IP Library › Granted Patent US 11,459,480
Granted Patent B2
US 11,459,480 · App. 16/765,942 · Granted Oct 4, 2022

Latex polymer with improved washability and block resistance

Inventors: Dana Christensen (Crystal Lake, IL); Tyler Bell (Crystal Lake, IL); Robert Sandoval (Crystal Lake, IL); Mary Jane Hibben (Elburn, IL); Michael Wildman (Hoffman Estates, IL)
C09D133/08C08F2/00C08F20/18C08K2003/2241
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Quick Facts
Patent No.
US 11,459,480
App. No.
16/765,942
Granted
Oct 4, 2022
Kind
B2
Abstract

Coating compositions or paint having a pigment blended with a polymer system including one or more latex polymers, wherein the polymer system contains an alkali-soluble resin having an acid value and molecular weight and provided in a preferably desired amount to demonstrate optimal performance characteristics of washability, stain resistance or scrubability without negatively impacting block resistance, especially when neutralized with a low-volatility base.

Claims (35)

1. A coating composition comprising:

a polymer system comprising:

one or more multistage latex polymers made from monomers comprising diacetone acrylamide; the one or more multistage latex polymers having a first Tg of 0° C. to 120° C. and a second stage with a Tg of −35° C. to 10° C.; and

and at least one alkali-soluble resin; and

at least one pigment;

wherein the coating composition contains at least about 2.5 wt. % of the alkali-soluble resin based upon the total resin solid content of the coating composition, the alkali-soluble resin having a weight average molecular weight (Mw) of about 1,500 to about 20,000 and an acid number greater than about 100 mg KOH/g resin.

2. A coating composition, comprising:

a dispersion of one or more multistage latex polymers made from monomers comprising diacetone acrylamide; the one or more multistage latex polymers having a first Tg of 0° C. to 120° C. and a second stage with a Tg of −35° C. to 10° C.; and

at least one alkali-soluble resin, wherein the dispersion contains at least about 2.5 wt. % of the alkali-soluble resin based upon the total resin solid content of the coating composition, and the alkali-soluble resin has a weight average molecular weight (Mw) of about 1,500 to about 20,000 and an acid number greater than about 100 mg KOH/g resin.

3. A coating composition according to claim 1 , wherein the coating composition contains up to about 15 wt. % of the alkali-soluble polymer based on total resin solid content of the coating composition.

4. A coating composition according to claim 2 , wherein the coating composition contains about 2.5 wt. % to about 7 wt. % of the alkali-soluble polymer based on total resin solid content of the coating composition.

5. A coating composition according to claim 1 , wherein a cured film of the coating composition applied to a black mylar substrate using a 7-mil Dow bar at 1 week at ambient temperature has at least one of the following properties: a washability rating of at least 7; a scrub resistance of at least about 600 scrubs; and a blocking resistance of at least 6.

6. A coating composition according to claim 1 , wherein the coating composition comprises a low-volatility base chosen from the group consisting of potassium hydroxide, sodium hydroxide, ammonia, 2-amino-2-methyl-1-propanol (AMP), diethyl amine (DEA), dimethylethanolamine (DMEA), triethylamine (TEA), monoethanol amine, diethyanol amine, triethanolamine (TEOA), alkanolamine, and combinations thereof.

7. A coating composition according to claim 2 , wherein the coating composition comprises a low-volatility base having a vapor pressure under about 100 mm Hg at 25° C.

8. A coating composition according to claim 2 , wherein a cured film of the coating composition has an improved washability compared to an analogous coating composition made without the alkali-soluble resin.

9. A coating composition comprising:

a dispersion of one or more multistage latex polymers having a first Tg of 0° C. to 120° C. and a second stage with a Tg of −35° C. to 10° C.; wherein the one or more latex polymers comprise a multistage latex polymer made from a first mixture of monomers for a first stage, the first mixture comprising methyl methacrylate, butyl acrylate, methacrylic acid, a ureido-functional monomer, and optionally diacetone acrylamide; and a second mixture of monomers for a second stage, the second mixture comprising methyl methacrylate, butyl acrylate, methacrylic acid, diacetone acrylamide, and a ureido-functional monomer; and

at least one alkali-soluble resin, wherein the dispersion contains at least about 2.5 wt. % of the alkali-soluble resin based upon the total resin solid content of the coating composition, and the alkali-soluble resin has a weight average molecular weight (Mw) of about 1,500 to about 20,000 and an acid number greater than about 100 mg KOH/g resin.

10. A coating composition according to claim 1 , wherein the alkali-soluble resin comprises an organic solution polymerized polymer having an acid number of at least about 100 to about 250 mg KOH/g resin.

11. A coating composition comprising:

a polymer system comprising:

one or more multistage latex polymers having a first Tg of 0° C. to 120° C. and a second stage with a Tg of −35° C. to 10° C.; and

and at least one alkali-soluble resin;

wherein the polymer system comprises one or more polymers comprising a copolymer of styrene, butyl acrylate, 2-(acetoacetoxy)ethyl methacrylate, methyl methacrylate, and butyl methacrylate; and

at least one pigment;

wherein the coating composition contains at least about 2.5 wt. % of the alkali-soluble resin based upon the total resin solid content of the coating composition, the alkali-soluble resin having a weight average molecular weight (Mw) of about 1,500 to about 20,000 and an acid number greater than about 100 mg KOH/g resin.

12. A coating composition according to claim 1 , wherein the coating composition comprises a coalescent.

13. A coating composition according to claim 12 , wherein the coating composition comprises a coalescent having a VOC content of less than about 5 g/L.

14. A coating composition according to claim 1 , wherein the coating composition has a pigment volume concentration between about 20 and about 40, or between about 10 and about 25.

15. A coating composition according to claim 2 , wherein the coating composition comprises an in-store tintable liquid base paint formulation.

16. A coating composition according to claim 15 , wherein the coating composition comprises an in-store tintable liquid base paint formulation in a container having headspace sufficient to receive a quantity of one or more low VOC colorants, wherein the colorant has less than about 20 g/L VOC.

17. A coating composition according to claim 2 , where in the coating composition comprises an architectural paint.

18. A method of preparing a coating composition, comprising:

forming a dispersion comprising one or more multistage latex polymers made from monomers comprising diacetone acrylamide, the one or more multistage latex polymers having a first Tg of 0° C. to 120° C. and a second stage with a Tg of −35° C. to 10° C., wherein the dispersion further comprises at least one alkali-soluble resin, wherein the dispersion comprises at least about 2.5 wt. % of the alkali-soluble resin based on the total resin solid content of the coating composition, and the alkali-soluble resin has an average molecular weight (Mw) of about 1,500 to about 20,000 and an acid number greater than about 100 mg KOH/g resin.

19. A method of preparing a coating composition according to claim 18 , wherein forming a dispersion comprises polymerizing one or more latex polymers in the presence of at least one alkali-soluble resin.