permeance
ratings (also referred to herein as variable water vapor perm
ratings). Unless otherwise noted, the water vapor permeance ratings
described herein are measured according to ASTM D1653, dated 2013,
which is also referred to as the "dry cup" method. It should be
noted that ASTM E96, Procedure A can also be used instead of ASTM
D1653 to determine the water vapor perm ratings. ASTM D1653 and
ASTM E96 are similar methodologies except the cup size used in the
protocols are different. The particular testing temperature used is
specified in the method and may be, for example, 15-40.degree. C.
and is typically around 21-23.degree. C. Reference to a "variable
water vapor perm rating" refers to the change in the measured water
vapor perm rating at different RH values. A lower water vapor perm
rating is indicative of higher resistance to water vapor flow. For
example, in some embodiments of the articles and compositions
described herein, the water vapor perm rating desirably increases
with increasing RH to permit water vapor to pass through more
readily, e.g., changes from less than 2 perms at 25% RH to about 25
perms or more at 95% RH as tested by ASTM D1653, or less than 1
perm at 25% RH to about 17 perms or more at 95% RH as tested by
ASTM E96. The variability in the water perm ratings need not be
linear as a function of RH, and in certain instances, the
variability may be logarithmic, exponential or otherwise non-linear
over a selected RH range.
[0036] In embodiments, the permeance profiles for the foregoing
cured coating on a cellulosic substrate, the article comprising a
cellulosic substrate and a plant oil macromonomer, the article
comprising a cellulosic substrate and a waterborne epoxy, the
method of providing a coating composition, the cured coating
provided by the kit, the method of facilitating use of a building
substrate, or the cured coating obtained from the composition can
include any combination of the following permeance values.
[0037] As tested by ASTM E96, the permeance is about 2.5 perm or
less at 25% average RH, such as 2.3 perm or less, 2.2 perm or less,
2.0 perm or less, 1.8 perm or less, 1.6 perm or less, 1.4 perm or
less, 1.2 perm or less, 1.1 perm or less. The permeance is at least
0.02 perm at 25% average RH. The permeance can range from 0.02 perm
to 2.5 perms at 25% average RH, such as from 0.5 perm to 2.4 perms,
or 0.8 perm to 2.3 perms.
[0038] As tested by ASTM E96, the permeance is about 5 perms or
less at 45% average RH, such as 4.8 perms or less, 4.5 perms or
less, 4.2 perm or less, 4.0 perms or less, 3.8 perms or less, 3.6
perms or less, 3.4 perms or less, 3.2 perms or less. The permeance
is at least 1.0 perm at 45% average RH. The permeance can range
from 1.0 perm to 5 perms at 45% average RH, such as from 2.0 perms
to 4.5 perms, or 2.5 perms to 4.0 perms. In at least one
embodiment, the difference between the permeance at 45% average RH
and 25% average RH is at least 0.5 perm, such as at least 0.8 perm,
at least 1.0 perm, at least 1.1 perms, or at least 1.2 perms.
[0039] As tested by ASTM E96, the permeance is at least 5.5 perms
at 75% average RH, such as at least 5.7 perms, at least 6.0 perms,
at least 6.5 perms, at least 7.0 perms, at least 7.3 perms, at
least 7.5 perms, at least 7.8 perms, or at least 8.0 perms. The
permeance is not greater than 12.0 perms at 75% average RH, such as
not greater than 11.5 perms, not greater than 11.0 perms, not
greater than 10.5 perms, not greater than 10.0 perms, not greater
than 9.5 perms, not greater than 9.0 perms, or not greater than 8.5
perms. The permeance can range from 6.0 perms to 12.0 perms at 75%
average RH, such as from 6.5 perms to 10.5 perms, or 7.0 perms to
9.0 perms at 75% average RH. In at least one embodiment, the
difference between the permeance at 75% average RH and 45% average
RH is at least 2 perms, such as at least 3 perms, at least 3.5
perms, at least 3.7 perms, or at least 4 perms. In at least one
embodiment, the difference between the permeance at 75% average RH
and 25% average RH is at least 3 perms, such as at least 4 perms,
at least 4.5 perms, at least 4.7 perms, or at least 5 perms.
[0040] As tested by ASTM E96, the permeance is at least 11 perms at
95% average RH, such as at least 12.0 perms, at least 15.0 perms,
at least 20.0 perms, at least 21.0 perms, at least 22.0 perms, at
least 23.0 perms, at least 25.0 perms, or at least 30.0 perms. The
permeance is not greater than 55.0 perms at 95% average RH. The
permeance can range from 11.0 perms to 55.0 perms at 95% average
RH, such as from 25 perms to 54 perms, or 30 perms to 53 perms at
95% average RH. In at least one embodiment, the difference between
the permeance at 95% average RH and 75% average RH is at least 3
perms, such as at least 5 perms, at least 10 perms, at least 15
perms, or at least 20 perms. In at least one embodiment, the
difference between the permeance at 95% average RH and 45% average
RH is at least 6 perms, such as at least 10 perms, at least 20
perms, at least 22 perms, or at least 25 perms.
[0041] The permeance profiles of the cured coatings are non-linear
across the range of the average relative humidity. In at least one
embodiment, as tested by ASTM E96, the permeance is between 1 perm
and 2.5 perms at 25% average RH, between 3.0 perms and 4.0 perms at
45% average RH, between 7.0 perm and 15.0 perms at 75% average
RH.
[0042] In some examples, the articles described herein can include
a coating that is substantially free of polyamides but has water
vapor perm ratings similar to those commonly provided by a coating
comprising polyamides, e.g., nylon 6, on a substrate. For example,
the article can include a cured coating that has substantially the
same perm ratings as a function of humidity as the perm ratings
provided by a coating comprising a polyamide such as nylon 6 even
though the instant coatings may be substantially free of
polyamides. In some embodiments, the substantially free polyamide
coating may have perm ratings within about 15-25% of the perm
rating of a coating comprising nylon 6 at 25% average RH, within
about 15-20% of the perm rating of a coating comprising nylon 6 at
45% average RH, within about 15-20% of the perm rating of a coating
comprising nylon 6 at about 75% average RH and within about 15-20%
of the perm rating of a coating comprising nylon 6 at 95% average
humidity.
[0043] In some embodiments, the coatings provided herein can be
present on a cellulosic substrate that is part of a building
material such as, for example, kraft paper coated fiberglass
insulation, oriented strand board, gypsum wallboard, or other
materials commonly used in the building industry that permit water
vapor to enter or exit a building structure. In another embodiment,
the substrate can be a woven or a non-woven material. In certain
embodiments, the articles described herein can include a
composition comprising an aqueous dispersion of material that can
be disposed and/or cured on a surface of a substrate to provide
desirable water vapor perm ratings at different RH values. In
certain examples, suitable materials for dispersal include those
which do not phase separate at a temperature of about 25-40.degree.
C. and can be generally coated or sprayed onto a substrate in an
aqueous carrier, e.g., an aqueous carrier that is not considered a
strong base or a strong acid, to provide a substantially
homogeneous cured coating on the substrate. In some examples, the
aqueous dispersion may comprise solid particles suspended in an
aqueous carrier. In other examples, the aqueous dispersion may
comprise an oil that is emulsified or suspended in an aqueous
carrier. As described herein, to facilitate dispersion of a desired
material in an aqueous carrier, it may be desirable to include one
or more detergents, surfactants, salts or other suitable materials
that can assist in suspension or emulsification of the materials in
the aqueous carrier. During application of the materials, the
aqueous carrier desirably is removed, e.g., through passive
evaporation, active evaporation (for example, using an air
current), wicking, decanting, heating or otherwise removal of the
aqueous carrier to provide a coating with a variable water vapor
perm rating on the surface of the substrate. In some instances, the
water vapor perm rating of the cured coating is about 2 perm or
less at 25% average RH as tested by ASTM D1653, or about 1 perm or
less at 25% average RH as tested by ASTM E96, when the aqueous
dispersion is cured as a coating on the substrate. In other
embodiments, the water vapor perm rating of the cured coating is
less than or equal to 5.0 perms at 45% average RH as tested by ASTM
D1653, or less than or equal to 2.5 perms at 45% average RH as
tested by ASTM E96. In additional embodiments, the water vapor perm
rating of the cured coating is about 12 perms to about 24 perms at
75% average RH as tested by ASTM D1653, or about 6 to 12 perms at
75% average RH as tested by ASTM E96. In other examples, the water
vapor perm rating of the cured coating is greater than 25 perms at
95% average RH as tested by ASTM D1653, or greater than 17 perms or
less at 95% average RH as tested by ASTM E96. Where a coating
displays the water vapor perm rating noted above at different RH
values, the change in perm rating as humidity increases may, as
noted herein, be linear or non-linear. Where cellulosic substrates
are used, the substrate may be a woven or non-woven substrate
comprising cellulose based materials, e.g., paper or paper fibers,
strands, etc. or other cellulose based materials which are present
in a non-woven material or are woven together optionally with
non-cellulose materials.
[0044] In other instances, the substrate may be a non-cellulosic
substrate. Non-cellulosic substrates are substrates that do not
include any cellulose based materials. For example, woven and
non-woven non-cellulosic substrates may be used with the aqueous
dispersions described herein. In some configurations, the
non-cellulosic substrate may be comprise a woven material including
one or more fabrics, Where non-woven cellulosic materials are used,
the non-woven can be selected, for example, from a polypropylene, a
polyethylene, a polystyrene, a polyester, a polyurethane, a
fiberglass, a spunbond polymer, and a point-bonded polymer. The
non-woven may be a wet-laid non-woven, an air laid non-woven or
non-woven materials that can be produced using other processes.
[0045] In certain examples, the aqueous dispersions described
herein can include one or more plant oils. Illustrative plant oils
include oils extracted from seeds and oils extracted from plant
structures other than seeds. In some embodiments, the plant oil is
a plant oil macromonomer. As used herein, the term macromonomer
refers to a molecule that includes a terminal moiety that can
function as a monomer. A single mole of macromonomer provides a
single monomeric unit to the chain of a polymer. As described
herein, a macromonomer can be polymerized and/or cured by reaction
with a suitable reactant. In some instances, the plant oil
macromonomer may be a fruit oil macromonomer, a tree oil
macromonomer, a shrub oil macromonomer, a herb oil macromonomer, a
flower oil macromonomer, a bush oil macromonomer, a vegetable oil
macromonomer (VOMM) and combinations thereof.
