Intermediate resin blend for improved coatings
The invention relates to a waterborne high solids emulsion resin system that can be formulated in a way to provide excellent water proofing, chemical resistance, scratch and mar resistance, resistance to hot tire pickup, while minimizing the possibility of osmotic blistering and being able to use any desired cosolvent to produce a one-coat, clear, high gloss coating or sealant for wood, cement, concrete, stone, stucco and cement-based substrates. Preferably, the resin system comprises ultra-fine particles of a hydrophobic acrylic latex copolymer resin having a high Tg temperature and a low coalescent demand that can produce a final coating or sealant at VOCs of 50 g/l or less. The acrylic resin is combined with an additional water resistance additive formed from an silane/siloxane emulsion blend of a type and amount that provides additional water resistance while simultaneously allowing water vapor pressure in the substrate to pass through the coating.
1. An intermediate resin blend useful for forming a one-coat composition for coating or sealing a substrate comprising:
a film forming hydrophobic acrylic resin that cures under ambient conditions via self cross-linking, has an average particle size of less than about 0.1 microns and has a glass transition temperature greater than about 45° C.;
a water repellency additive comprising silicic acid, diethoxyoctylsilyl trimethylsilyl ester and triethoxyoctylsilane in an amount sufficient to increase both the water repellency and vapor transmission rate of the acrylic resin;
a plasticizer;
wherein the intermediate resin blend has a coalescing requirement of from about 5 to about 15 weight percent cosolvent based on the total resin solids weight;
wherein the blend has a vapor transmission rate greater than that of the acrylic resin alone; and
wherein the blend is adapted to form a one-coat composition to be coated on a substrate selected from the group consisting of concrete, wood, stone, cement, stucco, cement based products and combinations thereof.
2. The blend of claim 1 wherein the acrylic resin has a mean particle size of about 0.7 and a glass transition temperature of at least about 50° C.
3. The blend of claim 1 wherein the water repellant additive comprises from about 15 to about 35 weight percent silicic acid, diethoxyoctylsilyl trimethylsilyl ester and from about 10 to about 30 weight percent triethoxyoctylsilane.
4. The blend of claim 3 wherein the water repellant additive further comprises from about 3 to about 7 weight percent dimethyl siloxane, hydroxyl-terminated and up to about 2 weight percent polyethylene oxide lauryl ether.
5. The blend of claim 1 further comprising a foam control additive, a surfactant and a mar resistance additive.
6. An intermediate resin blend useful for forming a one-coat composition for coating or sealing a substrate comprising:
a film forming hydrophobic acrylic resin that cures under ambient conditions via self cross-linking, has an average particle size of less than about 0.1 microns and has a glass transition temperature greater than about 45° C.;
a water repellency additive comprising silicic acid, diethoxyoctylsilyl trimethylsilyl ester and triethoxyoctylsilane in an amount sufficient to increase both the water repellency and vapor transmission rate of the acrylic resin;
a plasticizer;
a foam control additive;
a surfactant;
a mar resistance additive;
wherein the intermediate resin blend has a coalescing requirement of from about 5 to about 15 weight percent cosolvent based on the total resin solids weight;
wherein the blend has a vapor transmission rate greater than that of the acrylic resin alone;
wherein the foam control additive is a substituted siloxane emulsion, the surfactant is a low molecular weight organofunctional silicone and the mar resistance additive is an ethyl methyl methyl(2-phenylpropyl) siloxane.
7. The blend of claim 6 wherein the foam control additive, the surfactant and the mar resistance additive are each present in an amount of from about 0.25 to about 2.00 weight percent based on the weight of the blend.
8. The blend of claim 6
wherein the foam control additive, the surfactant and the mar resistance additive are each present in an amount of from about 0.25 to about 2.00 weight percent based on the weight of the blend.
9. The blend of claim 8 further comprising from about 5 to about 20 weight percent of a cosolvent to form a coating composition.
10. The composition of claim 9 wherein the coating composition when applied to a substrate provides a water/interface contact angle of at least about 135 degrees without reducing vapor transmission rates below that of the acrylic resin alone.
11. The composition of claim 10 wherein the coating composition when applied to a substrate has a moisture vapor transmission rate up to 50% higher than a coating composed of just the acrylic resin.
12. The composition of claim 9 wherein the cosolvent is selected from the group consisting of ethylene glycol mono butyl ether, texanol, butyl carbitol, 1-butoxy-2-propanol, 1-propoxy-2-propanol, and mixtures thereof.
13. The composition of claim 9 having a VOCs of about 50 g/l or less.
14. The composition of claim 9 wherein the coating composition provides a coefficient of friction (C.O.F.) of from about 0.5 to about 0.8 when applied to a substrate.
15. The composition of claim 9 wherein the coating composition can be coated on a substrate selected from the group consisting of concrete, wood, stone, cement, stucco, cement based products and combinations thereof.
16. The composition of claim 9 wherein the coating composition provides hot tire pickup resistance and resistance to solvents, chemicals and household condiments.
17. An intermediate resin blend useful for forming a one-coat composition for coating or sealing a substrate comprising:
a film forming hydrophobic acrylic resin that cures under ambient conditions via self cross-linking, has an average particle size of less than about 0.1 microns and has a glass transition temperature greater than about 45° C.;
a water repellency additive comprising silicic acid, diethoxyoctylsilyl trimethylsilyl ester and triethoxyoctylsilane in an amount sufficient to increase both the water repellency and vapor transmission rate of the acrylic resin;
a plasticizer;
wherein the intermediate resin blend has a coalescing requirement of from about 5 to about 15 weight percent cosolvent based on the total resin solids weight;
wherein the blend has a vapor transmission rate greater than that of the acrylic resin alone;
from about 5 to about 20 weight percent of a cosolvent to form a coating composition; and
wherein the coating composition is adapted to be coated on a substrate selected from the group consisting of concrete, wood, stone, cement, stucco, cement based products and combinations thereof.
18. The composition of claim 17 wherein the coating composition when applied to a substrate provides a water/interface contact angle of at least about 135 degrees without reducing vapor transmission rates below that of the acrylic resin alone.
19. The composition of claim 18 wherein the coating composition when applied to a substrate has a moisture vapor transmission rate up to 50% higher than a coating composed of just the acrylic resin.
20. The composition of claim 17 wherein the cosolvent is selected from the group consisting of ethylene glycol mono butyl ether, texanol, butyl carbitol, 1-butoxy-2-propanol, 1-propoxy-2-propanol, and mixtures thereof.
21. The composition of claim 17 having a VOCs of about 50 g/l or less.
22. The composition of claim 17 wherein the coating composition provides a coefficient of friction (C.O.F.) of from about 0.5 to about 0.8 when applied to a substrate.
23. The composition of claim 17 wherein the coating composition provides hot tire pickup resistance and resistance to solvents, chemicals and household condiments.