Coating compositions, elastic barrier coatings formed therefrom, and methods of applying such coatings
A coating composition that includes a polymer having (i) a barrier segment with aromatic groups and urethane linkages, urea linkages, or a combination thereof and (ii) an elastomeric segment that is different from (i). The barrier segment makes up at least 30 weight % of the polymer based on the total solids weight of the polymer. Further, the composition also includes an adhesion promoter having: (a) at least one epoxy functional polymer and a thiol functional crosslinker reactive with the epoxy functional polymer; and/or (b) a hydrazide functional component.
1. A coating composition comprising:
a polymer comprising: (i) a barrier segment comprising aromatic groups and urethane linkages, urea linkages, or a combination thereof; and (ii) an elastomeric segment that is different from (i), wherein the barrier segment comprises at least 30 weight % of the polymer based on the total solids weight of the polymer; and
an adhesion promoter comprising: (a) at least one epoxy functional polymer and a thiol functional crosslinker reactive with the epoxy functional polymer; and/or (b) a hydrazide functional component.
2. The coating composition of claim 1 , wherein the elastomeric segment comprises ester linkages, ether linkages, sulfide linkages, natural rubber, synthetic rubber, or a combination of any of the foregoing.
3. The coating composition of claim 1 , further comprising aqueous dispersed core-shell particles, wherein the core-shell particles comprise a polymeric core comprising an acrylic polymer, a vinyl polymer, or a combination thereof that is at least partially encapsulated by a polymeric shell comprising urethane linkages, urea linkages, or a combination thereof, and wherein at least a portion of the polymeric shell is covalently bonded to at least a portion of the polymeric core.
4. The coating composition of claim 1 , further comprising an additional crosslinker reactive with the polymer comprising the barrier segment and the elastomeric segment.
5. The coating composition of claim 1 , wherein the polymer comprising the barrier segment and the elastomeric segment is comprised by core-shell particles present in the coating composition, wherein the polymer comprising a barrier segment and an elastomeric segment forms a polymeric shell that at least partially encapsulates a polymeric core comprising an acrylic polymer, a vinyl polymer, or a combination thereof, and wherein at least a portion of the polymeric shell is covalently bonded to at least a portion of the polymeric core.
6. The coating composition of claim 5 , wherein the polymeric shell comprises at least 75 weight % of the core-shell particles based on the total solids weight of the core-shell particles.
7. The coating composition of claim 1 , wherein the adhesion promoter comprises the at least one epoxy functional polymer and thiol functional crosslinker.
8. The coating composition of claim 7 , wherein the adhesion promoter comprises: (1) a polymer comprising aromatic groups, hydroxyl groups, and two or more epoxy groups per molecule; (2) an epoxy functional polymer mixed with core-shell rubber particles; or a combination thereof.
9. The coating composition of claim 7 , wherein the adhesion promoter comprises at least two of the following: (1) a polymer comprising aromatic groups, hydroxyl groups, and two epoxy groups per molecule; (2) a polymer comprising aromatic groups, hydroxyl groups, and greater than two epoxy groups per molecule; and (3) an epoxy functional polymer mixed with core-shell rubber particles.
10. The coating composition of claim 7 , wherein the adhesion promoter comprises all of the following: (1) a polymer comprising aromatic groups, hydroxyl groups, and two epoxy groups per molecule; (2) a polymer comprising aromatic groups, hydroxyl groups, and greater than two epoxy groups per molecule; and (3) an epoxy functional polymer mixed with core-shell rubber particles.
11. The coating composition of claim 7 , wherein the equivalent ratio of epoxy functional groups to thiol functional groups is from 0.03:1 to 2:1.
12. The coating composition of claim 1 , wherein the adhesion promoter comprises the hydrazide functional component.
13. The coating composition of claim 12 , wherein the hydrazide functional component comprises a polymeric material comprising two or more hydrazide functional groups per molecule.
14. The coating composition of claim 13 , wherein the polymeric material having hydrazide functionality is comprised by core-shell particles present in the coating composition, the core-shell particles comprising (1) a polymeric core at least partially encapsulated by (2) a polymeric shell comprising hydrazide functional groups, wherein the polymeric core is covalently bonded to at least a portion of the polymeric shell.
15. The coating composition of claim 1 , wherein the adhesion promoter comprises both (a) the at least one epoxy functional polymer and thiol functional crosslinker and (b) the hydrazide functional component.