[0046] In certain embodiments, the aqueous dispersion may comprise
a vegetable oil macromonomer from one or more of a leaf vegetable
plant, a seed vegetable plant, a fruit vegetable plant, a root
vegetable plant, a flower vegetable plant, a bud vegetable plant, a
flax plant and combinations thereof. In some embodiments, the
vegetable oil macromonomer may be produced by a bean plant, a
soybean plant, a carrot plant, a beet plant, a turnip plant, a
radish plant or other vegetable plants. In certain embodiments, the
vegetable oil macromonomer can be naturally produced, can be
produced from naturally occurring materials or may be synthetic or
may be a derivative of a naturally produced vegetable oil
macromonomer. For example, the VOMM may be one or more of those
described in U.S. Pat. No. 8,450,414.
[0047] In some embodiments, the VOMM can be derivatized prior to
use by reacting the naturally produced oil with one or more
derivatizing agents. For example, many VOMMs (and many plant oils)
include one or more sites of unsaturation. These sites of
unsaturation may be advantageously used and/or may be consumed by
auto-oxidation as the dispersion/coating dries. Derivatized forms
may be particularly suitable for emulsion copolymerization with
other species to provide a coating on a substrate as described
herein. In one embodiment, an unsaturated plant oil can be reacted
with a primary or secondary amine followed by reaction with one or
more other species to provide a monomeric form suitable for
polymerization. In one embodiment, a vegetable oil can be converted
to a fatty amide (meth)acrylate monomer by reaction with
ethanolamine or substituted ethanolamine (e.g., N-methyl
ethanolamine, N-oleoylethanolamine, N-ethylethanolamine,
N-propylethanolamine, N-butylethanolamine,
N-tert-butylethanolamine, N-(tert-butoxycarbonyl)ethanolamine,
N-(allyloxycarbonyl)ethanolamine, benzyl
N-(2-hydroxyethyl)carbamate, ethyl-N-(2-hydroxyethyl)-carbamate, or
diethanolamine) followed by reaction with either (meth)acryloyl
chloride or (meth)acrylic acid. For example, a plant oil such as
linseed oil, soybean oil, safflower oil, tung oil and coconut oil
can be reacted with substances, e.g., (meth)acryloyl chloride or
(meth)acrylic acid. In another embodiment, a urethane fatty amide
(meth)acrylate monomer can be produced by reaction of
hydroxyethyl(meth)acrylate reacted with isophorone diisocyanate.
For example, hydroxyethyl(meth)acrylate can be reacted with
isophorone diisocyanate in a first reaction, e.g., the
hydroxyl(meth)acrylate is reacted in equimolar proportion with
isophorone diisocyanate. In a separate reaction, a plant oil, for
example, soybean oil, coconut oil, safflower oil, tung oil or
linseed oil is reacted with ethanolamine (or substituted
ethanolamine) to form the hydroxyl functional fatty amide. The
products of the two reactions can be reacted to provide a urethane
fatty amide (meth)acrylate monomer.
[0048] In certain embodiments, the resulting macromonomer can be
suspended or dispersed in an aqueous carrier optionally with a
surfactant or detergent. Polymerization of the macromonomer can
occur by the addition of a suitable reactant that can react with
the reactive sites of the macromonomer to provide a dispersed
polymer. While not limiting, many suitable reactants include one or
more sites of unsaturation, e.g., comonomers with vinyl
unsaturation or other sites of unsaturation. Illustrative reactants
that are suitable for reaction with the macromonomers include, but
are not limited to, vinyl acetate, vinyl chloride, vinyl ester of a
saturated tertiary branched carboxylic acid, acrylonitrile,
acrylamide, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate,
2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, glycidyl
acrylate, glycidyl methacrylate, acrylic acid, methacrylic acid,
butyl acrylate, butyl methacrylate, methyl methacrylate, methyl
acrylate, p-acetoxystyrene, polyvinyl alcohol, ethylene vinyl
alcohol and styrene or other derivatized forms of benzene that
include one or more unsaturated side chains, e.g., benzylic side
chains.
[0049] In certain embodiments, a generic formula of a vegetable oil
macromonomer is shown below as formula (I)
##STR00001##
where R is CH.sub.3, H or CH.sub.2CHOH, R' is a saturated or
unsaturated straight chain alkyl group of a fatty acid of a
vegetable oil (e.g., a straight chain alkyl group having from about
12 to about 24 carbons with 0, 1, 2, 3, 4 or 5 sites of
unsaturation within the chain), R'' is CH.sub.3 or H, and U is
CH.sub.2CH.sub.2, CH.sub.2CH.sub.2CH.sub.2 or a group of formula
(II)
##STR00002##
[0050] In some embodiments, the group R' may be the hydrocarbon
chain from lauric acid, myristic acid, palmitic acid, stearic acid,
eleostearic acid, caprylic acid, capric acid, lignoceric acid,
palmitoleic acid, oleic acid, linoleic acid, alpha-linolenic acid,
or gamma-linolenic acid.
[0051] In certain embodiments, R is CH.sub.3, R' is a 16-18 carbon
straight chain alkyl group with 1-3 vinyl groups, R'' is methyl and
U is CH.sub.2CH.sub.2. In other examples, R is CH.sub.3, R' is a
16-18 carbon straight chain alkyl group with 1-3 vinyl groups, R''
is hydrogen and U is CH.sub.2CH.sub.2. In some examples, R is
CH.sub.3, R' is a 17 carbon straight chain alkyl group with 2 vinyl
groups, R'' is methyl and U is CH.sub.2CH.sub.2. In some examples,
R is CH.sub.3, R' is a 17 carbon straight chain alkyl group with 2
vinyl groups, R'' is hydrogen and U is CH.sub.2CH.sub.2. In some
examples, R is CH.sub.3, R' is a 17 carbon straight chain alkyl
group with 2 vinyl groups (one at carbon 8 and one at carbon 11 as
counted from the carbonyl group bonded to R'), R'' is methyl and U
is CH.sub.2CH.sub.2. In other examples, R is CH.sub.3, R' is a 17
carbon straight chain alkyl group with 2 vinyl groups (one at
carbon 8 and one at carbon 11 as counted from the carbonyl group
bonded to R'), R'' is hydrogen and U is CH.sub.2CH.sub.2. In yet
other embodiments, a VOMM having formula (III) (referred to below
as SoyAA-1) can be used
##STR00003##
and can be combined in an aqueous dispersion with one or more of
vinyl acetate, vinyl chloride, vinyl ester of a saturated tertiary
branched carboxylic acid, acrylonitrile, acrylamide, 2-ethylhexyl
acrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl acrylate,
2-hydroxyethyl methacrylate, glycidyl acrylate, glycidyl
methacrylate, acrylic acid, methacrylic acid, butyl acrylate, butyl
methacrylate, methyl methacrylate, methyl acrylate,
p-acetoxystyrene, polyvinyl alcohol, ethylene vinyl alcohol and
styrene or other derivatized forms of benzene that include one or
more unsaturated side chains, e.g., benzylic side chains. The
combination of formula (III) with one or more of these compounds
can result in polymerization, which can provide the coatings having
the variable water vapor perm ratings described herein once the
dispersions are disposed on a suitable substrate and a final
coating is formed.
[0052] In other embodiments, the aqueous dispersion can include one
or more waterborne epoxy materials or resins that can polymerize to
provide a coating. In some embodiments, the waterborne epoxy
material can be a Type I or a Type II epoxy material. Type I epoxy
materials generally are low molecular weight materials that can be
cured with a reactant that can also function as an emulsifier. Type
I epoxy resins are often based on bisphenol A or bisphenol F and
have an epoxide equivalent weight of less than 250. Type II epoxy
materials are high molecular weight materials that tend to be
present in solid form with epoxide equivalent weights of more than
450, e.g., about 750-1500 EEWs. Type II solid epoxy resins can be
dispersed at about 50-55% solids in water and typically are used
with an emulsifier or surfactant. The reactant used with a Type II
system can diffuse into the dispersed solid particles and crosslink
the epoxy groups. Illustrative reactants for use with Type I and
Type II epoxy resins may be those with one or more free amine
groups as discussed herein. Illustrative commercially available
waterborne epoxy resins include, but are not limited to,
EPI-REZ.TM. epoxy waterborne resins (available from Momentive),
Ancarez.TM.555 (available from Air Products), the THW grades of
waterborne epoxy resins (available from Epotec) or other
commercially available epoxy resins. In certain examples, the epoxy
resin can be selected such that substantially zero VOCs are present
in the aqueous dispersion to provide the coatings described herein
with the desirable variable water vapor perm values. For example,
where a Type II epoxy resin is used, glycol ether is often added to
aid in processing. In the aqueous dispersions provided herein,
however, glycol ether (and other VOCs) may be omitted even where a
Type II epoxy resin system is implemented.
[0053] In some embodiments, the waterborne epoxy material can
include a single reactive epoxy group at one end of the molecule,
e.g., can react as a macromonomer. In other embodiments, the
waterborne epoxy material can include two or more reactive epoxy
groups in the molecule. In certain examples, the waterborne epoxy
material can have a formula as shown in formula (IV), or be a
derivative of formula (IV)
##STR00004##
which is generally a diglycidyl ether of bisphenol-A. In some
instances, the epoxy material can be reacted with a reactant that
comprises one or more amine groups, e.g., an aliphatic amine or an
aliphatic diamine, which can result in opening of the epoxy ring
and coupling of the amine group to the epoxy material. If the amine
is a diamine, a similar reaction can occur with an additional epoxy
group to build up the polymer. In addition, cross-linking may occur
at the amine sites by reaction with an epoxy group. Suitable amines
for use with the epoxy materials described herein include primary
aliphatic amines, secondary aliphatic amines, primary aliphatic
diamines, secondary aliphatic diamines and mixed diamines (e.g.,
where one amine site is primary and one amine site is secondary).
