U.S. patent application number 15/881448 was filed with the patent office on 2018-05-31 for stain repellent and voc eliminating coatings and use thereof.
The applicant listed for this patent is CERTAINTEED CORPORATION. Invention is credited to Alan L. Boyd, Darran L. Martin.
Application Number | 20180148581 15/881448 |
Document ID | / |
Family ID | 52740763 |
Filed Date | 2018-05-31 |
United States Patent
Application |
20180148581 |
Kind Code |
A1 |
Martin; Darran L. ; et
al. |
May 31, 2018 |
STAIN REPELLENT AND VOC ELIMINATING COATINGS AND USE THEREOF
Abstract
A coating dispersion or building article can include titanium
dioxide, and a dihydrazide. The coating dispersion or building
article can further include calcium carbonate, calcined aluminum
silicate, acrylic polymers, and a fluoroalkyl polymer.
Inventors: |
Martin; Darran L.;
(Lafayette Hill, PA) ; Boyd; Alan L.;
(Collegeville, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CERTAINTEED CORPORATION |
Malvern |
PA |
US |
|
|
Family ID: |
52740763 |
Appl. No.: |
15/881448 |
Filed: |
January 26, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14503011 |
Sep 30, 2014 |
9914839 |
|
|
15881448 |
|
|
|
|
61884933 |
Sep 30, 2013 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C09D 133/08 20130101;
C09D 5/1606 20130101; C09D 7/63 20180101; C08K 2003/327 20130101;
C08K 2003/2241 20130101; C09D 5/1681 20130101; C08K 5/25 20130101;
C08K 2003/265 20130101; C09D 5/024 20130101; C09D 5/1625 20130101;
C09D 133/08 20130101; C08L 33/16 20130101; C09D 133/08 20130101;
C08L 33/16 20130101; C08K 3/22 20130101; C08K 3/34 20130101; C08K
3/26 20130101; C08K 5/25 20130101 |
International
Class: |
C09D 5/16 20060101
C09D005/16 |
Claims
1. A coating dispersion, the coating dispersion comprising: water;
titanium dioxide; calcium carbonate; calcined aluminum silicate;
acrylic polymers; a dihydrazide; and a fluoroalkyl polymer present
at up to 5 wt % of the coating dispersion.
2. The coating dispersion according to claim 1, wherein the amount
of titanium dioxide is at least 5 wt % of the coating
dispersion.
3. The coating dispersion according to claim 2, wherein the amount
of titanium dioxide is not greater than 15 wt % of the coating
dispersion
4. The coating dispersion according to claim 1, wherein the amount
of calcium carbonate is at least 18 wt % of the coating
dispersion.
5. The coating dispersion according to claim 4, wherein the amount
of calcium carbonate is not greater than 35 wt % of the coating
dispersion
6. The coating dispersion according to claim 1, wherein the amount
of calcined aluminum silicate is at least 5 wt % of the coating
dispersion.
7. The coating dispersion according to claim 6, wherein the amount
of calcined aluminum silicate is not greater than 12 wt % of the
coating dispersion.
8. The coating dispersion according to claim 1, wherein the amount
of acrylic polymers is at least 7 wt % of the coating
dispersion.
9. The coating dispersion according to claim 8, wherein the amount
of acrylic polymers is not greater than 20 wt % of the coating
dispersion.
10. The coating dispersion according to claim 1, wherein the amount
of the dihydrazide is at least 0.1 wt % of the coating
dispersion.
11. The coating dispersion according to claim 10, wherein the
amount of the dihydrazide is not greater than 0.5 wt % of the
coating dispersion.
12. The coating dispersion according to claim 1, wherein the amount
of the fluoroalkyl polymer is 0.1 wt % to 5 wt % of the coating
dispersion.
13. The coating dispersion according to claim 1, further comprising
at least one ingredient selected from the group of Magnesium
silicate, anhydrous aluminum silicate, or a mixture thereof of the
coating dispersion.
14. The coating dispersion according to claim 13, wherein the at
least one ingredient is present in an amount of at least 2 wt % of
the coating dispersion.
15. The coating dispersion according to claim 13, wherein the at
least one ingredient is present in an amount of not greater than 12
wt % of the coating dispersion.
16. The coating dispersion according to claim 1, further comprising
zinc oxide.
17. The coating dispersion according to claim 16, wherein the zinc
oxide is present in an amount of at least 0.2 wt % of the coating
dispersion.
