Phosphorus acid functionalized coating composition

Patent metadata

Field	Value
Publication number	US-11254990-B2
Application number	US-201615183930-A
Country	US
Kind code	B2
Filing date	Jun 16, 2016
Priority date	Jun 19, 2015
Publication date	Feb 22, 2022
Grant date	Feb 22, 2022

Abstract

The present invention relates to a composition comprising an aqueous dispersion of submicron-sized polymer particles and micron-sized polymer beads, wherein the polymer particles or beads or both are functionalized with phosphorus acid groups. The composition of the present invention is useful for providing a matte finish on substrates, such as leather, textiles, wallboard, decorative coatings, concrete, and wood, with improved stain resistance. The present invention also relates to a leather substrate coated with a clear matte finish comprising an acrylic or styrene-acrylic polymer film and micron-sized polymer beads, wherein the film or the beads or both are functionalized with a phosphorus acid monomer.

First claim

The invention claimed is:

1. A composition comprising an aqueous dispersion of 1) polymer particles having an average particle size of from 50 to 300 nm; and b) polymer beads having an average particle size of from 2 to 30 μm; wherein the polymer particles and the polymer beads comprise from 0.1 to 5 weight percent structural units of a phosphorus acid monomer.

2. The composition of claim 1 wherein the weight-to-weight ratio of polymer beads to polymer particles is from 10:90 to 80:20, and the polymer particles have an average particle size in the range of from 80 to 300 nm.

3. The composition of claim 2 wherein the polymer beads comprise a hard phase and a soft phase, wherein the weight-to-weight ratio of the soft phase to the hard phase is from 1:1 to 10:1, wherein the weight-to-weight ratio of polymer beads to polymer particles is from 30:70 to 70:30.

4. The composition of claim 3 wherein the soft phase of the polymer beads comprises structural units of a crosslinking agent.

5. The composition of claim 4 wherein the polymer particles are film-forming at less than or equal to 25° C. and greater than or equal to −60° C.

6. The composition of claim 5 wherein the phosphorus acid monomer is phosphoethyl methacrylate, wherein the composition further comprises a substantial absence of pigments.

7. The composition of claim 6 which comprises less than 1 weight percent of pigments, wherein the polymer beads and polymer particles are each functionalized with from 0.2 to 3 weight percent structural units of phosphoethyl methacrylate.

8. The composition of claim 7 wherein the composition comprises less than 0.1 weight percent of pigments and further comprises a rheology modifier, a coalescent, a defoamer, and a surfactant.

9. The composition of claim 8 wherein the weight-to-weight ratio of polymer beads to polymer particles is from 30:70 to 70:30; wherein the polymer beads comprise a hard phase and a soft phase, wherein the weight-to-weight ratio of the soft phase to the hard phase is from 1:1 to 10:1.

10. The composition of claim 1 which further comprises a suspension stabilizing agent which is hydroxyethyl cellulose, polyvinyl pyrrolidone, or gelatin.

11. An article comprising a leather substrate coated with clear matte finish comprising an acrylic or styrene-acrylic polymer film and polymer beads having an average particle size of from 2 to 30 μm; wherein the acrylic or styrene-acrylic polymer film and the polymer beads comprise from 0.1 to 5 weight percent structural units of a phosphorus acid monomer.

12. The article of claim 11 wherein the acrylic or styrene-acrylic polymer film and the polymer beads comprise from 0.1 to 5 weight percent structural units of phosphoethyl methacrylate.

13. The article of claim 12 wherein the acrylic or styrene-acrylic polymer film and the polymer beads comprise from 0.2 to 3 weight percent structural units of phosphoethyl methacrylate.

14. A composition comprising an aqueous dispersion of 1) polymer particles having an average particle size of from 50 to 300 nm; and b) polymer beads having an average particle size of from 5 μm to 30 μm; wherein the polymer particles and the polymer beads each comprise structural units of a phosphorus acid monomer; wherein the polymer particles are film-forming at less than or equal to 20° C. and greater than or equal to −60° C.

15. The composition of claim 14 wherein the polymer particles are acrylic or styrene-acrylic polymer particles that comprise from 0.1 to 5 weight percent structural units of the phosphorus acid monomer, and the polymer beads comprise a hard domain having a T g greater than 40° C. and a crosslinked soft domain having a T g less than 25° C., wherein:
a) the weight-to-weight ratio of the soft domain to the hard domain is from 1:1 to 10:1;
b) the hard domain is functionalized with structural units of I) the phosphorus acid monomer; and II) methyl methacrylate or styrene or a combination thereof at II:I ratio in the range of from 99.5:0.5 to 94:6.

16. The composition of claim 15 wherein the soft domain of the polymer beads comprises structural units of butyl acrylate or 2-ethylhexyl acrylate or a combination thereof; and allyl methacrylate.

17. The composition of claim 16 wherein the weight-to-weight ratio of structural units of butyl acrylate or 2-ethylhexyl acrylate, or a combination thereof, to allyl methacrylate is in the range of from 99:1, to 92:8.

18. The composition of claim 17 wherein the polymer particles further comprise, based on the weight of the polymer particles; from 40 to 99 weight percent structural units of butyl acrylate or 2-ethylhexyl acrylate; and styrene or methyl methacrylate.

19. The composition of claim 14 wherein the phosphorus acid monomer is phosphoethyl methacrylate and the composition comprises less than 0.1 weight percent of pigments.

Assignees

• Rohm & Haas

Inventors

• Gallagher Joy A
• Harsh Philip R
• Luo Pu
• Nungesser Edwin

Classifications

• C09D133/12

  Homopolymers or copolymers of methyl methacrylate · CPC title

• C14C11/003 Primary

  using macromolecular compounds · CPC title

• C09D151/003 Primary

  grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds (C09D151/04, C09D151/06 take precedence) · CPC title

• C08F265/06

  Polymerisation of acrylate or methacrylate esters on to polymers thereof · CPC title

• C09D7/67

  Particle size smaller than 100 nm · CPC title