In other instances, non-aliphatic amines may be used in place of an
aliphatic amine. If desired, amine reactants with branching or
unsaturation sites can also be used to polymerize the epoxy
materials described herein. In some embodiments, the reactant may
be one or more of the Anquamine reactants commercially available
from Air Products, e.g., Anquamine 721, 701, 401, 360, 287, 735 or
419.
[0054] In certain embodiments, the dispersions described herein can
include one or more additives or materials to facilitate
polymerization, deposition or otherwise alter the properties of the
dispersion and any resulting coating on a substrate. In some
embodiments, the additive may be a surfactant that can assist in
dispersion of the macromonomers and/or epoxy materials in an
aqueous carrier. If desired, the surfactant may be ionic or
non-ionic. The surfactant can be present in an effective amount to
either assist in dispersal of the material in the aqueous carrier
or to reduce surface tension of the aqueous dispersion as it is
disposed on the substrate or both. In some instances, the
surfactant can also assist in providing a coating that has
substantially the same thickness along the planar surface of a
substrate. Where macromonomers and/or epoxy materials are used, it
may be desirable to use a non-ionic surfactant. In some
embodiments, the surfactant may be substituted or derivatized with
groups other than carbon, hydrogen and oxygen. For example, the
surfactant can include halo groups, (e.g., fluoro, chloro, bromo,
or iodo groups), phospho groups, sulfo groups or other groups. In
some embodiments, the surfactant can be present in an effective
amount to reduce the surface tension of the aqueous dispersion as
it is coated onto a substrate to provide for easier coating and/or
a more uniform coating. Illustrative commercially available
surfactants are available from 3M (e.g., Novec fluorosurfactants
such as FC-4430, FC-4432, FC-4434), Sigma Aldrich (e.g., Triton.TM.
surfactants, Zonyl.RTM. surfactants), Maflon (e.g., PDM112, Hexafor
647, 648, 670, 675 or 678D), AkzoNobel and other companies that
provide surfactants.
[0055] In other embodiments, the dispersions can include one or
more fillers or filler materials. For example, in some embodiments
the filler can include one or more of a clay, a montmorillonite, a
calcium filler, a bentonite, a muscovite, an illite, a cookeite, a
kaolonite, a chlorite or other filler materials. The filler may
comprise inorganic materials, organic materials or combinations
thereof. In some examples, the filler may provide reinforcement in
the cured coating, may provide flame retardancy in the cured
coating, may improve the physical properties of the cured coating
(e.g., increase the coefficient of linear thermal expansion (CLTE)
as compared to the CLTE of a cured coating without the filler), or
may provide other desired features, e.g., may increase the overall
viscosity of the aqueous dispersion to facilitate more uniform
coating on a substrate. Illustrative commercially available
fillers, include, but are not limited to, Bentolite.RTM.,
Cloisite.RTM., Nanofil.RTM., Nanothix.RTM., and Permont.RTM.
fillers available from Southern Clay Products, Inc.
[0056] In certain examples, the dispersions can include one or more
biocidal agents. The biocidal agent can be effective to deter or
prevent growth of organisms on the coating and/or surface of the
substrate. In some embodiments, the biocidal agent can be effective
as a fungicide, e.g., a moldicide, to prevent growth of mold or
other fungus on the surface of the substrate. The biocidal agent
can prevent growth of mold and fungus on or in the dispersion. In
other embodiments, the biocidal agent can be effective to prevent
growth of bacteria, mold, fungus, moss, algae or other organisms on
the surface of the substrate. Where present, the biocidal agent may
be present in an effective amount to deter or prevent growth of
bioorganisms.
[0057] In some embodiments, the dispersions can include
stain-resistance additives. In some examples, the stain-resistance
additive can act to reduce or prevent materials from being adsorbed
into the coating and can generally assist in sealing the coating
from penetration by materials other than water and gases. For
example, the stain-resistance additive can provide oil resistance
or oil repellency to prevent non-polar species from becoming
trapped in the coating. The stain-resistance additives may also
inhibit fading of the coating if exposed to heat, ultraviolet light
or other forms of energy. Illustrative stain-resistance additives
are commercially available, for example, from 3M (e.g., SRC-220,
PM-5000, PM-1680, PM-4800) and AkzoNobel (e.g., Elotex.RTM.
stain-resistance additives).
[0058] In certain embodiments, the dispersions described herein can
comprise one or more polyamides or polyamide precursors mixed with
macromonomer or epoxy resin. In some instances, the polyamide may
be produced from naturally occurring polyamide precursors such as
those present in castor oil. In other embodiments, the polyamide
may be Nylon 6 precursors, e.g., caprolactam, that can be mixed in
monomeric form with the macromonomer or the epoxy resin. Where a
polyamide precursor is present, it is desirably used in an amount
that does not result in phase separation in the aqueous dispersion.
In some instances, the polyamide precursors can be used as a
reactant in the aqueous dispersion. In other embodiments, a
polyamide, e.g., Nylon 6, can be added to the aqueous dispersion
either before or during coating. In yet one further embodiment, the
coating can be adjacent to a polyamide layer. The polyamide layer
can include Nylon 6. In one embodiment, the polyamide layer can
range from 0.005 mil to 2 mil, such as from 0.008 mil to 0.1 mil,
or from 0.01 mil to 0.05 mil.
[0059] In certain examples, the aqueous dispersions described
herein can be used to provide a cured coating on a building
substrate, e.g., kraft paper of fiberglass insulation, oriented
strand board or as a coating on a house wrap or other material used
that can be used to seal a building envelope. Referring to FIG. 1A,
an article 100 is shown comprising a substrate 110 with a coating
120 disposed thereon. The exact thickness of the substrate 110 and
the coating 120 can vary, but in most cases the thickness of the
substrate 110 will be substantially larger than the thickness of
the coating 120. While the thickness of the coating 120 is shown as
being substantially the same in the planar direction of the
substrate 110, such uniformity is not required. In particular, so
long as the thickness of the coating 120 is effective to provide
the variable water vapor perm values described herein, the
thickness need not be uniform in every area of the substrate 110.
In another embodiment and as shown in FIG. 1B, an article 100
comprises a substrate 110 and two coatings 1202 and 1204 on
opposite surfaces of the substrate 110, The thickness of the
coatings 1202 and 1204 can be the same or different. The
thicknesses can be chosen to provide the variable water vapor perm
values described herein. In at least one embodiment, the thickness
of coating 120, 1202, or 1204 can be at least 0.001 cm, such as at
least 0.01 cm, at least 0.05 cm, at least 0.1 cm, at least 0.12 cm,
at least 0.14 cm, at least 0.16 cm, at least 0.18 cm, at least 0.20
cm, or at least 0.22 cm. In another embodiment, the thickness of
coating 120, 1202, or 1204 can be not greater than 1 cm, such as
not greater than 0.9 cm, not greater than 0.8 cm, not greater than
0.7 cm, not greater than 0.6 cm, not greater than 0.55 cm, not
greater than 0.5 cm, not greater than 0.45 cm, not greater than 0.4
cm, not greater than 0.35 cm, not greater than 0.3 cm, not greater
than 0.28 cm, not greater than 0.26 cm, or not greater than 0.24
cm. In yet one further embodiment, the thickness of coating 120,
1202, or 1204 can range from 0.001 cm to 1 cm, such as from 0.05 cm
to 0.5 cm, or from 0.1 cm to 0.25 cm.
[0060] In certain embodiments, the substrate 110 can be any
suitable substrate commonly used in the building industry. For
example, buildings typically have some form of insulation in the
wall, floor and/or ceiling cavities. This insulation is often
fiberglass insulation that can include a vapor retarder to prevent
moisture from entering the insulated cavities. Common vapor
retarders are kraft paper coated with asphalt. Kraft paper itself
has a high rate of moisture transmission. When used with an asphalt
coating and/or adhesive, the kraft paper can act as a suitable
vapor retarder. Reduced moisture in the wall cavity can prevent a
reduction in the thermal conductivity within the wall cavity, which
can further assist in reduction of energy costs. In some instances,
the substrate 110 may be kraft paper that can be applied to a
larger building substrate, e.g., fiberglass insulation, using an
adhesive or other suitable attachment means. The exact weight of
the kraft paper can vary, and illustrative weights include, but are
not limited to, about 25 pounds to about 75 pounds per ream (3000
ft.sup.2), for example about 39 pounds. If desired, the kraft paper
can be omitted, and the coating 120 can be disposed directly on the
fiberglass insulation to provide a coating. In some examples where
the kraft paper is omitted, it may be desirable to include a web,
scrim, permeable film or some other material on the fiberglass
insulation to receive the aqueous dispersion that forms the
coating. In other embodiments, the substrate may be oriented strand
board that is applied as sheathing on external surfaces of a
building or between various floors of a building. The oriented
strand board can be coated directly without any intervening film or
material to provide an oriented strand board substrate having
variable water vapor perm ratings. In other instances, the coating
can be applied directly to drywall or other materials commonly used
to finish interior surfaces of a building structure. For example,
gypsum boards can be coated with the aqueous dispersion to provide
a gypsum wallboard with variable water perm ratings. Similarly,
wood paneling, wood planks, plywood, fiber board or other materials
used to finish exterior or interior walls or ceilings can be coated
with the aqueous dispersions described herein to provide variable
water vapor perm ratings. Additional building substrates that can
be coated with the aqueous dispersions will be readily selected by
the person of ordinary skill in the art, given the benefit of this
disclosure.
[0061] In yet one further embodiment, the article 100 can further
include striping (not shown) to bond the article to a base
material. The striping can include an adhesive. In one embodiment,
the striping can include asphalt. In yet another embodiment, the
striping can be water vapor impermeable. The striping can be
adjusted to adjust the water vapor perm ratings through the article
and the base material. More striping reduces the water vapor perm
rating, less striping increases the water vapor permeance.