18. The coating dispersion according to claim 17, wherein the zinc
oxide is present in an amount of not greater than 1.2 wt % of the
coating dispersion.
19. A building article comprising the coating dispersion of claim
1.
20. The building article according to claim 19, wherein the
building article includes a tile, a mineral board, a gypsum board,
fiberglass, or any combination thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a continuation of U.S. patent
application Ser. No. 14/503,011, filed Sep. 30, 2014, entitled
"STAIN REPELLENT AND VOC ELIMINATING COATINGS AND USE THEREOF,"
naming inventors Darran L. Martin and Alan L. Boyd, and claims
priority under 35 U.S.C. .sctn. 119(e) to U.S. Patent Application
No. 61/884,933, filed Sep. 30, 2013, entitled "STAIN REPELLENT AND
VOC ELIMINATING COATINGS AND USE THEREOF," naming inventors Darran
L. Martin and Alan L. Boyd, filed Sep. 30, 2013, of which both are
assigned to the current assignee hereof and incorporated herein by
reference in their entireties.
FIELD OF THE DISCLOSURE
[0002] The invention relates to a building article having stain
repellent coatings and containing a dihydrazide as an agent capable
of trapping formaldehyde.
BACKGROUND
[0003] Highly varied composite materials are used in construction
of dwellings, schools, hospitals, and offices, as well as of
transportation vehicles. Some of these materials, such as sound
and/or thermal insulators, wooden panels, furniture parts and
decorative parts, use adhesives, paints and varnishes comprising
formaldehyde-based resins. The proportion of free formaldehyde in
these materials is kept at a very low level owing to the
incorporation of a small amount of agents capable of trapping
formaldehyde.
[0004] Moreover, in public places, schools, and hospitals, the
panels, boards, and furniture parts are held in white or off white
colors which require that they can be easily cleaned. Accordingly
coatings that have acceptable stain repellency are in demand.
[0005] However, regulations regarding protection against
undesirable emissions of products, such as formaldehyde, which may
exhibit a risk to the health of the individual are becoming
stricter and require a further reduction in the amount of free
formaldehyde present in materials or capable of being emitted by
materials over time.
[0006] Accordingly, there is a need for building and construction
material that comply with the demanding regulation and are easily
to clean.
SUMMARY
[0007] To achieve this aim, the present invention provides a stain
repellent coating that at least one dihydrazide. A coating
dispersion or building article can include titanium dioxide, and a
dihydrazide. The coating dispersion or building article can further
include calcium carbonate, calcined aluminum silicate, acrylic
polymers, and a fluoroalkyl polymer.
DETAILED DESCRIPTION
[0008] A dihydrazide in accordance with the present invention
corresponds to the following formula:
H.sub.2N--NH--CO--R--CO--NH--NH.sub.2
[0009] in which R represents a linear or branched alkylene radical
preferably containing 1 to 18 carbon atoms, optionally substituted
by one or more hydroxyl radicals; or an arylene, preferably
phenylene or biphenylene, radical optionally substituted by one or
more hydroxyl radicals, one or more halogen atoms, especially F, Cl
or Br, or one or more linear or branched alkyl radicals containing
1 to 4 carbon atoms.
[0010] Advantageously, the dihydrazide is chosen from the
dihydrazides for which the radical R is a C.sub.1-C.sub.12,
preferably C.sub.1-C.sub.8 alkylene radical. The preferred
dihydrazide is adipic acid dihydrazide. In embodiments, the amount
of dihydrazide represents 0.1 to 20 wt %, such as 0.2 to 10 wt %,
or 0.3 to 5 wt % of the coating.
[0011] In embodiments, the dihydrazide is present in coatings
having stain and water repellency. Such properties can be achieved
by mixing in a polymeric material into the dispersion. As examples,
polymeric materials that may be used are polyolefin, for example of
polyethylene, of polypropylene, of polyisobutylene and of
polymethylpentene, of polyvinyl acetate (homopolymer or copolymer),
for example of ethylene/vinyl acetate (EVA), of polyvinyl alcohol
(homopolymer or copolymer), for example of ethylene/vinyl alcohol,
of polylactic acid, of acrylonitrile, for example modacrylic
(containing 35 to 85% of acrylonitrile units), of polyoxyalkylene,
for example of polyoxyethylene, of polyoxyphenylene, of polyacrylic
or of polyacrylate, for example of polymethyl methacrylate (PMMA),
of polyester, especially of polyalkylene terephthalate, for example
of polyethylene terephthalate and polybutylene terephthalate, of
polyamide, of polyimide, of chlorinated and/or fluorinated polymer,
for example of polyvinyl chloride, of polychiorofluoroethylene, of
perfluoroethylene and of perfluoropropylene, of polysulfone, for
example polyethersulfone, of polyurethane, especially elastane (at
least 85% of thermoplastic polyurethane elastomer), of
polybenzimidazole and of aramid.
