COATING COMPOSITION, IN PARTICULAR FOR PRODUCING A COATED WALL, FLOOR OR CEILING COVERING, IN PARTICULAR FOR PRODUCING COATED WALLPAPER

Abstract

The present invention relates to a coating composition for the production of a coated substrate and, in particular, for the production of a coated wall, floor and ceiling covering.

Claims

1. Coating composition for the production of a coated substrate and, in particular, for the production of a coated wall, floor and ceiling covering, said coating composition containing: a) 15 to 80% by weight of at least one ethylene vinyl acetate copolymer, b) 0.1 to 30% by weight of at least one hydrocarbon resin, c) 0.1 to 20% by weight of at least one wax, d) 0.1 to 80% by weight of at least one filler, e) 0.01 to 20% by weight of at least one lubricant that is selected from the group consisting of carboxylic acid amides, fatty alcohols, metal soaps, complex esters and any mixture of two or more of the aforementioned compounds, and f) 0.0 to 10% by weight of optionally a blowing agent, where the sum of all the components is 100% by weight.

2. Coating composition for the production of a coated substrate and, in particular, for the production of a coated wall, floor and ceiling covering, said coating composition being obtained by combining the components: a) 15 to 80% by weight of at least one ethylene vinyl acetate copolymer, b) 0.1 to 30% by weight of at least one hydrocarbon resin, c) 0.1 to 20% by weight of at least one wax, d) 0.1 to 80% by weight of at least one filler, e) 0.01 to 20% by weight of at least one lubricant that is selected from the group consisting of carboxylic acid amides, fatty alcohols, metal soaps, complex esters and any mixture of two or more of the aforementioned compounds, and f) 0.0 to 10% by weight of optionally a blowing agent, where the sum of all the components is 100% by weight.

3. Coating composition, as claimed in claim 1, characterized in that the at least one lubricant is a carboxylic acid amide of the general formula (I) and/or a salt thereof, ##STR00002## where R.sub.1 is a substituted or unsubstituted, straight-chain or branched alkyl group, a substituted or unsubstituted, straight-chain or branched alkenyl group, a substituted or unsubstituted, straight-chain or branched alkynyl group, a substituted or unsubstituted cycloaliphatic group, a substituted or unsubstituted aromatic group, a substituted or unsubstituted heterocyclic group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted alkoxy carbonyl group, a substituted or unsubstituted carboxyl group or a substituted or unsubstituted alkyl amide group; and R.sub.2 and R.sub.3 are the same or different from each other and denote hydrogen, a substituted or unsubstituted, straight-chain or branched alkyl group, a substituted or unsubstituted, straight-chain or branched alkenyl group, a substituted or unsubstituted, straight-chain or branched alkynyl group, a substituted or unsubstituted cycloaliphatic group, a substituted or unsubstituted aromatic group, a substituted or unsubstituted heterocyclic group, a substituted or unsubstituted alkoxy group, a substituted or unsubstituted alkoxy carbonyl group, a substituted or unsubstituted carboxyl group or a substituted or unsubstituted alkyl amide group.

4. Coating composition, as claimed in claim 1, characterized in that the at least one lubricant is a carboxylic acid amide of the general formula (I) and/or a salt thereof, where R.sub.1 is a C.sub.10-24 alkyl group and preferably a C.sub.15-20 alkyl group; and R.sub.2 and R.sub.3 are the same or different from each other and denote hydrogen or a substituted or unsubstituted alkyl amide group.

5. Coating composition, as claimed in claim 1, characterized in that the carboxylic acid amide is a secondary bis amide.

6. Coating composition, as claimed in claim 1, characterized in that the at least one ethyl vinyl acetate copolymer is a copolymer that does not contain, apart from the comonomers ethene and vinyl acetate, any other comonomer.

7. Coating composition, as claimed in claim 1, characterized in that the proportion of the vinyl acetate in the at least one ethyl vinyl acetate copolymer is in the range of from 15 to 80% by weight, preferably in the range of more than 18 to 60% by weight, in particular, preferably in the range of from 20 to 50% by weight and most preferably in the range of from 25 to 40% by weight.

8. Coating composition, as claimed in claim 1, characterized in that at least one resin that is selected from the group consisting of aliphatic resins, cycloaliphatic resins, indene-coumarone resins, polystyrene resins, poly methyl styrene resins and any mixture of two or more of the aforementioned compounds, preferably a cycloaliphatic resin, an indene-coumarone resin and/or a poly methyl styrene resin, in particular, preferably a dicyclopentadiene resin, an indene-coumarone resin and/or a poly alpha methyl styrene resin and most preferably an indene-coumarone resin or a dicyclopentadiene resin having a weighted average molecular weight of from 200 to 1,000 g/mol and/or a poly alpha methyl styrene resin having a weighted average molecular weight of from 500 to 2,000 g/mol is contained as a hydrocarbon resin in the coating composition.