Accordingly, the striping serves as a vapor retarder across the
article and the bonded base material.
[0062] In one embodiment, the base material can be any non-woven
sheeting material, a gypsum wallboard, a wooden wallboard, a brick
wall, or other building substrates. In one particular embodiment,
the base material can be a porous material. In one particular
embodiment, the base material can be a foam material.
[0063] In certain embodiments, the coating 110 can be disposed on
the substrate 120 by rolling, spraying, roll coating or other means
that can dispose a layer of the aqueous dispersion on the
substrate. If desired, additional aqueous dispersion can be added
to a cured coating layer to build up the thickness of the layers of
the coating. In some embodiments, it may be desirable to first coat
the substrate with a first aqueous dispersion, e.g., one including
a VOMM, and then after curing the first layer coat the substrate
again with a second aqueous dispersion, e.g., one including a
waterborne epoxy resin system. In other instances, different
aqueous dispersions can be mixed with each other and coated onto
the substrate simultaneously. Once cured, the coating on the
substrate desirably provides variable water vapor perm ratings,
e.g., about 2 perm or less at 25% average RH, is less than or equal
to 5 perms at 45% average RH, is about 12 perms to about 24 perms
at 75% average RH, and is greater than 30 perms at 95% average RH
as tested by ASTM D1653; or about 2.5 perm or less at 25% average
RH, is less than or equal to 5 perms at 45% average RH, is about 6
perms to about 12 perms at 75% average RH, and is greater than 12
perms at 95% average RH as tested by ASTM E96.
[0064] In some embodiments, the aqueous dispersion can be
co-sprayed onto the substrate with a reactant so reaction does not
occur prematurely in the aqueous dispersion. For example, where the
aqueous dispersion comprises a VOMM, the dispersion can be
co-sprayed with styrene or some other reactant directly onto the
substrate to form the coating. Additionally, one or more
surfactants, biocidal agents, filler materials or other additives
can also be co-sprayed into the surface of the substrate. In some
instances, one component of the coating can be rolled onto the
substrate and another component, e.g., the reactant, can be sprayed
onto the rolled aqueous dispersion on the substrate. If desired,
however, the components can all be mixed in the aqueous dispersion
and then disposed on the substrate in a desired manner. In some
instances, the aqueous dispersions may have a viscosity that is too
low to facilitate easy deposition onto a substrate. In such
instances, it may be desirable to include a viscosity modifier,
e.g., a thixotropic agent, an anti-thixotropic agent, or the like
to provide a desirable viscosity suitable for coating or otherwise
disposing the aqueous dispersion onto a desired substrate.
[0065] In certain examples, the aqueous dispersions provided herein
can be used either to provide pre-coated building substrates or to
permit on-site coating of building substrates. For example,
fiberglass insulation batts with kraft paper can be pre-coated with
one or more of the components followed by coating of an additional
component on-site to provide the final operative coating. In other
instances, the coating can be produced at the production site such
that an installer need not do anything to provide the coating. In
yet other cases, the installer may spray the aqueous dispersion
onto a substrate after it has been installed to provide the coating
on the installed substrate. In some instances, the substrate may be
a cellulosic substrate, e.g., one based on wood or prepared, at
least in part, using wood, wood fibers, wood products or other
plant materials that include cellulose.
[0066] In certain examples, the components of the coatings
described herein may be packaged in the form of a kit. In one
embodiment, the kit can include a coating dispersion and an
applicator to provide the coating dispersion onto a substrate. The
applicator can be a brush, a spray nozzle, or a roller. In another
embodiment, the kit can include a precursor to the coating
dispersion. For example, materials suitable for providing an
aqueous dispersion, e.g., a macromonomer or a waterborne epoxy
resin, can be packaged separate from a reactant and any other
additives, e.g., fillers, surfactants or the like. The components
can be mixed by a user, and the mixed components may then be coated
onto a substrate. In some embodiments, the kit may be packaged as a
2-part kit where the various components of the coating are mixed
in-line prior to spraying or depositing on the substrate.
[0067] For example, one canister or reservoir can include a
polymerizable component and the other canister or reservoir can
include a reactant and/or other additives. During application, the
system or device, e.g., a sprayer or similar device, can mix the
two different components in-line prior to spraying. In some
examples, an aqueous carrier can be added to the components
immediately prior to mixing. In some instances, the aqueous carrier
can be mixed with the components using an impeller, gas or other
means to facilitate dispersion of the components in the aqueous
carrier.
[0068] One aspect to the present coatings is the low content of
VOCs during preparation and/or curing of the coatings. VOC content
can be determined by ASTM D3960 and be quantified mass of VOC per
mass unit of coating solids. In one embodiment, as tested by ASTM
D3960, the VOC content of the herein described coatings is less
than 3 wt %, such as less than 1 wt %, less than 0.5 wt %, less
than 100 ppm, less than 50 ppm, less than 40 ppm, less than 30 ppm,
less than 20 ppm, less than 10 ppm, less than 5 ppm, less than 1
ppm, less than 0.5 ppm, or less than 0.1 ppm.
[0069] Certain specific examples are described below to facilitate
a better understanding of the technology described herein.
EXAMPLE 1
[0070] All coating systems were applied on kraft paper with a
wirewound bar and allowed to dry at ambient for one week before
evaluation. The coated paper was placed in perm cups with flanged
edges and the cups were placed in an environmental chamber that
provided mean RH levels of 25%, 45%, 75% and 95% to evaluate the
water permeability following the ASTM D1653 and/or E96 protocol.
The coated side of the paper was kept facing the high humidity side
in all evaluations. Each cup containing the coated paper along with
water/desiccant was weighed before being placed in the
environmental chamber and weighed every day thereafter for 10 days.
A 2 mil nylon 6 film was employed as an internal control in every
test. Each system was analyzed in triplicate and the average was
reported. The experimental conditions were as described in Table 1.
The target perm values for the coatings are listed in Table 2.
TABLE-US-00001 TABLE 1 Experimental Setup Environmental Chamber RH
Cup (Air Temperature in Chamber: 70-73.degree. F.) Containing 50%
90% Desiccant 25% mean RH for test sample 45% mean RH for test
sample Water 75% mean RH for test sample 95% mean RH for test
sample
TABLE-US-00002 TABLE 2 Target Perm Values ASTM ASTM Average
Relative D1653 E96 Humidity (RH) Perms Perms 25% .ltoreq.2.0
.ltoreq.1.0 50% .ltoreq.5.0 .ltoreq.2.5 75% 12-24 6-12 95% >25
>17
[0071] A number of aqueous dispersions were evaluated including:
[0072] a) Michem.RTM. Emulsion D310 (MED310), a multi-purpose
aqueous dispersion of a high melt polyamide supplied by Michelman,
Inc. at 22-24% solids by weight, <100 cPs (spindle #3, 60 rpm),
pH 9.7-10.7; [0073] b) Neocar.RTM. 820 (an ultra-small particle
size, hydrophobic modified acrylic latex, supplied by Arkema,
Inc.); [0074] c) ENCOR.RTM. 443 is a styrene-acrylic latex (41%
solids by weight, viscosity 600 cPs, density 8.7 lb/gal, and pH
7.0); [0075] d) A SoyAA-1:styrene (46:54 by weight) latex (50%
solids by weight) referred to as EK 3-32R2 in the Table 3 below;
[0076] e) Ancarez.RTM. AR555 (a waterborne solid epoxy resin
dispersion delivered at 55% solids in water, epoxy equivalent
weight 550, supplied by Air Products and Chemicals, Inc.). The
epoxy resin is based on diglycidyl ether of bisphenol-A; and [0077]
f) Anquamine.RTM. 401 (a modified aliphatic amine supplied at 70%
solids in water, theoretical amine hydrogen equivalent weight 200,
employed here as a reactant for Ancarez AR555, supplied by Air
Products and Chemicals, Inc.).
[0078] Additives employed in this Example include: [0079] a)
Oxylink.RTM. 3101 is an aqueous dispersion containing nano zinc
oxide (44% solids in water, pH 7-9, VOC <0.2%, viscosity <10
mPasec, density 1.5-1.6 g/mL, supplied by Buhler, Inc.) [0080] b)
Nanofil aqueous dispersion (Nanofil 116 is a natural
montmorillonite clay, supplied by Southern Clay Products, Inc., the
aqueous dispersion was prepared in our lab) [0081] c) SRC-220 (an
aqueous fluorinated polyurethane stain-resistance additive,
supplied by 3M) [0082] d) FC-4434 (a nonionic fluorinated
surfactant, supplied by 3M) [0083] e) Nanobyk.RTM. 3810 (a cerium
oxide nanoparticle dispersion in water, supplied by BYK Additives)
[0084] f) Cobalt Hydrocure.RTM. (a drier containing 6% cobalt
metal, supplied by OM Group, Inc.)
[0085] To obtain a baseline value for the substrate and the
control, the first evaluation was conducted with kraft paper,
nylon, and kraft paper+nylon along with kraft paper coated
individually with the polyamide emulsion and SoyAA-1/styrene latex.
The perm values obtained during the evaluation are listed in Table
3.