[0012] Other polymers, that can be used are thermoplastic polymers,
for example styrene/acrylonitrile, acrylonitrile/butadiene/styrene,
cellulose (tri)acetate, expanded polystyrene, a polyolefin such as
polyethylene and polypropylene, a poly(meth)acrylate, a polyvinyl
acetate or a polyoxymethylene; a thermosetting polymer, for example
an unsaturated polyester, an epoxide, a phenolic resin such as a
novolac or a resol, in particular having a content of free
aldehyde(s) of less than 0.05%, a polyimide, a polyurethane, a
phenoplast or a biopolymer, for example a polysaccharide or a
protein; an elastomeric polymer, for example a fluoropolymer, in
particular based on vinylidene fluoride, neoprene, a polyacrylic, a
polybutadiene, a polyether amide, a silicone, a natural rubber or
styrene-butadiene rubber (SBR), or a biopolymer, for example a
polysaccharide or a protein.
[0013] The polymers can be present in an amount from 2 to 30 wt %,
such as 5 to 25 wt %, or 10 to 25 wt % of the coating.
[0014] In order to achieve stain repellency, the coating of
interest can include fluoropolymers. Such fluoropolymers include
polytetrafluoroethylene (PTFE),
tetrafluoroethylene-hexafluoropropylene (FEP), modified
tetrafluoroethylene-hexafluoropropylene (mFEP),
perfluoroalkoxyethylene (PFA), modified perfluoroalkoxyethylene
(mPFA), ethylene-tetrafluoroethylene (ETFE),
tetrafluoro-ethylene-perfluoro (methyl vinyl ether) (MFA), modified
polytetrafluoroethylene (TFM), polyvinylidene fluoride (PVDF),
ethylene-chlorotrifluoroethylene (ECTFE), and combination
thereof.
[0015] The fluoropolymer can be present in an amount of at least
0.1 to 5 wt %, 0.2 to 4 wt %, or 0.3 to 3 wt %.
[0016] Another aspect of the present disclosure is to provide a
stain repellent coating in wall and ceiling coverings. A ceiling
tile having such stain repellency is more efficiently prevented
from getting dirty during installation or use. Moreover, it is an
object to provide a method for mounting an improved suspended
ceiling.
[0017] A further object of the present invention is to provide an
improved ceiling tile which is adapted to be mounted in a grid of
profiles forming a frame which supports the ceiling tile. The
ceiling tile has a first and a second pair of non-adjacent
side-edge portions, wherein the grid of profiles engage from below
with the first pair of side-edge portions, and wherein the grid of
profiles engage from above with the second pair of side-edge
portions. The grid of profiles engages with said first and second
pair of side-edge portions such that a clamping action that
counteracts lateral displacement of the ceiling tile is provided.
The ceiling tile has further a coating as described herein.
[0018] An advantage of the present inventive concept is that the
ceiling tile is prevented from getting dirty or stained during
installation employing a locking system that secures the tile to a
suspended frame. The ceiling tile includes side-edge portion of the
ceiling tile may be a part of an underside of the ceiling tile, a
part of an upper side of the ceiling tile, a groove or cavity
provided in a side portion of the ceiling tile, a protrusion
provided in a side portion of the ceiling tile, etc.
[0019] In particular, there is reduced cleaning requirement for the
ceiling since any part of the suspended ceiling comprising the
coating. Thus, in a mounted state the ceiling tiles comprised in
the inventive suspended ceiling are more efficiently prevented from
involuntary staining which may be caused by a wind uplift, impacts
from objects, forces applied to the ceiling panel from below, e.g.
during a cleaning process, a sudden change of air pressure in the
room when a door connected to the room is abruptly opened, etc.
[0020] By means of the clamping action, or frictional fit, the
ceiling tile can be fixed in a lateral position, being restrained
by friction. Preferably, the clamping action is such that the
ceiling tile is kept fixed at least in a first lateral direction.
More preferably, the clamping action is such that the ceiling tile
is kept fixed in two perpendicular lateral directions.
