Coating compositions for polymeric roofing materials

Patent metadata

Field	Value
Publication number	US-10858532-B2
Application number	US-201916383359-A
Country	US
Kind code	B2
Filing date	Apr 12, 2019
Priority date	Apr 13, 2018
Publication date	Dec 8, 2020
Grant date	Dec 8, 2020

Abstract

A latex emulsion may include an aqueous carrier liquid and a latex copolymer formed from reactants comprising butyl methacrylate, wherein the reactants include at least 20 wt. % butyl methacrylate, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer. A coating formed from the latex emulsion exhibits a wet adhesion to a thermoplastic polyolefin roofing membrane of greater than about 1 pound per linear inch when tested using fabric embedded peel adhesion testing per ASTM C794. The latex emulsion may be used as part of an aqueous coating composition or a roofing system including a polymeric roofing membrane.

First claim

What is claimed is:

1. A composition comprising:
an aqueous carrier liquid; and
a latex copolymer formed from reactants comprising a chain transfer agent and a vinyl monomer having an alkyl group including between 2 and 20 carbon atoms, wherein the reactants comprise between 20 wt. % and 60 wt. % of the vinyl monomer having an alkyl group including between 2 and 12 carbon atoms, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer, and wherein a homopolymer formed from the vinyl monomer exhibits a glass transition temperature of between about −10° C. and about 30° C.;
wherein the latex copolymer exhibits a gel fraction of between 0% and about 10%, and wherein the solubilized portion of the latex copolymer exhibits a weight average molecular weight of less than about 230,000 g/mol;
wherein the latex copolymer exhibits a glass transition temperature of between about −50 ° C. and about −15° C.; and
wherein a coating formed from the composition exhibits a wet adhesion to a thermoplastic polyolefin roofing membrane of greater than about 1 pound per linear inch when tested using fabric embedded peel adhesion testing per ASTM D903 at a coverage of about 80 ft 2 /gallon.

2. The composition of claim 1 , wherein the vinyl monomer comprises butyl methacrylate, ethylhexyl methacrylate, a vinyl ester of neodecanoic acid, or combinations thereof.

3. The composition of claim 2 , wherein the butyl methacrylate, ethylhexyl methacrylate, the vinyl ester of neodecanoic acid, or combinations thereof comprises n-butyl methacrylate or a mixture of n-butyl methacrylate and ethylhexyl methacrylate.

4. The composition of claim 1 , further comprising a dispersant, a biocide, a fungicide, an UV stabilizer, a thickener, a wetting agent, a defoamer, a filler, a pigment or colorant, or combinations thereof.

5. The composition of claim 1 , wherein the reactants comprise between 30 wt. % and 60 wt. % of the vinyl monomer having an alkyl group including between 2 and 20 carbon atoms, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer.

6. The composition of claim 1 , wherein the reactants comprise between 20 and 50 wt. % of the vinyl monomer having an alkyl group including between 2 and 20 carbon atoms, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer.

7. The composition of claim 1 , wherein the reactants further comprise:
an ethylenically unsaturated polar monomer.

8. The composition of claim 7 , wherein the chain transfer agent comprises dodecyl mercaptan.

9. The composition of claim 1 , wherein the reactants further comprise a second (meth)acrylate, wherein the second (meth)acrylate forms a homopolymer that has a glass transition temperature that is less than −25° C.

10. The composition of claim 9 , wherein the second (meth)acrylate comprises 2-ethylhexyl acrylate.

11. The composition of claim 1 , wherein the reactants further comprise a ureido-functional ethylenically unsaturated monomer.

12. The composition of claim 1 , wherein the coating formed from the composition exhibits a wet adhesion of greater than about 2 pounds per linear inch when tested using fabric embedded peel adhesion testing per ASTM D903.

13. The composition of claim 1 , wherein the latex copolymer exhibits a glass transition temperature of between about −50° C. and about −20° C.

14. A roofing system comprising:
a polymeric roofing membrane; and
a coating on a surface of the polymeric roofing membrane, wherein the coating is formed from a composition comprising:
an aqueous carrier liquid; and
a latex copolymer formed from reactants comprising a chain transfer agent and a vinyl monomer having an alkyl group including between 2 and 20 carbon atoms, wherein the reactants comprise between 20 wt. % and 60 wt. % of the vinyl monomer having an alkyl group including between 2 and 12 carbon atoms, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer, and wherein a homopolymer formed from the vinyl monomer exhibits a glass transition temperature of between about −10° C. and about 30° C.;

wherein the latex copolymer exhibits a glass transition temperature of between about −50° C. and about −15° C.; and
wherein a coating formed from the coating composition exhibits a wet adhesion to a thermoplastic polyolefin roofing membrane of greater than about 1 pound per linear inch when tested using fabric embedded peel adhesion testing per ASTM D903 at a coverage of about 80 ft 2 /gallon.

15. The roofing system of claim 14 , wherein the polymeric roofing membrane comprises a thermoplastic polyolefin, ethylene propylene diene monomer rubber, or poly(vinyl chloride) roofing membrane.

16. The roofing system of claim 14 , wherein the coating comprises a primer coat, further comprising a top coat on the primer coat.

17. A method comprising:
reacting reactants comprising a chain transfer agent and a vinyl monomer having an alkyl group including between 2 and 20 carbon atoms to form a latex emulsion including a latex copolymer, wherein the reactants comprise between 20 wt. % and 60 wt. % of the vinyl monomer having an alkyl group including between 2 and 20 carbon atoms, based on the total weight of ethylenically unsaturated monomers used to make the latex copolymer, wherein a homopolymer formed from the vinyl monomer exhibits a glass transition temperature of between about −10° C. and about 30° C., wherein the latex copolymer exhibits a gel fraction of between 0% and about 5%, and wherein the solubilized portion of the latex copolymer exhibits a weight average molecular weight of less than about 230,000 g/mol, wherein the latex copolymer exhibits a glass transition temperature of between about −50° C., and about −15° C., and wherein a coating formed from the latex emulsion exhibits a wet adhesion to a thermoplastic polyolefin roofing membrane of greater than about 1 pound per linear inch when tested using fabric embedded peel adhesion testing per ASTM D903 at a coverage of about 80 ft 2 /gallon.

18. The method of claim 17 , wherein the vinyl monomer comprises butyl methacrylate, ethylhexyl methacrylate, a vinyl ester of neodecanoic acid, or combinations thereof.

19. The method of claim 18 , wherein the butyl methacrylate, ethylhexyl methacrylate, the vinyl ester of neodecanoic acid, or combinations thereof comprises n-butyl methacrylate or a mixture of n-butyl methacrylate and ethylhexyl methacrylate.

Assignees

• Swimc Llc

Inventors

• Hibben Mary Jane
• Bulick Allen
• Crenshaw Brent
• Rodgers Ashley
• Frazee Glenn
• Sandoval Robert

Classifications

• C09D133/08 Primary

  Homopolymers or copolymers of acrylic acid esters · CPC title

• C09D5/022 Primary

  Emulsions, e.g. oil in water · CPC title

• C08F220/1808

  C8-(meth)acrylate, e.g. isooctyl (meth)acrylate or 2-ethylhexyl (meth)acrylate · CPC title

• C08F220/1804

  C4-(meth)acrylate, e.g. butyl (meth)acrylate, isobutyl (meth)acrylate or tert-butyl (meth)acrylate · CPC title

• C08K5/37

  Thiols · CPC title