TABLE-US-00003 TABLE 3 ASTM D1653 Perm Results-I Average RH Desired
Perms Substrate with no Coating Perms 25% RH .ltoreq.2.0 Kraft
paper 28.46 Nylon 1.58 Kraft paper + Nylon 3.18 45% RH .ltoreq.5.0
Kraft paper -- Nylon 4.19 Kraft paper + Nylon 10.26 75% RH 12-24
Kraft paper 157.51 Nylon 14.79 Kraft paper + Nylon 17.51 95% RH
>25 Kraft paper 363.32 Nylon 68.63 Kraft paper + Nylon 66.87
Average RH Desired Perms Coating on Kraft Paper Perms 25% RH
.ltoreq.2.0 MED 310 21.00 EK 3-32R2 17.54 45% RH .ltoreq.5.0 MED
310 29.77 EK 3-32R2 10.10 75% RH 12-24 MED 310 157.69 EK 3-32R2
64.03 95% RH >25 MED 310 275.00 EK 3-32R2 54.42
EXAMPLE 2
[0086] Three systems were evaluated, i.e., a) SoyAA-1/styrene
(referred to as EK 3-32R2 in Tables 4 and 5 below) with 1% Oxylink,
b) SoyAA-1/styrene (repeat), and c) nylon (repeat) at 45% and 90%
RH levels. The repeats were necessary to determine the
repeatability of the systems. The results are provided in Table 4.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00004 TABLE 4 ASTM D1653 Perm Results-II Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
45% RH .ltoreq.5.0 EK 3-32R2 8.77 16.38 EK 3-32R2 + 1% Oxylink 8.90
14.69 95% RH >25 EK 3-32R2 120.14 14.70 EK 3-32R2 + 1% Oxylink
77.56 17.55
[0087] At 45% RH level, a good reproducibility was noted between
the second and third iterations for nylon and SoyAA-1/styrene. At
the 95% RH level, only the nylon sample showed good
reproducibility. Of the three samples tested with SoyAA-1/styrene,
one sample gave extremely high water loss readings, indicating that
the sample might have had some tear that allowed water vapor to
move freely. Overall, incorporating 1% Oxylink to the
SoyAA-1/styrene latex seemed to have a positive effect on the
permeability values of the coated kraft paper, i.e., it moved the
perm values closer to the target perm values (Table 5).
TABLE-US-00005 TABLE 5 ASTM D1653 Perm Results-III Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 EK 3-32R2 7.92 15.47 EK 3-32R2 + 1% Oxylink 7.36
16.62 75% RH 12-24 EK 3-32R2 89.74 12.98 EK 3-32R2 + 1% Oxylink
66.60 14.45
[0088] At 25% RH level, the system with 1% Oxylink performed better
than the system without Oxylink.
EXAMPLE 3
[0089] Blends of MED 310 with SoyAA-1/styrene (46:54 by weight and
referred to as EK 3-32R2 in Table 6 below) in the ratios of a)
65:35, b) 35:65, and c) 50:50 (all on solids by weight), and a
blend of MED 310 with ENCOR 443 at 50:50 by weight on solids were
applied on kraft paper and evaluated at 25% and 75% RH levels. The
results are provided in Table 6. The ASTM D1653 protocol was used
for the testing.
TABLE-US-00006 TABLE 6 ASTM D1653 Perm Results-IV Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 MED 310:EK 3-32R2 35:65 38.36 10.68 MED 310:EK
3-32R2 50:50 37.96 9.04 MED 310:Encor 433 50:50 42.07 9.43 75% RH
12-24 MED 310:EK 3-32R2 35:65 99.18 10.41 MED 310:EK 3-32R2 50:50
142.29 10.04 MED 310:Encor 433 50:50 159.11 8.98
[0090] The MED 310 blends exhibited phase separation upon
application to the kraft paper that was manifest as areas with
uneven gloss and appearance. The phase separation is believed to
compromise the water vapor permeability of the coated system as
noted from the high permeability values. Consequently, these
systems were not evaluated at 45% and 95% RH levels.
EXAMPLE 4
[0091] The following systems were applied on kraft paper and
evaluated at 25% and 75% RH levels: [0092] 1) Ancarez AR555, a
waterborne solid epoxy resin dispersion supplied at 55% solids in
water, [0093] 2) Encor 443, [0094] 3) Encor 443+3% Oxylink 3101,
[0095] 4) SoyAA-1/styrene (46:54 by weight and referred to as EK
3-32R2 in Table 7 below)+1% Oxylink 3101, [0096] 5) SoyAA-1/styrene
(46:54 by weight)+3% Oxylink 3101, [0097] 6) SoyAA-1/styrene (46:54
by weight)+1% Nanofil aqueous dispersion, [0098] 7) SoyAA-1/styrene
(46:54 by weight)+3% Nanofil, [0099] 8) SoyAA-1/styrene (46:54 by
weight) with 0.5% SRC-220, [0100] 9) SoyAA-1/styrene (46:54 by
weight)+0.1% FC-4434, and [0101] 10) SoyAA-1/styrene (46:54 by
weight)+0.4% Nanobyk 3810
[0102] The samples described in Table 7 were coated at 5 mils wet
film thickness. The ASTM D1653 protocol was used for the testing.
In this evaluation, the SoyAA-1/styrene+1% Oxylink 3101 was applied
at 3 mils wet film thickness while the SoyAA-1/styrene+3% Oxylink
3101 was applied at 1 mil wet film thickness. The perm results
together with the coating weights for this evaluation are listed in
Table 7.
TABLE-US-00007 TABLE 7 ASTM D1653 Perm Results-V Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 Ancarez AR 555 5.03 5.69 Encor 443 42.40 4.84
Encor 443 with 3% Oxylink 3101 40.70 5.02 EK 3-32R2 with 1% Oxylink
3101 43.10 4.06 EK 3-32R2 with 3% Oxylink 3101 37.33 2.24 EK 3-32R2
with 1% Nanofil 6.20 8.37 EK 3-32R2 with 3% Nanofil 6.78 7.73 EK
3-32R2 with 0.5% SRC-220 10.14 8.02 EK 3-32R2 with 0.1% FC 4434
7.32 8.70 EK 3-32R2 with 0.4% Nanobyk 9.15 7.81 3810 75% RH 12-24
Ancarez AR 555 32.72 5.88 Encor 443 123.97 3.72 Encor 443 with 3%
Oxylink 3101 121.37 4.77 EK 3-32R2 with 1% Oxylink 3101 119.66 3.41
EK 3-32R2 with 3% Oxylink 3101 121.64 2.43 EK 3-32R2 with 1%
Nanofil 48.12 7.68 EK 3-32R2 with 3% Nanofil 26.83 9.93 EK 3-32R2
with 0.5% SRC-220 23.00 8.83 EK 3-32R2 with 0.1% FC 4434 38.47 9.28
EK 3-32R2 with 0.4% Nanobyk 63.57 8.61 3810
[0103] To meet the target perm ratings at 25% and 75% RH, the
coating weights for the systems need to be increased.
EXAMPLE 5
[0104] Separate systems including Ancarez 550 and Neocar 820 were
tested. The systems that were applied on kraft paper were comprised
of: [0105] 1) Ancarez AR555 with 1% Nanofil [0106] 2) Ancarez AR555
with 3% Nanofil [0107] 3) Ancarez AR555 with SRC-220 and FC-4434
[0108] 4) Ancarez AR555 with SRC-220 [0109] 5) Ancarez AR555 with
FC-4434 [0110] 6) Neocar 820 with 1% Nanofil [0111] 7) Neocar 820
with 3% Nanofil [0112] 8) Neocar 820 with SRC-220 and FC-4434
[0113] 9) Neocar 820 with SRC-220 [0114] 10) Neocar 820 with
FC-4434
[0115] The perm results of this evaluation are provided in Table 8.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00008 TABLE 8 ASTM D1653 Perm Results-VI Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 Ancarez AR 555 + 1% Nanofil 4.11 17.16 Ancarez
AR 555 + 3% Nanofil 6.51 14.24 Ancarez AR 555 + SRC-220 + 5.96
14.86 FC-4434 Ancarez AR 555 + SRC-220 7.61 12.98 Ancarez AR 555 +
FC-4434 5.59 14.35 Neocar 820 + 1% Nanofil 8.54 13.01 Neocar 820 +
3% Nanofil 8.65 13.00 Neocar 820 + SRC-220 + FC-4434 6.84 14.10
Neocar 820 + SRC-220 6.08 14.36 Neocar 820 + FC-4434 10.00 11.30
75% RH 12-24 Ancarez AR 555 + 1% Nanofil 40.52 12.24 Ancarez AR 555
+ 3% Nanofil 39.01 13.58 Ancarez AR 555 + SRC-220 + 35.25 13.17
FC-4434 Ancarez AR 555 + SRC-220 39.72 12.01 Ancarez AR 555 +
FC-4434 36.92 12.51 Neocar 820 + 1% Nanofil 51.61 11.62 Neocar 820
+ 3% Nanofil 23.19 13.08 Neocar 820 + SRC-220 + FC-4434 17.49 12.78
Neocar 820 + SRC-220 16.41 11.76 Neocar 820 + FC-4434 43.56
11.82
EXAMPLE 6
[0116] The most promising systems from Tables 5 and 6 were selected
for evaluation at 45% and 95% RH.
[0117] 1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R2
in Table 9)+FC-4434
[0118] 2) Ancarez AR555
[0119] 3) Ancarez AR555+1% Nanofil
[0120] 4) Ancarez AR555+SRC-220+FC-4434
[0121] 5) Ancarez AR555+FC-4434
[0122] 6) Neocar 820+3% Nanofil
[0123] 7) Neocar 820+SRC-220+FC-4434
[0124] 8) Neocar 820+SRC-220
[0125] The perm results of this evaluation are listed in Table 9.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00009 TABLE 9 ASTM D1653 Perm Perm Results-VII Coating
Average Desired Weight RH Perms Coating on Kraft Paper Perms
(g/ft.sup.2) 45% RH .ltoreq.5.0 EK 3-32R2 + 0.1% FC-4434 11.13 8.11
Ancarez AR 555 10.31 5.19 Ancarez AR 555 + 1% Nanofil 6.89 7.29
Ancarez AR 555 + SRC-220 + 7.34 9.74 FC-4434 Ancarez AR 555 +
FC-4434 6.91 7.87 Neocar 820 + 3% Nanofil 7.09 8.38 Neocar 820 +
SRC-220 + FC-4434 6.13 7.48 Neocar 820 + SRC-220 11.92 3.99 95% RH
>25 EK 3-32R2 + 0.1% FC-4434 81.79 10.06 Ancarez AR 555 114.38
6.59 Ancarez AR 555 + 1% Nanofil 153.54 6.92 Ancarez AR 555 +
SRC-220 + 117.54 10.42 FC-4434 Ancarez AR 555 + FC-4434 129.31 9.14
Neocar 820 + 3% Nanofil 100.07 9.84 Neocar 820 + SRC-220 + FC-4434
41.22 8.27 Neocar 820 + SRC-220 58.13 6.46
[0126] At 45% RH, none of the above systems met the target perm
rating but all met the target at 95% RH.