[0021] The following represents an exemplary list of embodiments in
accordance with the invention:
[0022] Item 1. A coating dispersion, the coating dispersion
comprising: [0023] water; [0024] titanium dioxide; [0025] calcium
carbonate; [0026] calcined aluminum silicate; [0027] acrylic
polymers; [0028] a dihydrazide; and [0029] a fluoroalkyl
polymer.
[0030] Item 2. The coating dispersion according to item 1, wherein
the amount of titanium dioxide is at least 5 wt %, at least 6 wt %,
or at least 7 wt %, and not greater than 15 wt %, not greater than
12 wt %, or not greater than 10 wt %.
[0031] Item 3. The coating dispersion according to item 1, wherein
the amount of calcium carbonate is at least 18 wt %, at least 23 wt
%, or at least 28 wt %, and not greater than 35 wt %, not greater
than 32 wt %, or not greater than 30 wt %.
[0032] Item 4. The coating dispersion according to item 1, wherein
the amount of calcined aluminum silicate is at least 5wt %, at
least 6wt %, or at least 7 wt %, and not greater than 12 wt %, not
greater than 10 wt %, or not greater than 8 wt %.
[0033] Item 5. The coating dispersion according to item 1, wherein
the amount of acrylic polymers is at least 7 wt %, at least 10 wt
%, or at least 13 wt %, and not greater than 20 wt %, not greater
than 17 wt %, or not greater than 14 wt %.
[0034] Item 6. The coating dispersion according to item 1, wherein
the amount of the dihydrazide is at least 0.1 wt %, at least 0.15
wt %, or at least 0.18 wt %, and not greater than 0.5 wt %, not
greater than 0.4 wt %, or not greater than 0.3 wt %.
[0035] Item 7. The coating dispersion according to item 1, wherein
the amount of the a fluoroalkyl polymer is at least 0.2 wt %, or at
least 0.3 wt %, at least 0.35 wt %, and not greater than 0.9 wt %,
not greater than 0.7 wt %, or not greater than 0.4 wt %.
[0036] Item 8. The coating dispersion according to any of the
foregoing items, further comprising at least one ingredient
selected from the group of Magnesium silicate, anhydrous aluminum
silicate, or a mixture thereof.
[0037] Item 9. The coating dispersion according to item 8, wherein
the at least one ingredient is present in an amount of at least 2
wt %, at least 4 wt %, or at least 6 wt %, and not greater than 12
wt %, not greater than 10 wt %, or not greater than 8 wt %.
[0038] Item 10. The coating dispersion according to any of the
foregoing items, further comprising zinc oxide.
[0039] Item 11. The coating dispersion according to item 10,
wherein the zinc oxide is present in an amount of at least 0.2 wt
%, at least 0.4 wt %, or at least 0.6 wt %, and not greater than
1.2 wt %, not greater than 1 wt %, or not greater than 0.8 wt
%.
[0040] Item 12. A building article comprising a coating, wherein
the coating includes: [0041] titanium dioxide, calcium carbonate,
calcined aluminum silicate, acrylic polymers, a dihydrazide, and a
fluoroalkyl polymer.
[0042] Item 13. The building article according to item 12, wherein
the amount of calcium carbonate is at least 25 wt %, at least 30 wt
%, or at least 35 wt %, and not greater than 55 wt %, not greater
than 50 wt %, or not greater than 45 wt %.
[0043] Item 14. The building article according to item 12, wherein
the amount of titanium dioxide is at least 6 wt %, at least 8 wt %,
or at least 10 wt %, and not greater than 16 wt %, not greater than
14 wt %, or not greater than 12 wt %.
[0044] Item 15. The building article according to item 12, wherein
the amount of calcined aluminum silicate is at least 6 wt %, at
least 8 wt %, or at least 10 wt %, and not greater than 16 wt %,
not greater than 14 wt %, or not greater than 12 wt %.
[0045] Item 16. The building article according to item 12, the
amount of acrylic polymers is at least 10 wt %, at least 15 wt %,
or at least 18 wt %, and not greater than 30 wt %, not greater than
25 wt %, or not greater than 22 wt %.
[0046] Item 17. The building article according to item 12, wherein
the amount of the dihydrazide is at least 0.15 wt %, at least 0.2
wt %, or at least 0.25 wt %, and not greater than 0.6 wt %, not
greater than 0.5 wt %, or not greater than 0.4 wt %.
