Coating compositions containing low VOC compounds

Details Coating compositions containing low VOC compounds Coating compositions containing low VOC compounds

2002-02-22

2004-07-13

Niland, Patrick D. (Department: 1714)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

At least one aryl ring which is part of a fused or bridged...

C524S300000, C524S306000, C524S308000, C524S310000, C524S311000, C524S320000

Reexamination Certificate

active

06762230

ABSTRACT:

BACKGROUND
Coating compositions, such as paints, that include latex polymer particles typically also include a coalescent (i.e., coalescing agent or film-forming agent) in addition to pigments and fillers. The coalescent functions as a solvent as well as a plasticizer for the polymer particles to soften the latex polymer particles and assist in the formation of a continuous coating or film after applying to a surface and allowing to dry.
Useful coalescents are generally stable in the presence of water, compatible with other ingredients typically used in paint formulations, particularly the latex polymers, such that the stability of the latex-based composition is not compromised. They are also typically sufficiently volatile to escape when the applied coating composition is allowed to dry, but sufficiently nonvolatile to evaporate more slowly than other ingredients (e.g., drying retarders, antifreezes) that delay film formation. However, there is a general desire in the industry to reduce volatile organic emissions, thereby reducing the environmental and health concerns.
Governments have established regulations setting forth guidelines relating to volatile organic compounds that may be released into the atmosphere. To reduce the level of volatile organic compounds, new high solids coating compositions have been developed as well as powder coating compositions that do not include volatile compounds, have a reduced concentration of volatile compounds, or incorporate compounds having a lower volatility. Reducing the volatility of coalescents, solvents, plasticizers, etc. can adversely affect the balance of properties needed in a latex-based coating composition, however. Thus, there is a need for coalescents, solvents, plasticizers, etc. that can be used in coating compositions, such as paints, that do not compromise stability, compatibility, film formation ability, or the desirable properties of the applied coating, etc.
SUMMARY
The present invention provides a class of compounds that have a relatively low volatile organic content. Such compounds can be used in coating compositions, preferably paints, as coalescing agents, solvents, plasticizers, etc. A suitable coalescent is dispersible in the coating composition, which is preferably stable over time. Preferably, the compound, when used as a coalescent, facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (more preferably, at about 4° C. to about 10° C., and most preferably, at about 4° C. to about 5° C.). Thus, there is provided a coating composition that includes a latex polymer and a coalescent (which can also function as a solvent or a plasticizer). Such coating compositions can be coated onto a substrate and dried, as with a paint, for example.
In one embodiment, a coating composition (preferably, a paint) includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X
r
—O)
n
—R
2
wherein: R
1
is an organic group (preferably, having less than 100 carbon atoms); X is a divalent organic group (preferably, having 2 to 8 carbon atoms, and more preferably, 3 to 5 carbon atoms); r is 0 to 1; n is 1 to 10 (preferably, n is 1 to 5, more preferably, n is 1 to 3, and most preferably, n is 2 to 3); and R
2
is hydrogen or an organic group (preferably, having less than 100 carbon atoms); with the proviso that R
1
includes at least three carbon atoms when X is not —(CH
2
)
s
— wherein s is 2 to 8; with the proviso that the coalescent has less than two aliphatic unsaturated carbon-carbon bonds when r is zero (preferably, the coalescent does not include aliphatic unsaturated carbon-carbon bonds when r is zero, and more preferably, the coalescent does not include aliphatic unsaturated carbon-carbon bonds); wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%, more preferably, less than about 20%, and most preferably, less than about 15%) and is dispersible in the coating composition. Preferably, r is one.
In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X
r
—O)
n
—R
2
wherein: R
1
is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R
2
is hydrogen or an organic group; with the proviso that R
1
includes at least three carbon atoms when X is not —(CH
2
)
s
— wherein s is 2 to 8; with the proviso that the coalescent does not include aliphatic unsaturated carbon-carbon bonds; with the proviso that r is one when R
2
is H; wherein the coalescent has a volatile organic content of less than about 50%, is dispersible in the coating composition, and facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (preferably, at a temperature of about 4° C. to about 10° C., and more preferably, at a temperature of about 4° C. to about 5° C.).
In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X
r
—O)
n
—R
2
wherein: R
1
has the formula R
3
—(CH
2
)
m
—(O(CH
2
)
p
)
q
— wherein R
3
is an alkyl or aryl group, m is 0 to 24, p is 1 to 4, and q is 0 to 50; X has the formula —(CH
2
)
s
—, wherein s is 2 to 8; r is 0 to 1; n is 1 to 10; and R
2
is hydrogen or R
1
; wherein the coalescent has a volatile organic content of less than about 50%, is dispersible in the coating composition, and facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (preferably, at a temperature of about 4° C. to about 10° C., and more preferably, at a temperature of about 4° C. to about 5° C.).
In yet another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X—O)
n
—H wherein: R
1
is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X is a divalent hydrocarbyl moiety or an organic group containing nonperoxidic oxygen atoms and carbonyl groups; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.
In still another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X—O)
n
—H wherein: R
1
is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X has the formula —(CH
2
)
s
—, wherein s is 2 to 8; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.
In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R
1
—(C(O)—X—O)
n
—H wherein: R
1
is a hydrocarbyl moiety or an organic group containing nonperoxidic oxygens; X is an organic group containing nonperoxidic oxygens and carbonyl groups; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.
The present invention also provides methods of coating that include: providing a coating composition as described herein; applying the coating composition to a substrate (e.g., wall); and allowing the coating composition to dry.
DEFINITIONS
The term “dispersible” in the context of a dispersible coalescent means that the coalescent can be mixed into the coating composition to form a uniform mixture without the use of high shear mixing.
The term “stable” in the context of a coating composition containing a dispersible coalescent means that the coalescent does not phase separate from the coating composition upon standing at 120° F. (49° C.) for four weeks.
The terms “volatile organic content” and “VOC” herein mean the volatility of the compound as measured by ASTM method D2369-90.
The term “organic group” means

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