EXAMPLE 7
[0127] Several additional systems were evaluated at 45% and 95% RH:
[0128] 1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R2
in Table 10)+1% Nanofil [0129] 2) SoyAA-1/styrene (46:54 by
weight)+3% Nanofil [0130] 3) Neocar 820+1% Nanofil [0131] 4)
Ancarez AR555+SRC-220 [0132] 5) Ancarez AR555+3% Nanofil [0133] 6)
Ancarez AR555 crosslinked with Anquamine 401 (epoxy:amine ratio
2:1)
[0134] The perm results of this evaluation are listed in Table 10.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00010 TABLE 10 ASTM D1653 Perm Results-VIII Coating
Average Desired Weight RH Perms Coating on Kraft Paper Perms
(g/ft.sup.2) 45% RH .ltoreq.5.0 EK 3-32R2 + 1% Nanofil 18.77 6.02
EK 3-32R2 + 3% Nanofil 18.36 9.09 Neocar 820 + 1% Nanofil 11.89
6.70 Ancarez AR 555 + SRC-220 10.93 7.90 Ancarez AR 555 + 3%
Nanofil 6.91 10.26 Ancarez AR 555 crosslinked with 3.55 12.79
Anquamine 401 95% RH >25 EK 3-32R2 + 1% Nanofil 88.72 7.69 EK
3-32R2 + 3% Nanofil 123.03 8.39 Neocar 820 + 1% Nanofil 22.77 9.72
Ancarez AR 555 + SRC-220 93.47 9.67 Ancarez AR 555 + 3% Nanofil
145.89 9.12 Ancarez AR 555 crosslinked with 26.00 13.03 Anquamine
401
[0135] Only Ancarez AR 555 crosslinked with Anquamine 401 system
met the desired perms as Table 10 showed.
EXAMPLE 8
[0136] The following samples were evaluated at all four RH
levels.
[0137] 1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-85 in
Table 11) (5 mils)
[0138] 2) SoyAA-1/styrene (46:54 by weight) with 1% Nanofil+FC-4434
(3 mils)
[0139] 3) SoyAA-1/styrene (46:54 by weight) with 1% Nanofil+FC-4434
(5 mils)
[0140] 4) SoyAA-1/styrene (46:54 by weight)+FC-4434 (5 mils)
[0141] 5) Neocar 820+FC-4434
[0142] The perm results of this evaluation are listed in Table 11.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00011 TABLE 11 ASTM D1653 Perm Results-IX Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 EK 3-85 7.89 7.27 EK 3-85 + Nanofil + FC-4434
9.47 4.45 (3 mils) EK 3-85 + Nanofil + FC-4434 6.88 7.63 (5 mils)
EK 3-85 + FC-4434 10.02 6.55 Neocar 820 + FC-4434 5.22 4.89 45% RH
<5.0 EK 3-85 7.53 7.94 EK 3-85 + Nanofil + FC-4434 8.93 4.43 (3
mils) EK 3-85 + Nanofil + FC-4434 7.89 7.88 (5 mils) EK 3-85 +
FC-4434 7.14 7.93 Neocar 820 + FC-4434 6.94 8.25 75% RH 12-24 EK
3-85 24.73 7.76 EK 3-85 + Nanofil + FC-4434 53.11 3.99 (3 mils) EK
3-85 + Nanofil + FC-4434 23.45 7.57 (5 mils) EK 3-85 + FC-4434
33.10 7.02 Neocar 820 + FC-4434 15.12 8.35 95% RH >25 EK 3-85
64.20 8.20 EK 3-85 + Nanofil + FC-4434 119.17 5.26 (3 mils) EK 3-85
+ Nanofil + FC-4434 54.69 9.91 (5 mils) EK 3-85 + FC-4434 113.07
6.37 Neocar 820 + FC-4434 107.53 6.97
[0143] None of the tested systems met the target perm ratings at
25%, 45% and 75% RH due to low coating weights on the kraft paper
substrate. However, all systems met the target perm ratings at 95%
RH.
EXAMPLE 9
[0144] In the next round of testing, the following systems were
evaluated at all four RH levels: [0145] 1) SoyAA-1/styrene (46:54
and listed as EK 4-23 in Table 12) [0146] 2) SoyAA-1/styrene (46:54
and listed as EK 4-25 in Table 12) [0147] 3) AR555+1% Nanofil+0.1%
FC-4434 [0148] 4) AR555+1% Nanofil+0.2% FC-4434 [0149] 5) AR555+1%
Nanofil+0.5% SRC-220 [0150] 6) AR555+1% Nanofil+0.2% FC-4434+0.5%
SRC-220 [0151] 7) AR555+1% Nanofil+0.1% FC-4434+1% SRC-220 [0152]
8) SoyAA-1/styrene (46:54 and listed as EK 3-85 in Table 12)+1%
Nanofil+0.1% FC-4434 [0153] 9) SoyAA-1/styrene (46:54)+1%
Nanofil+0.2% FC-4434 [0154] 10) SoyAA-1/styrene (46:54)+1%
Nanofil+0.1% FC-4434+0.5% SRC-220 [0155] 11) SoyAA-1/styrene
(46:54)+1% Nanofil+0.2% FC-4434+0.5% SRC-220 [0156] 12)
SoyAA-1/styrene (46:54)+1% Nanofil+0.1% FC-4434+1% SRC-220 [0157]
13) SoyAA-1/styrene (46:54)+2% Nanofil+0.1% FC-4434
[0158] The perm results of this evaluation are listed in Table 12.
The ASTM D1653 protocol was used for the testing.
TABLE-US-00012 TABLE 12 ASTM D1653 Perm Results-X Coating Average
Desired Weight RH Perms Coating on Kraft Paper Perms (g/ft.sup.2)
25% RH .ltoreq.2.0 EK 4-23 8.34 7.23 EK 4-25 9.39 6.91 AR 555 + 1%
Nanofil + 0.1% 3.81 12.53 FC4434 AR 555 + 1% Nanofil + 0.2% 3.76
12.83 FC4434 AR 555 + 1% Nanofil + 0.5% SRC 4.53 11.34 220 AR 555 +
1% Nanofil + 0.2% FC 4.41 11.93 4434 + 0.5% SRC 220 AR 555 + 1%
Nanofil + 0.1% FC 3.81 12.43 4434 + 1% SRC 220 EK 3-85 + 1% Nanofil
+ 0.1% FC 8.67 7.12 4434 EK 3-85 + 1% Nanofil + 0.2% FC 8.29 7.15
4434 EK 3-85 + 1% Nanofil + 0.1% FC 6.27 8.42 4434 + 0.5% SRC 220
EK 3-85 + 1% Nanofil + 0.2% FC 7.66 7.53 4434 + 0.5% SRC 220 EK
3-85 + 1% Nanofil + 0.1% FC 6.59 8.00 4434 + 1% SRC 220 EK 3-85 +
2% Nanofil + 0.1% FC 6.07 9.19 4434 45% RH <5.0 EK 4-23 5.48
6.71 EK 4-25 5.60 6.90 AR 555 + 1% Nanofil + 0.1% 4.40 12.72 FC4434
AR 555 + 1% Nanofil + 0.2% 5.01 11.83 FC4434 AR 555 + 1% Nanofil +
0.5% SRC 4.43 10.26 220 AR 555 + 1% Nanofil + 0.2% FC 5.06 11.95
4434 + 0.5% SRC 220 AR 555 + 1% Nanofil + 0.1% FC 4.61 11.95 4434 +
1% SRC 220 EK 3-85 + 1% Nanofil + 0.1% FC 5.69 9.47 4434 EK 3-85 +
1% Nanofil + 0.2% FC 5.45 8.38 4434 EK 3-85 + 1% Nanofil + 0.1% FC
5.49 9.91 4434 + 0.5% SRC 220 EK 3-85 + 1% Nanofil + 0.2% FC 5.45
10.38 4434 + 0.5% SRC 220 EK 3-85 + 1% Nanofil + 0.1% FC 5.60 9.70
4434 + 1% SRC 220 EK 3-85 + 2% Nanofil + 0.1% FC 5.60 8.72 4434 75%
RH 12-24 EK 4-23 30.49 7.03 EK 4-25 36.56 7.34 AR 555 + 1% Nanofil
+ 0.1% FC 44.70 13.30 4434 AR 555 + 1% Nanofil + 0.2% FC 42.79
13.28 4434 AR 555 + 1% Nanofil + 0.5% SRC 45.98 12.37 220 AR 555 +
1% Nanofil + 0.2% FC 43.40 11.52 4434 + 0.5% SRC 220 AR 555 + 1%
Nanofil + 0.1% FC 43.20 12.07 4434 + 1% SRC 220 EK 3-85 + 1%
Nanofil + 0.1% FC 31.36 8.50 4434 EK 3-85 + 1% Nanofil + 0.2% FC
40.85 6.96 4434 EK 3-85 + 1% Nanofil + 0.1% FC 26.28 8.81 4434 +
0.5% SRC 220 EK 3-85 + 1% Nanofil + 0.2% FC 34.07 7.91 4434 + 0.5%
SRC 220 EK 3-85 + 1% Nanofil + 0.1% FC 36.38 8.09 4434 + 1% SRC 220
EK 3-85 + 2% Nanofil + 0.1% FC 28.49 12.41 4434 95% RH >25 EK
4-23 43.60 7.57 EK 4-25 110.92 6.18 AR 555 + 1% Nanofil + 0.1% FC
152.52 12.75 4434 AR 555 + 1% Nanofil + 0.2% FC 131.98 12.25 4434
AR 555 + 1% Nanofil + 0.5% SRC 144.36 11.35 220 AR 555 + 1% Nanofil
+ 0.2% FC 137.05 11.44 4434 + 0.5% SRC 220 AR 555 + 1% Nanofil +
0.1% FC 136.66 12.42 4434 + 1% SRC 220 EK 3-85 + 1% Nanofil + 0.1%
FC 85.95 7.61 4434 EK 3-85 + 1% Nanofil + 0.2% FC 55.73 8.11 4434
EK 3-85 + 1% Nanofil + 0.1% FC 47.94 8.13 4434 + 0.5% SRC 220 EK
3-85 + 1% Nanofil + 0.2% FC 44.67 9.66 4434 + 0.5% SRC 220 EK 3-85
+ 1% Nanofil + 0.1% FC 60.48 8.13 4434 + 1% SRC 220 EK 3-85 + 2%
Nanofil + 0.1% FC 74.16 9.68 4434
[0159] None of the systems met the target perm rating at 25% RH,
whereas some tested systems met the perm ratings at 45% RH, 75% RH
and 95% RH.