9. Coating composition, as claimed in claim 1, characterized in that the at least one wax is a polyolefin wax, preferably a polyethylene wax and, in particular, preferably a polyethylene wax having a weighted average molecular weight of from 500 to 2,000 g/mol.

10. Coating composition, as claimed in claim 1, characterized in that the inorganic filler is calcium carbonate or a mixture of calcium carbonate and magnesium carbonate, preferably dolomite.

11. Coating composition, as claimed in claim 1, characterized in that the proportion of the filler in the coating composition is 10 to 80% by weight, preferably 20 to 70% by weight, in particular, preferably 30 to 60% by weight and most preferably 40 to 55% by weight.

12. Coating composition, as claimed in claim 1, characterized in that the weight ratio of filler to ethylene vinyl acetate copolymers of the component a) is in the range of from 20:80 to 90:10, preferably from 30:70 to 80:20, in particular, from 40:60 to 70:30.

13. Coating composition, as claimed in claim 1, characterized in that the solid content in the coating composition is at least 15% by weight; preferably at least 30% by weight, in particular, preferably at least 40% by weight, in particular, at least 50% by weight.

14. Coating composition, as claimed in claim 1, characterized in that coating composition contains, in addition, as component f), at least one blowing agent that is selected preferably from the group consisting of hollow microspheres, metal carbonates, azodicarbonamide, oxybis benzenesulfonyl hydrazide, C.sub.3-10 alkanes and/or mixtures of two or more of the aforementioned compounds.

15. Coating composition, as claimed in claim 1, characterized in that said coating composition contains: a) 20 to 50% by weight of a random ethyl vinyl acetate copolymer that does not contain, apart from the comonomers ethene and vinyl acetate, any other comonomer, b) 1 to 20% by weight of a hydrocarbon resin that is selected from the group consisting of aliphatic resins, cycloaliphatic resins, indene-coumarone resins, polystyrene resins, poly methyl styrene resins and any mixture of two or more of the aforementioned compounds, c) 0.5 to 15% by weight of at least one polyolefin wax, d) 20 to 70% by weight of a filler that is selected from the group consisting of calcium carbonate, mixtures of calcium carbonate and magnesium carbonate, aluminum hydroxide, barium sulfate and any mixture of two or more of the aforementioned compounds, and e) 0.05 to 5% by weight of a carboxylic acid amide of the general formula (I) and/or a salt thereof, where R.sub.1 is a C.sub.10-24 alkyl group; and R.sub.2 and R.sub.3 are the same or different from each other and denote hydrogen or a substituted or unsubstituted alkyl amide group, where the sum of all the components is 100% by weight.

16. Coated substrate and, in particular, a coated wall, floor and ceiling covering, said coated substrate comprising a web-shaped substrate that is coated at least in sections on at least one of its two sides with a coating composition, as claimed in claim 1.

17. Coated substrate, as claimed in claim 16, characterized in that the substrate is selected from the group consisting of wood, wood components, wood materials, papers, plastics, organic fibers, synthetic fibers, mineral compounds, metals, two dimensional textile products and combinations of two or more of the aforementioned substances.

18. Method for producing a coated substrate and, in particular, a coated wall, floor and ceiling covering, wherein said method comprises the following process steps: (i) providing a web-shaped substrate, preferably a wallpaper, (ii) providing a coating composition, as claimed in claim 1, (iii) applying the coating composition to at least one section or at least one side of the substrate, preferably over the entire surface of one of the two sides of the substrate, (iv) curing, solidifying and/or cooling the coating composition, (v) optionally printing on the coating composition, (vi) optionally thermoforming the coating composition, (vii) optionally laminating/pasting a thin film.

19. Method for producing a coated substrate, as claimed in claim 18, characterized in that the application of the coating composition to the web-shaped substrate is carried out by a brushing process, spraying process or printing process, preferably by a printing process.

20. Method for producing a coated substrate, as claimed in claim 19, characterized in that the printing process is selected from the group consisting of screen printing processes, gravure printing processes, letterpress printing processes or inkjet printing processes, in particular, preferably, consisting of rotary screen printing processes, flat screen printing processes, rotogravure printing processes, flexographic printing processes or inkjet printing processes.

21. Method for producing a coated substrate, as claimed in claim 20, wherein the coating composition is printed with aqueous printing inks, preferably by a printing process selected from gravure, flexographic, inkjet or screen printing processes.

22. Use of a coating composition, as claimed in claim 1, for the production of a wall covering, in particular, a wallpaper.

