Coating compositions for building materials and coated building material substrates

Patent metadata

Field	Value
Publication number	US-2016185994-A1
Application number	US-201514971516-A
Country	US
Kind code	A1
Filing date	Dec 16, 2015
Priority date	Dec 19, 2014
Publication date	Jun 30, 2016
Grant date	—

Abstract

Embodiments of the present disclosure are directed to coating compositions, coated articles, and methods in which the coated article is adapted to exhibit a particular permeance profile, such as, for example, a variable water vapor perm rating of about 1 perm or less at 25% average RH and about 15 perms or more at 95% average relative humidity, as tested by ASTM E96 at 21° C.

First claim

What is claimed is:

1 . A coating composition adapted to selectively retard water vapor as a function of humidity when cured into a barrier layer, the composition comprising:
a. a hydrophobic component; and b. a hydrophilic component; c. wherein the composition once cured is effective to provide a variable water vapor perm rating of about 1 perm or less at 25% average RH and about 15 perms or more at 95% average relative humidity, as tested by ASTM E96 at 21° C. and as tested by coating and curing the composition on a kraft paper.

2 . The composition of claim 1 , wherein the composition once cured is effective to provide a water vapor perm rating of about 2.5 perms or less at 45% average RH and a water vapor perm rating of between 6 and 12 perms at 75% average RH as tested by ASTM E96 at 21° C. and as tested by coating and curing the composition on a kraft paper.

3 . The composition of claim 1 , wherein a ratio of the volume % of the hydrophobic component to the hydrophilic component is at least about 2:1 and no greater than about 200:1.

4 . The composition of claim 1 , wherein the hydrophobic component comprises a water insoluble polymer.

5 . The composition of claim 1 , wherein the hydrophilic component comprises a material having percent water absorption of at least about 1%.

6 . The composition of claim 1 , wherein the hydrophobic component comprises or is derived from a latex of styrene butadiene, styrene acrylic, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof.

7 . The composition of claim 1 , wherein the hydrophilic component comprises polyvinyl alcohol (PVOH), poly(vinyl pyrolidone), starch, cellulose, salts of polyacrylic acid, poly acrylic acid, highly carboxylated latexes, amines, inorganic hydrophilic filler, polyethylene oxide, vinyl ethers, highly hydrolyzed polymers (eg, hydrolyzed maleic anhydride), polysaccharides or combinations thereof.

8 . The composition of claim 1 ,
a. wherein the hydrophobic component comprises or is derived from a latex of styrene butadiene, styrene acrylic, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof; b. wherein the hydrophilic component comprises polyvinyl alcohol (PVOH), poly(vinyl pyrolidone), starch, cellulose, salts of polyacrylic acid, poly acrylic acid, highly carboxylated latexes, amines, inorganic hydrophilic filler, polyethylene oxide, vinyl ethers, highly hydrolyzed polymers (eg, hydrolyzed maleic anhydride), polysaccharides or combinations thereof; and c. wherein a ratio of the volume % of the hydrophobic component to the hydrophilic component is at least about 2:1 and no greater than about 200:1.

9 . An article adapted to selectively retard water vapor as a function of humidity, the article comprising:
a. a building material substrate; and b. a barrier layer disposed on the building material substrate, the barrier layer comprising:
i. a hydrophobic component; and
ii. a hydrophilic component;
c. wherein the article has a water vapor perm rating of about 1 perm or less at 25% average RH and about 15 perms or more at 95% average relative humidity, as tested by ASTM E96 at 21° C.

10 . The article of claim 9 , wherein the article has a water vapor perm rating of about 2.5 perms or less at 45% average RH and a water vapor perm rating of between 6 and 12 perms at 75% average RH as tested by ASTM E96 at 21° C.

11 . The article of claim 9 , wherein the substrate comprises a kraft paper facing, a scrim, a polymer sheet, a gypsum wall board, or combinations thereof.

12 . The article of claim 9 , wherein the substrate comprises a woven or non-woven material.

13 . The article of claim 9 , wherein the substrate comprises a non-woven material comprising spun bond or point bond fabric.

14 . The article of claim 9 , wherein the barrier layer is embedded within the substrate by at least about 5% of the thickness of the barrier layer.

15 . The article of claim 9 , wherein the article has a nail tear resistance of at least about 10 N/5 cm as measured according to EIN 12310-1.

16 . The article of claim 9 ,
a. wherein the substrate comprises a synthetic fabric having a pore structure; b. wherein the barrier layer is partly embedded within the substrate; c. wherein the hydrophobic component comprises or is derived from a latex of styrene butadiene, styrene acrylic, acrylic, vinyl acetate ethylene, vinylidene chloride, polyethylene, wax, polyvinyl chloride, polyvinyl butyral, polypropylene, butadiene or combinations thereof; d. wherein the hydrophilic component comprises polyvinyl alcohol (PVOH), poly(vinyl pyrolidone), starch, cellulose, salts of polyacrylic acid, poly acrylic acid, highly carboxylated latexes, amines, inorganic hydrophilic filler, polyethylene oxide, vinyl ethers, highly hydrolyzed polymers (eg, hydrolyzed maleic anhydride), polysaccharides or combinations thereof; and e. wherein a ratio of the volume % of the hydrophobic component to the hydrophilic component is at least about 2:1 and no greater than about 200:1.

17 . An article adapted to selectively retard water vapor as a function of humidity, the article comprising:
a. a building material substrate comprising a synthetic fabric having a pore structure; and b. a barrier layer; c. wherein the article has a water vapor perm rating of about 1 perm or less at 25% average RH and about 15 perms or more at 95% average relative humidity, as tested by ASTM E96 at 21° C.; d. wherein at least about 1% of the barrier layer is embedded into the pore structure of the synthetic fabric substrate.

18 . The article of claim 17 , wherein the article has a water vapor perm rating of about 2.5 perms or less at 45% average RH and a water vapor perm rating of between 6 and 12 perms at 75% average RH as tested by ASTM E96 at 21° C.

19 . The article of claim 17 , wherein the barrier layer comprises a hydrophobic component and a hydrophilic component.

20 . The article of claim 19 ,
a. wherein the hydrophobic component comprises a water insoluble polymer; b. wherein the hydrophilic component comprises a material having percent water absorption of at least about 1%; and c. wherein a ratio of the volume % of the hydrophobic component to the hydrophilic component is at least about 2:1 and no greater than about 200:1.

Assignees

• Certain Teed Corp

Inventors

• Peet Jeffrey H
• Yuan Sam
• Coogan Timothy J

Classifications

• C09D109/08 Primary

  Latex · CPC title