EXAMPLE 10
[0160] The following samples were evaluated at all four RH levels.
The results are listed in Table 13. The ASTM D1653 protocol was
used for the testing. [0161] 1) SoyAA-1/styrene (46:54 by weight
and listed as EK 3-85 in Table 13) (2 month sample) [0162] 2)
SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R6 in Table
13)+0.1% Cobalt Hydrocure II metal on resin solids [0163] 3)
SoyAA-1/styrene (46:54 by weight)+3% Additol as supplied on resin
solids [0164] 4) SoyAA-1/styrene (46:54 by weight)+1% Oxycoat as
supplied on resin solids [0165] 5) SoyAA-1/styrene (46:54 by
weight)+2% Nanofil+0.2% FC-4434 [0166] 6) SoyAA-1/styrene (46:54 by
weight)+2% Nanofil+0.1% FC-4434+0.5% SRC-220 [0167] 7)
SoyAA-1/styrene (46:54 by weight)+2% Nanofil+0.2% FC-4434+1%
SRC-220 [0168] 8) AR555+2% Nanofil+0.1% FC-4434 [0169] 9) AR555+2%
Nanofil+0.2% FC-4434 [0170] 10) AR555+2% Nanofil+0.1% FC-4434+0.5%
SRC-220 [0171] 11) AR555+2% Nanofil+0.2% FC-4434+1% SRC-220
TABLE-US-00013 [0171] TABLE 13 ASTM D1653 Perm Results-XI Coating
Average Desired Weight RH Perms Coating on Kraft Paper Perms
(g/ft.sup.2) 25% RH .ltoreq.2.0 EK 3-85 (2 month sample) 7.64 7.88
EK 3-32R6 + 0.1% Cobalt 10.29 7.40 Hydrocure II metal on resin
solids EK 3-32R6 + 3% Additol as 11.89 3.98 supplied on resin
solids EK 3-32R6 + 1% Oxycoat as 10.50 4.28 supplied on resin
solids EK 3-85 + 2% Nanofil + 0.2% 6.61 4.90 FC4434 EK 3-85 + 2%
Nanofil + 0.1% 7.94 9.06 FC4434 + 0.5% SRC 220 EK 3-85 + 2% Nanofil
+ 0.2% 8.37 8.24 FC4434 + 1% SRC 220 AR555 + 2% Nanofil + 0.1%
10.18 7.84 FC4434 AR555 + 2% Nanofil + 0.2% 5.05 8.71 FC4434 AR555
+ 2% Nanofil + 0.1% 6.75 9.89 FC4434 + 0.5% SRC220 AR555 + 2%
Nanofil + 0.2% 8.15 10.01 FC4434 + 1% SRC220 45% RH <5.0 EK 3-85
(2 month sample) -- -- EK 3-32R6 + 0.1% Cobalt 6.13 9.58 Hydrocure
II metal on resin solids EK 3-32R6 + 3% Additol as 6.72 5.92
supplied on resin solids EK 3-32R6 + 1% Oxycoat as 7.45 5.75
supplied on resin solids EK 3-85 + 2% Nanofil + 0.2% 7.85 7.92
FC4434 EK 3-85 + 2% Nanofil + 0.1% 6.99 7.33 FC4434 + 0.5% SRC 220
EK 3-85 + 2% Nanofil + 0.2% 7.52 6.96 FC4434 + 1% SRC 220 AR555 +
2% Nanofil + 0.1% 6.84 9.93 FC4434 AR555 + 2% Nanofil + 0.2% 9.58
7.86 FC4434 AR555 + 2% Nanofil + 0.1% FC4434 + 0.5% SRC220 5.38
9.23 AR555 + 2% Nanofil + 0.2% 5.75 9.48 FC4434 + 1% SRC220 75% RH
12-24 EK 3-85 (2 month sample) 20.78 6.54 EK 3-32R6 + 0.1% Cobalt
26.07 7.53 Hydrocure II metal on resin solids EK 3-32R6 + 3%
Additol as 28.81 4.79 supplied on resin solids EK 3-32R6 + 1%
Oxycoat as 40.59 4.69 supplied on resin solids EK 3-85 + 2% Nanofil
+ 0.2% 22.26 10.57 FC4434 EK 3-85 + 2% Nanofil + 0.1% 21.41 10.26
FC4434 + 0.5% SRC 220 EK 3-85 + 2% Nanofil + 0.2% 20.36 9.52 FC4434
+ 1% SRC 220 AR555 + 2% Nanofil + 0.1% 39.81 10.52 FC4434 AR555 +
2% Nanofil + 0.2% 39.93 11.95 FC4434 AR555 + 2% Nanofil + 0.1%
44.93 10.73 FC4434 + 0.5% SRC220 AR555 + 2% Nanofil + 0.2% 38.06
11.25 FC4434 + 1% SRC220 95% RH >25 EK 3-85 (2 month sample) --
-- EK 3-32R6 + 0.1% Cobalt 163.82 7.51 Hydrocure II metal on resin
solids EK 3-32R6 + 3% Additol as 151.02 6.13 supplied on resin
solids EK 3-32R6 + 1% Oxycoat as 119.80 6.11 supplied on resin
solids EK 3-85 + 2% Nanofil + 0.2% 120.13 7.13 FC4434 EK 3-85 + 2%
Nanofil + 0.1% 110.79 8.73 FC4434 + 0.5% SRC 220 EK 3-85 + 2%
Nanofil + 0.2% 135.97 8.86 FC4434 + 1% SRC 220 AR555 + 2% Nanofil +
0.1% 229.11 9.68 FC4434 AR555 + 2% Nanofil + 0.2% 190.38 10.51
FC4434 AR555 + 2% Nanofil + 0.1% 192.27 9.89 FC4434 + 0.5% SRC220
AR555 + 2% Nanofil + 0.2% 238.66 11.16 FC4434 + 1% SRC220
EXAMPLE 10
[0172] The following systems were selected for testing along with a
Nylon 6 control
TABLE-US-00014 TABLE 14b Ancarez AR555 + 1% Nanofil + 0.1% FC-4434
Raw Materials Grams % Solids Ancarez AR555 97.05 55.0 Nanofil base
2.85 19.3 FC-4434 0.10 Total 100.00
TABLE-US-00015 TABLE 14a SoyAA-1/styrene + 2% Nanofil + 0.1%
FC-4434 Raw Materials Grams % Solids SoyAA- 94.99 50.0 1/styrene
(46:54 by weight) Nanofil base 4.92 19.3 FC-4434 0.09 Total
100.00
TABLE-US-00016 TABLE 14c Ancarez AR555 + 1% Nanofil + 0.1% FC-4434
+ 1% SRC-220 Raw Materials Grams % Solids Ancarez AR555 96.09 55.0
Nanofil Base 2.82 19.3 FC-4434 0.10 SRC-220 0.99 Total 100.00
[0173] The Nanofil base mentioned in the above tables was prepared
under high shear in a Ross mixer by slowly adding Nanofil 116 to
water as per the proportion described in Table 15.
TABLE-US-00017 TABLE 15 Nanofil Base Raw Material Grams % Solids
Nanofil 116 19.30 100 Water 80.70 -- Total 100.00
[0174] An additional system including a reduced cross-linker was
also tested as shown in Table 16.
TABLE-US-00018 TABLE 16 Ancarez AR555 with Reduced Crosslinker Raw
Materials Grams % Solids Ancarez AR555 98.35 55 Anquamine 401 1.65
70 Total 100.00
[0175] Each of the systems represented by the four formulations in
Tables 14a-14c and 16 were applied on three (3) sheets of
6''.times.12'' kraft paper. The coating weights expressed in g/ft2
and determined over 1 inch squares of the coated sheets are listed
in Table 17.
TABLE-US-00019 TABLE 17 Coating Weights Weight System (g/ft.sup.2)
AR555 + 1% Nanofil + 0.1% FC-4434 1.703 SoyAA-1/styrene (EK 3-85) +
2% Nanofil + 0.1% 2.810 FC-4434 AR555 + 1% Nanofil + 0.1% FC-4434 +
1% SRC-220 1.803 AR555 with reduced crosslinker (Table 16)
1.867
[0176] Some of the results of the testing are shown in FIG. 2. The
ASTM D1653 protocol was used for the testing. As can be seen from
the graph, the tested coatings provided perm ratings similar to
those provided by the Nylon 6 control. For reference purposes, the
SoyAA-1/styrene sample is labeled as EK 3-85 in the graph. At 25%
RH, the Ancarez AR555+1% Nanofil+0.1% FC4434 provided a perm rating
of 3.81 perms, the other two coatings provided a perm rating of
about 6.1 perms while the Nylon 6 film control sample had 1.58
perms. The SoyAA-1/styrene system provided a perm rating of about
5.6 perms at 45% average RH while the Nylon 6 film had 9.78 perms.
At 75% RH, only the Neocar 820+SRC-220+FC4434 system provided
similar perm to the Nylon 6 film sample. All samples showed greater
than 17 perms at 95% RH.
EXAMPLE 11
[0177] The following system was selected for testing along with a
Nylon 6 control following ASTM E 96 standard test method:
TABLE-US-00020 TABLE 18 Ancarez AR555 + Anquamine 401 Raw Materials
Grams % Solids Ancarez AR555 66.67 55 Anquamine 401 33.33 70 Total
100.00
[0178] The ASTM E96 water vapor permeance test results for the
Nylon 6 film control sample and the Ancarez AR555+Anquamine 401
coating system on kraft paper sample are shown in Table 19 and
plotted in FIG. 3.
