Aqueous dispersion of inorganic fibers and method for formulating aqueous coating composition therefrom

Patent metadata

Field	Value
Publication number	US-11987719-B2
Application number	US-201816487431-A
Country	US
Kind code	B2
Filing date	Feb 20, 2018
Priority date	Feb 20, 2017
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

The present disclosure is directed to an aqueous dispersion of inorganic fibers and a method for formulating an aqueous coating composition therefrom. The aqueous dispersion of inorganic fibers comprises water, inorganic fibers, a dispersing agent, an anti-settling agent and optionally additional additives, wherein the inorganic fibers have an average fiber diameter of from 1 micron to 100 microns and have a number average aspect ratio of from 1.1:1 to 10:1; and wherein the aqueous dispersion does not contain a film-forming amount of a polymeric resin.

First claim

What is claimed:

1. An aqueous dispersion of inorganic fibers, comprising: water, inorganic fibers, a dispersing agent, an anti-settling agent and optionally additional additives,
wherein the inorganic fibers comprise glass fibers;
wherein the inorganic fibers have an average fiber diameter of from 1 micron to 100 microns and have a number average aspect ratio of from 1.1:1 to 5:1; and
wherein the aqueous dispersion does not contain a film-forming amount of a polymeric resin.

2. The aqueous dispersion according to claim 1 , wherein the inorganic fibers have an average fiber diameter of from 1 micron to 50 microns.

3. The aqueous dispersion according to claim 1 , wherein the inorganic fibers have at least 50% by number of the fibers with an aspect ratio of 1.2:1 or greater.

4. The aqueous dispersion according to claim 1 , wherein the inorganic fibers further comprises silica fibers, boron fibers, ceramic fibers, metal fibers or combination thereof.

5. The aqueous dispersion according to claim 1 , wherein the dispersing agent comprises an anionic dispersing agent, a polymeric dispersing agent, a non-ionic dispersing agent or combination thereof.

6. The aqueous dispersion according to claim 1 , wherein the anti-settling agent comprises bentonite.

7. The aqueous dispersion according to claim 1 , wherein the inorganic fiber is surface modified with a coupling agent.

8. The aqueous dispersion according to claim 7 , wherein the coupling agent comprises a silane coupling agent, a titanate coupling agent, an aluminate coupling agent or combination thereof.

9. The aqueous dispersion according to claim 8 , wherein the coupling agent comprises a silane compound having structure of the following formula:

in which
each X 1 is independently selected from the groups consisting of —Cl, —OCH 3 , —OCH 2 CH 3 , —OC 2 H 4 OCH 3 , —OSiMe 3 , and —OCOCH 3 ; and
Y 1 is an alkyl group terminated with —Cl, —NH 2 , —SH, —OH, epoxy, —N 3 , γ-methacryloxypropyl or isocyanate groups.

10. The aqueous dispersion according to claim 8 , wherein the coupling agent comprises a silane compound comprising γ-methacryloxypropyl trimethoxy silane, 3-aminopropyltriethoxysilane, γ-glycidoxypropyl trimethoxysilane or the mixture thereof.

11. The aqueous dispersion according to claim 8 , wherein the coupling agent comprises an oligomeric silane having structure of the following formula:

wherein each of X 2 , X 3 and X 4 is independently selected from the group consisting of —Cl, —OCH 3 , —OCH 2 CH 3 , —OC 2 H 4 OCH 3 , —OSiMe 3 , —OCOCH 3 , —H, —CH 3 , —C 2 H 5 , and —OH with the proviso that at least one of X 2 , X 3 and X 4 is not —H, —CH 3 , —C 2 H 5 , or —OH;
each of Y 2 , Y 3 and Y 4 is independently an alkyl group ended with —Cl, —NH 2 , —SH, —OH, epoxy, —N 3 , γ-methacryloxypropyl or isocyanate groups; and
each of m 1 , m 2 and m 3 is from 0 to 200, with the proviso that at least one of m 1 , m 2 and m 3 is not 0.

12. The aqueous dispersion according to claim 8 , wherein the coupling agent comprises a titanate having a structure of the formula:
X 5 O (4-n) Ti(—OY 5 —Y 6 -Y 7 ) n

wherein X 5 O is a hydrolyzable short chain alkoxy;
OY 5 is carboxyl, sulfonic, or phosphate group;
Y 6 is a long chain alkyl group;
Y 7 is hydroxyl, thiol, amino, or epoxy group;
n is 2 or 3.

13. The aqueous dispersion according to claim 8 , wherein the coupling agent comprises an aluminate compound comprising distearoyl isopropoxy aluminate, trimethyl aluminate, triisopropyl aluminate, tribenzyl aluminate or a mixture thereof.

14. The aqueous dispersion according to claim 1 , comprising:
5-80 wt % of water,
10-80 wt % of the inorganic fibers,
0.2-5 wt % of the dispersing agent,
1-5 wt % of the anti-settling agent, and
0-30 wt % of additional additives,
relative to the total weight of the aqueous dispersion.

15. The aqueous dispersion according to claim 1 , comprising:
6-40 wt % of water,
50-80 wt % of the inorganic fibers,
0.2-5 wt % of the dispersing agent,
1-5 wt % of the anti-settling agent, and
0-30 wt % of additional additives,
relative to the total weight of the aqueous dispersion.

16. A process for the formulation of an aqueous coating composition, comprising:
i) formulating the aqueous dispersion according to claim 1 ; and
ii) mixing the aqueous dispersion of step i) with water, an aqueous polymer latex and optionally additional additives to formulate the aqueous composition.

17. A coating formed from the aqueous coating composition formulated by the process of claim 16 , which does not exhibit significant blushing when it is subjected to bending or folding one or more times.

18. A coating formed from the aqueous coating composition formulated by the process of claim 16 , which has a pencil hardness of at least H, as measured according to ASTM D3363.

19. A coating formed from the aqueous coating composition formulated by the process of claim 16 , which is capable of resisting scratch loading of 180 g or more, as measured according to ASTM D2197.

20. A coating formed from the aqueous coating composition formulated by the process of claim 16 , which has a film thickness retention ratio of 75% or more, when it is subjected to brushing with an aqueous medium containing sand particles having a particle size of 300-400 mesh by wet abrasion scrub tester REF 903 available from Sheen, England 500 cycles.

Assignees

• Guangdong Huarun Paints Co Ltd
• Swimc Llc

Inventors

• Kai Weihua
• Duan Gang
• Zhao Xi
• Fan Shigang

Classifications

• C09D5/024

  characterised by the additives · CPC title

• C09D133/00 Primary

  Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers · CPC title

• C09D17/001 Primary

  in aqueous medium (C09D17/003, C09D17/004 take precedence) · CPC title

• C08K3/346

  Clay · CPC title

• C08K7/06

  Elements · CPC title