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...
Reexamination Certificate
2001-08-20
2003-10-07
Wu, David W. (Department: 1713)
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...
C524S561000, C524S558000, C524S523000, C524S577000, C524S555000, C525S221000, C525S227000, C525S228000, C427S388400, C427S393400, C427S393500, C427S133000
Reexamination Certificate
active
06630533
ABSTRACT:
This invention relates to an exterior finishing composition. In particular, this invention relates to an exterior finishing composition which includes polymers containing hydrophobic monomers as polymerized units and to a method of using the exterior finishing composition.
Multilayered exterior wall systems such as exterior insulation and finish systems (EIFS) are used extensively as the exterior wall surface of commercial and residential buildings. These systems, which include a substrate covered by one or more exterior finishing compositions, provide walls which are insulated and resistant to moisture. The multilayered exterior wall system may be prepared by covering a substrate such as plywood or gypsum board with a layer of insulation board, covering the insulation board with a layer of basecoat embedded with a reinforcing mesh, and finishing with a topcoat. In contrast to other surface finishes such as paints, exterior finishing compositions such as EIFS basecoats and topcoats are typically applied with a trowel to form a layer with a thickness from 0.1 to 2.5 cm.
The exterior finishing composition must provide basecoat or topcoat layers which are protective and, for a topcoat, is also decorative. The layer formed from the exterior finishing composition must be resistant to moisture, flexible in response to temperature changes, and resistant to the pickup of dirt. Typical exterior finishing compositions contain polymer, filler such as clay or calcium carbonate, and aggregate such as sand to provide surface texture. Polymers containing hydrophobic monomers as polymerized units are known in the art to provide coatings with improved resistance to moisture. In EP1,004,554 A2, a masonry composition is disclosed which contains masonry and a polymer containing as polymerized units 20 to 100 parts by weight of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid. The polymer may be admixed with masonry, applied onto masonry in a cement containing slurry coat, or coated onto masonry with a wet thickness of 15 to 150 microns. EP1,004,554 A2 discloses that the use of a polymer containing from 20 to 100% by weight of a hydrophobic monomer as a masonry modifier was found to increase the water resistance and the flexural strength of the masonry. However, the masonry compositions disclosed in EP1,004,554 A2 do not have sufficient resistance to sagging when applied as thick layers onto vertical surfaces and therefore, are unsuitable as exterior finishing compositions such as basecoats or topcoats in multilayered exterior wall systems. Exterior finishing compositions with water resistance and suitable resistance to sag to allow application onto vertical surfaces are desired.
In the present invention, an exterior finishing composition is provided with improved water resistance as measured by resistance to water whitening, improved drying at low temperature, high humidity conditions, resistance to dirt pickup, and suitable resistance to sag to allow application onto vertical surfaces. The exterior finishing composition includes a polymer containing hydrophobic monomers as polymerized units and a rheology modifier to provide the necessary rheology to the exterior finish composition to allow the application of a thick layer onto a vertical surface without sagging prior to set up and drying of the exterior finish composition.
In the first aspect of this invention, an exterior finishing composition is provided including from 3 to 65 weight % based on weight of the exterior finishing composition of a polymer containing as polymerized units: from 20 to 100 parts by weight of the polymer of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid, from 0 to 80 parts by weight of the polymer of at least one ethylenically unsaturated monomer, and from 0 to 10 parts by weight of the polymer of at least one ethylenically unsaturated acid containing monomer or salts thereof; from 0.06 to 3.0 weight % of at least one rheology modifier, based on weight of the exterior finishing composition; from 10 to 55 weight % water, based on weight of the exterior finishing composition; from 0 to 30 weight % of at least one filler, based on weight of the exterior finishing composition; and from 0 to 80 weight % of at least one aggregate, based on weight of the exterior finishing composition, wherein the exterior finishing composition contains at least 2 weight % filler and aggregate, based on weight of the exterior finishing composition.
In the second aspect of this invention, an exterior finishing composition is provided including 5 to 65 weight % polymer, wherein the polymer contains as polymerized units from 20 to 100 parts by weight of the polymer of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid, from 0 to 80 parts by weight of the polymer of at least one ethylenically unsaturated monomer, and from 0 to 10 parts by weight of the polymer of at least one ethylenically unsaturated acid containing monomer or salts thereof; from 0.1 to 3.0 weight % of at least one rheology modifier, based on weight of the exterior finishing composition; and from 30 to 55 weight % water, based on weight of the exterior finishing composition.
In a third aspect of this invention, a method of coating an exterior vertical surface is provided including the steps of applying on the exterior vertical surface, an exterior finishing composition containing 3 to 65 weight % based on weight of the exterior finishing composition of a polymer containing as polymerized units: from 20 to 100 parts by weight of the polymer of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid, from 0 to 80 parts by weight of the polymer of at least one ethylenically unsaturated monomer, and from 0 to 10 parts by weight of the polymer of at least one ethylenically unsaturated acid containing monomer or salts thereof; from 0.06 to 3.0 weight % of at least one rheology modifier, based on weight of the exterior finishing composition; from 10 to 55 weight % water, based on weight of the exterior finishing composition; from 0 to 30 weight % of at least one filler, based on weight of the exterior finishing composition; and from 0 to 80 weight % of at least one aggregate, based on weight of the exterior finishing composition, wherein the exterior finishing composition contains at least 2 weight % filler and aggregate, based on weight of the exterior finishing composition; and drying or allowing to dry the exterior finishing composition.
As used herein, the term “(meth)acrylate” refers to either acrylate or methacrylate and the term “(meth)acrylic” refers to either acrylic or methacrylic. As used herein, the term “hydrophobic monomer” refers to a C
12
to C
40
alkyl ester of (meth)acrylic acid.
The present invention provides an exterior finishing composition containing a polymer, at least one rheology modifier, water, optionally at least one filler, and optionally at least one aggregate.
The polymer contains as polymerized units from 20 to 100 parts by weight, preferably from 35 to 100 parts by weight, and more preferably from 50 to 100 parts by weight of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid. It is further preferred that the polymer used in this invention contains as polymerized units from 40 to 96 parts by weight, more preferably 40 to 93 parts by weight of at least one C
12
to C
40
alkyl ester of (meth)acrylic acid. It is preferred that the alkyl ester of (meth)acrylic acid be a C
16
to C
18
alkyl ester of (meth)acrylic acid. Suitable alkyl esters of (meth)acrylic acid include cetyl (meth)acrylate, stearyl (meth)acrylate, behenyl (meth)acrylate, and eicosyl (meth)acrylate. Beneficial properties may be obtained by utilizing more than one C
12
to C
40
alkyl ester of (meth)acrylic acid.
The polymer used in this invention may also contain as polymerized units from 0 to 80 parts by weight, preferably from 0 to 50 parts by weight, and more preferably 1 to 20 parts by weight of at least one ethylenically unsaturated monomer wherein the ethylenically unsaturated monomer is not a C
12
to C
40
alkyl ester of (m
Kohr Alan Wayne
Konopka Kenneth Michael
O'Brien Michael Joseph
Greenblatt Gary D.
Rohm and Haas Company
Sastri Satya
Wu David W.
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