TABLE-US-00021 TABLE 19 ASTM E96 Test Results Water Vapor Permeance
Test Results Per ASTM E96 for Ancarez AR555 + Anquamine 401 Item
Dry Cup Wet Cup Dry Cup Wet Cup Chamber RH (%) 50 90 Mean RH (%) 25
75 45 95 Target permeance values <1 6-12 <2.5 >17
Permeance (perms) 0.79 6.86 1.68 17.28 Water Vapor Permeance Test
Results Per ASTM E96 for 2 mil Nylon 6 Film Item Dry Cup Wet Cup
Dry Cup Wet Cup Chamber RH (%) 50 90 Mean RH (%) 25 75 45 95
Permeance (perms) 0.62 9.71 1.81 34.81
[0179] The results in Table 19 and plotted in FIG. 3 show that the
tested coating on kraft provided perm ratings similar to those
provided by the Nylon 6 control for three of all four average RH
values except the 95% RH. At 25% RH, the Ancarez AR555+Anquamine
401 coating system provided a perm rating of 0.79 perms while the
Nylon 6 film had 0.62 perms. The Ancarez AR555+Anquamine 401
coating system on kraft provided a perm rating of 1.68 perms while
the Nylon 6 film control sample had 1.81 perms at 45% RH. Even
though the Ancarez AR555+Anquamine 401 coating system on kraft
provided a 6.86 perms rating at 75% RH, which is lower than the
Nylon 6 film (9.71 perms), it still meets the target of 6-12 perms.
At 95% RH the Ancarez AR555+Anquamine 401 coating system on kraft
provided a 17.28 perms rating, which is slightly greater than the
target of 17 perms.
EXAMPLE 12
[0180] Anquamine 401 is diluted with water by adding 4 weight parts
water to 1 weight part of Anquamine 401 (AQ401). The dilution is
mixed with moderate shear at ambient conditions for 15 minutes to
avoid formation of foam. Then, Ancarez AR555 is added to the
diluted Anquamine 401 solution in a ratio of 3 weight parts Ancarez
AR555 to 1.25 weight parts of diluted Anquamine 401 and stirred for
15 minutes at moderate shear and ambient condition. The resulting
blend was applied onto kraft paper sheets. Table 20 lists the
weight ratio of the ingredient. Tables 21A and 21B show the results
of the ASTM E96 tests. The results are also summarized in FIG.
4.
TABLE-US-00022 TABLE 20 Solids Weight Wt % % Solids Ancarez AR555
1.80 70.59 55 39.82 Anquamine 401 0.60 23.53 70 16.47 Water 0.15
5.88 0.00 2.55 100.00 55.29 Desired coverage (g/m.sup.2)-Min 55
Desired coverage (g/m.sup.2)-Max 60 Wet coating weight in lb
required/m.sup.2- 0.2406 Min Wet coating weight in lb
required/m.sup.2- 0.2624 Max
TABLE-US-00023 TABLE 21 A Test A: Water Vapor Permeance for Coated
Kraft Sample Water Vapor Permeance, perms Replicate 25% Mean RH 45%
Mean RH Sample 1 1.33 3.86 Formulation: AR555 + 2 1.29 3.90 AQ401 3
1.07 3.29 Mean 1.23 3.68 SD 0.14 0.34 Water Vapor Permeance, perms
Replicate 75% Mean RH 95% Mean RH 1 11.17 31.99 2 10.31 27.57 3
11.70 30.91 Mean 11.06 30.16 SD 0.70 2.30
TABLE-US-00024 TABLE 21 B Test B: Water Vapor Permeance for Coated
Kraft Sample Water Vapor Permeance, perms Replicate 25% Mean RH 45%
Mean RH Sample B7 0.74 2.09 Formulation: AR555 + B8 0.51 1.45 AQ401
B9 0.68 1.79 Mean 0.64 1.78 SD 0.12 0.32 Water Vapor Permeance,
perms Replicate 75% Mean RH 95% Mean RH B10 7.45 20.51 B11 8.19
22.86 B12 7.10 19.30 Mean 7.58 20.89 SD 0.56 1.81
EXAMPLE 13
[0181] Anquamine 401 is diluted with water by adding 4 weight parts
water to 1 weight part of Anquamine 401. The dilution is mixed with
moderate shear at ambient conditions for 15 minutes to avoid
formation of foam. Then, 1 weight part of SoyAA-1 latex (known as
EK 5-02/22) is blended with 1.25 weight part of the diluted
Anquamine 401. Thereafter, 3 weight parts of Ancarez AR555 is added
to 2.25 weight parts of the diluted Anquamine 401/SoyAA-1 latex
blend. The resulting blend had a weight ratio of Ancarez
AR555:Anquamine 401:Soy AA-1 latex of 3:1.25:1. The resulting blend
was applied onto kraft paper sheets. Tables 22A and 22B show the
results of the ASTM E96 tests. The results are also summarized in
FIG. 5.
TABLE-US-00025 TABLE 22 A Test C: Water Vapor Permeance for Coated
Kraft Sample Water Vapor Permeance, perms Replicate 25% Mean RH 45%
Mean RH Sample 1 2.32 5.87 VOMM Formulation: 2 2.11 2.30 SoyAA-1
latex + AR555 + 3 1.67 2.00 AQ401 Mean 2.03 3.39 SD 0.33 2.15 Water
Vapor Permeance, perms Replicate 75% Mean RH 95% Mean RH 1 7.21
10.11 2 8.28 13.52 3 8.15 10.63 Mean 7.88 11.42 SD 0.59 1.84
TABLE-US-00026 TABLE 22 B Test D: Water Vapor Permeance for Coated
Kraft Sample Water Vapor Permeance, perms Replicate 25% Mean RH 45%
Mean RH Sample 1 1.29 3.21 VOMM Formulation: 2 0.87 2.30 SoyAA-1
latex +AR555 + 3 0.86 2.00 AQ401 Mean 1.01 2.50 SD 0.25 0.63 Water
Vapor Permeance, perms Replicate 75% Mean RH 95% Mean RH 1 4.74
12.23 2 5.70 14.58 3 4.92 12.85 Mean 5.12 13.22 SD 0.51 1.22
[0182] Comparison samples were prepared with polyethylene
dispersions, PE1 and PE2. PE1 is Michem.RTM. Emulsion 93235 (a
nonionic polyethylene emulsion); PE1 is Michem.RTM. Emulsion 61335
(an anionic polyethylene emulsion). For PE1, the SoyAA-1
latex:polyether ratio was 1:1. For PE2, the SoyAA-1 latex:polyether
ratio was 3:2. The resulting blend was applied onto kraft paper
sheets. Tables 23A and 23B show the results of the ASTM E96
evaluation.
TABLE-US-00027 TABLE 23A Comparative Test A: Water Vapor Permeance
for Coated Kraft Sample Water Vapor Permeance, perms Replicate 25%
Mean RH 45% Mean RH Sample 1 12.69 23.07 VOMM Formulation: 2 13.58
24.75 SoyAA-1 latex + PE1 3 11.00 19.71 Mean 12.42 22.51 SD 1.31
2.56 Water Vapor Permeance, perms Replicate 75% Mean RH 95% Mean RH
1 38.36 63.67 2 31.75 53.73 3 32.69 54.53 Mean 34.27 57.31 SD 3.57
5.52
TABLE-US-00028 TABLE 23B Comparative Test B: Water Vapor Permeance
for Coated Kraft Sample Water Vapor Permeance, perms Replicate 25%
Mean RH 45% Mean RH Sample 1 5.01 9.03 VOMM Formulation: 2 4.84
8.64 SoyAA-1 latex + PE1 3 4.70 8.35 Mean 4.85 8.67 SD 0.15 0.34
Water Vapor Permeance, perms Replicate 75% Mean RH 95% Mean RH 1
20.25 39.16 2 19.32 36.44 3 18.68 37.49 Mean 19.42 37.70 SD 0.79
1.37
TABLE-US-00029 TABLE 23C Comparative Test C: Water Vapor Permeance
for Coated Kraft Sample Water Vapor Permeance, perms Replicate 25%
Mean RH 45% Mean RH Sample 1 13.15 22.37 VOMM Formulation 2: 2
12.81 21.56 SoyAA-1 latex + PE2 3 11.76 20.04 Additive Mean 12.57
21.32 SD 0.72 1.18 Water Vapor Permeance, perms Replicate 75% Mean
RH 95% Mean RH 1 36.68 56.32 2 36.41 56.54 3 33.70 52.63 Mean 35.59
55.17 SD 1.65 2.20
TABLE-US-00030 TABLE 23D Comparative Test D: Water Vapor Permeance
for Coated Kraft Sample Water Vapor Permeance, perms Replicate 25%
Mean RH 45% Mean RH Sample 1 8.75 15.94 VOMM Formulation 2 2 6.88
12.21 SoyAA-1 latex + PE2 3 6.63 11.92 Additive Mean 7.42 13.36 SD
1.16 2.24 Water Vapor Permeance, perms Replicate 75% Mean RH 95%
Mean RH 1 20.97 31.18 2 18.85 28.54 3 17.64 27.93 Mean 19.15 29.22
SD 1.68 1.73
[0183] When introducing elements of the examples disclosed herein,
the articles "a," "an," "the" and "said" are intended to mean that
there are one or more of the elements. The terms "comprising,"
"including" and "having" are intended to be open-ended and mean
that there may be additional elements other than the listed
elements. It will be recognized by the person of ordinary skill in
the art, given the benefit of this disclosure, that various
components of the examples can be interchanged or substituted with
various components in other examples.
[0184] Although certain aspects, examples and embodiments have been
described above, it will be recognized by the person of ordinary
skill in the art, given the benefit of this disclosure, that
additions, substitutions, modifications, and alterations of the
disclosed illustrative aspects, examples and embodiments are
possible.
* * * * *