[0047] Item 18. The building article according to item 12, the
amount of the a fluoroalkyl polymer is at least 0.2 wt %, or at
least 0.3 wt %, at least 0.35 wt %, and not greater than 1 wt %,
not greater than 0.8 wt %, or not greater than 0.6 wt %.
[0048] Item 19. The building article according to item 12 further
comprising at least one ingredient selected from the group of
Magnesium silicate, anhydrous aluminum silicate, or a mixture
thereof.
[0049] Item 20. The building article according to item 19, wherein
the at least one ingredient is present in an amount of at least 2
wt %, at least 4 wt %, or at least 6 wt %, and not greater than 20
wt %, not greater than 16 wt %, or not greater than 12 wt %.
[0050] Item 21. The building article according to item 12, further
comprising zinc oxide.
[0051] Item 22. The building article according to item 22, wherein
the zinc oxide is present in an amount of at least 0.5 wt %, at
least 0.7 wt %, or at least 0.9 wt %, and not greater than 2 wt %,
not greater than 1.5 wt %, or not greater than 1.2 wt %.
[0052] Item 23. The coating dispersion or building article
according to any one of the preceding items, wherein the
dihydrazide is selected from isophthalic dihydrazide, sebacic
dihydrazide, adipic dihydrazide, or any combination thereof.
[0053] Item 24. The building article according to any one of items
12-24, wherein the building article includes a tile, a mineral
board, a gypsum board, fiberglass, or any combination thereof.
[0054] Item 25. The building article according to any one of items
12-24, wherein coating has a thickness of at least 1 mil, at least
2 mils, or at least 3 mils, and not more than 6 mils, 5 mils, or 4
mils.
[0055] The following example makes it possible to illustrate the
invention without however limiting it.
EXAMPLE 1
[0056] a) Preparing a Coating Dispersion
[0057] Into a container, 1563.04 g of water, 10.4 g of adipic acid
dihydrazide, 2.4 g of Surfynol (surfactant), 5.6 g of hydro-cracked
parafinnic oil (90%), 2.3 g of sodium polyacrylate emulsion (43%),
395 g of titanium dioxide, 1410 g of precipitated calcium
carbonate, 160g of Magnesium silicate, 350 g of calcined aluminum
silicate, 150 g of anhydrous aluminum silicate (calcined kaolin),
674 g of acrylic polymers, 71.6 g of zinc oxide dispersion (50 wt
%), 95 g of fluoroalkyl methacrylate copolymer, and 27.4 g of
polyethylene acrylate mixture are mixed. The mixture was painted on
a gypsum board panel and air-dried.
[0058] b) Compliance Test
[0059] A panel having the coating was submitted to berkeley
analytical for VOC Emission testing in accordance with California
Department of Public Health standard CDPH/EHLB/Standard Method
V1.1-2010. The result was the panel was complain to School
classroom and private office criteria with formaldehyde amounts at
less than 9 micrograms/m.sup.3.
[0060] c) Stain Removal
[0061] Stain Removal was conducted according to ASTM Standard D4828
using method reference 8.7 and 8.4 on an actual panel Tables 1-3
show the results.
TABLE-US-00001 TABLE 1 Rating <100 double rubs Rating <100
double rubs Stain/Soil Bleach soln. Quat NH soln. Betadine (H
brand) 10 10 Mustard (French's) 3 3 Cola (Coca Cola) 10 10 Coffee
(Starbucks) 5 5 Ketchup (Heinz) 10 10
TABLE-US-00002 TABLE 2 Rating <100 double rubs Rating <100
double rubs Stain/Soil EtOH soln. Peroxide soln. Betadine (H brand)
10 10 Mustard (French's) 3 3 Cola (Coca Cola) 10 10 Coffee
(Starbucks) 5 5 Ketchup (Heinz) 10 10 0: No change from original
intensity (depth) of soil or stain, 3: Slight change from original,
but readily visible, 5: Moderate change from original, slightly
visible, 7: Large change from original, barely visible, and 10: All
soil and stain removed.
TABLE-US-00003 TABLE 3 1000 wash 2000 wash 5000 cycles cycles 2500
wash cycles wash cycles Gloss change N N N/I I Color change N N N
SD Erosion N S S S Gloss Change N--None I--Increase II--Large
increase D--Decrease DD--Large decrease Color Change N--None
SD--Slightly darker CD--Considerably darker SL--Slightly lighter
CL--Considerably lighter Erosion N--None S--Slight M--Moderate
* * * * *