16. The coating composition of claim 1 , further comprising an additional polymer selected from a polyester, a polyether, a polysulfide, natural rubber, synthetic rubber, or a copolymer thereof, or a combination of any one of the foregoing.
17. The coating composition of claim 1 , further comprising a decorative component, wherein the decorative component comprises a pigment and a resin dispersed in an aqueous medium.
18. The coating composition of claim 17 , wherein the pigment of the decorative component comprises a white pigment and the resin of the decorative component comprises an acrylic resin.
19. A substrate at least partially coated with a coating formed from the coating composition of claim 1 .
20. A multi-layer elastic barrier coating comprising:
(a) an adhesive coating layer to be applied over at least a portion of a substrate, wherein the adhesive coating layer is formed from a coating composition comprising at least one epoxy functional polymer and a thiol functional crosslinker reactive with the epoxy functional polymer; and
(b) an elastic barrier coating formed from the coating composition of claim 1 applied over at least a portion of the adhesive coating layer.
21. The multi-layer elastic barrier coating of claim 20 , wherein the elastomeric segment comprises ester linkages, ether linkages, sulfide linkages, natural rubber, synthetic rubber, or a combination of any one of the foregoing.
22. The multi-layer elastic barrier coating of claim 20 , wherein the coating composition that forms the elastic barrier coating further comprises aqueous dispersed core-shell particles, wherein the core-shell particles comprise a polymeric core comprising an acrylic polymer, a vinyl polymer, or a combination thereof that is at least partially encapsulated by a polymeric shell comprising urethane linkages, urea linkages, or a combination thereof, and wherein at least a portion of the polymeric shell is covalently bonded to at least a portion of the polymeric core.
23. The multi-layer elastic barrier coating of claim 20 , wherein the coating composition that forms the elastic barrier coating further comprises a crosslinker reactive with the polymer comprising the barrier segment and the elastomeric segment.
24. The multi-layer elastic barrier coating of claim 20 , wherein the polymer comprising the barrier segment and the elastomeric segment is comprised by core-shell particles present in the coating composition that forms the elastic barrier coating, wherein the polymer comprising a barrier segment and an elastomeric segment forms a polymeric shell that at least partially encapsulates a polymeric core comprising an acrylic polymer, a vinyl polymer, or a combination thereof, and wherein at least a portion of the polymeric shell is covalently bonded to at least a portion of the polymeric core.
25. The multi-layer elastic barrier coating of claim 24 , wherein the polymeric shell comprises at least 75 weight % of the core-shell particles based on the total solids weight of the core-shell particles.
26. The multi-layer elastic barrier coating of claim 20 , wherein the at least one epoxy functional polymer comprises: (1) a polymer comprising aromatic groups, hydroxyl groups, and two or more epoxy groups per molecule; (2) an epoxy functional polymer mixed with core-shell rubber particles; or a combination thereof.
27. The multi-layer elastic barrier coating of claim 20 , wherein the at least one epoxy functional polymer comprises at least two of the following: (1) a polymer comprising aromatic groups, hydroxyl groups, and two epoxy groups per molecule; (2) a polymer comprising aromatic groups, hydroxyl groups, and greater than two epoxy groups per molecule; and (3) an epoxy functional polymer mixed with core-shell rubber particles.
28. The multi-layer elastic barrier coating of claim 20 , wherein the at least one epoxy functional polymer comprises all of the following: (1) a polymer comprising aromatic groups, hydroxyl groups, and two epoxy groups per molecule; (2) a polymer comprising aromatic groups, hydroxyl groups, and greater than two epoxy groups per molecule; and (3) an epoxy functional polymer mixed with core-shell rubber particles.
29. The multi-layer elastic barrier coating of claim 20 , wherein at least one of (a) the coating composition that forms the elastic barrier coating and (b) the coating composition that forms the adhesive coating layer further comprises a hydrazide functional component.
30. The multi-layer elastic barrier coating of claim 29 , wherein the hydrazide functional component comprises a polymeric material comprising two or more hydrazide functional groups per molecule.
31. The multi-layer elastic barrier coating of claim 20 , wherein the coating composition that forms the elastic barrier coating further comprises an additional polymer selected from a polyester, a polyether, a polysulfide, natural rubber, synthetic rubber, or a copolymer thereof, or a combination of any one of the foregoing.
32. The multi-layer elastic barrier coating of claim 20 , wherein the coating composition that forms the elastic barrier coating further comprises a decorative component, wherein the decorative component comprises a pigment and a resin dispersed in an aqueous medium mixture.