Description

EXAMPLE A

[0151]

TABLE-US-00001 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Copolymer Copolymers (A)-(D) 50 to +20 20 to 80 dispersion Inorganic Filler 5 to 40 filler Microspheres/ Blowing agent 5 to 10 Sodium hydrogen carbonate Other Defoamer/Thickener/ 0.1 to 30.sup. auxiliary Wetting agent/ substances Pigment/Plasticizer

EXAMPLE B

[0152]

TABLE-US-00002 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Copolymer Copolymers (A)-(D) 30 to +15 30 to 60 dispersion Inorganic Filler .sup.5 to 40 Filler Fischer- Wax 0.1 to 10 Tropsch wax Microspheres Blowing agent .sup.1 to 10 Other Defoamer/Thickener/ 0.1 to 30 auxiliary Wetting agent/ substances Pigment/Plasticizer

EXAMPLE C

[0153]

TABLE-US-00003 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Acrylate Copolymer (B) +11 35 to 40 copolymer dispersion Ethylene Copolymer (A) +3 40 to 45 vinyl acetate copolymer dispersion Calcium Filler 10 to 15 carbonate Microspheres Blowing agent 5 to 10 Other Defoamer/Thickener/ 0.1 to 10 auxiliary Wetting agent/ substances Plasticizer/Pigment

EXAMPLE D

[0154]

TABLE-US-00004 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Acrylate Copolymer (B) +11 35 to 40 copolymer dispersion Acrylate Copolymer (B) 25 40 to 45 copolymer dispersion Calcium Filler 10 to 15 carbonate Microspheres Blowing agent 5 to 10 Other Defoamer/Thickener/ 0.1 to 10 auxiliary Wetting agent/ substances Plasticizer/Pigment/

Class E

[0155]

TABLE-US-00005 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Acrylate Copolymer (B) +11 70 to 80 copolymer dispersion Polyvinyl Hydrocarbon resin 1 to 5 alcohol Dolomite Inorganic filler 0.1 to 10 Expanded Organic filler 0.1 to 5 microspheres Microspheres Blowing agent .sup.5 to 10 Other Defoamer/Thickener/ 0.1 to 20 auxiliary Wetting agent/ substances Plasticizer/Pigment

Class F

[0156]

TABLE-US-00006 Glass Proportion in the Class of Temperature Composition Compound Function (Tg in C.) (% by weight) Polyvinyl Copolymer (B) 0 .sup.0 to 80 acetate copolymer dispersion Amino Polymer dispersion 2 to 5 plastics Dolomite Inorganic filler 0.1 to 10 Expanded Organic filler 0.1 to 5 microspheres Microspheres Blowing agent .sup.5 to 10 Other Defoamer/Thickener/ 0.1 to 20 auxiliary Wetting agent/ substances Plasticizer/Pigment

[0157] The present invention is explained in more detail below by means of two examples that describe, but do not restrict the invention.

EXAMPLES

[0158] Three coating compositions of the present invention were mixed together according to the formulations summarized in the table below.

TABLE-US-00007 Example 1 Example 2 Example 3 Component (% by weight) (% by weight) (% by weight) EVA 40 28 30 DCPD resin 12 8 Alpha methyl 8 styrene resin PE wax A 3 PE wax B 5 3 Carboxylic 0.5 0.3 acid amide Dolomite 43.5 54.7 58 Blowing agent 1 4 0.0 Metal soap 1.0

[0159] With respect to the raw materials the following information may be added: [0160] EVA: copolymer of ethylene and vinyl acetate with a vinyl acetate content of 33% by weight, based on the copolymer [0161] DCPD resin: dicyclopentadiene resin [0162] Carboxylic acid amide: octadecanamide [0163] Blowing agent: microcapsules containing isooctane [0164] Metal soap: zinc stearate

[0165] The viscosity of the coating compositions, produced in this way, was measured in a rotating mode (plate/plate) at 140 C., using a Physics MCR 301 rheometer from the company Anton Paar; and the storage modulus was measured in an oscillating mode (plate/plate) at 20 C. in GPa, also using a Physics MCR 301 rheometer from the company Anton Paar.

[0166] In addition, the curling behavior of a substrate, coated with the corresponding coating composition, was measured. For this purpose the coating compositions of the examples were melted in a first step; and the melts, obtained in this way, were uniformly applied to a non-woven wallpaper in two different layer thicknesses of 200 m and 100 m. After cooling, the flatness of the coated substrates, produced in this way, was determined.

[0167] The corresponding results are summarized in the table below. FIG. 1 shows the photographic comparison with a wallpaper made in accordance with the prior art.

[0168] The viscosity of the coating compositions, produced in this way, was measured in a rotating mode (plate/plate) at 140 C., using a Physics MCR 301 rheometer from the company Anton Paar; and the storage modulus was measured in an oscillating mode (plate/plate) at 20 C. in GPa, also using a Physics MCR 301 rheometer from the company Anton Paar.

TABLE-US-00008 Example 1 Example 2 Example 3 Property (% by weight) (% by weight) (% by weight) Curling Not significant Not significant Not significant Viscosity 140 C. 90,000 200,000 260,000 (mPa .Math. s) Storage modulus G 12 9 13 20 C. (GPa)

[0169] These examples show that the coating compositions of the present invention are easy to process using the wall adhesion technique and exhibit properties that are suitable for wall, floor and ceiling coverings.