Water Borne Coating Composition, Use of Such Composition, Method for Coating a Substrate Using Such Composition and Coated Substrates

Abstract

The present invention is directed to a water borne coating composition. The composition according to the present invention comprises an emulsified binder, wherein the binder is a polymer selected from the group consisting of polymers prepared by emulsion polymerization of unsaturated vinyl, acrylate and/or methacrylate monomers, alkyd, polyurethane, and epoxy, 0.3% to 10% by weight of a second polymer selected from one or more of the group consisting of poly(vinyl alcohol) and water-soluble copolymers having repeat units of vinyl alcohol, wherein, if the second polymer is poly(vinyl alcohol), at least 85 wt % of the second polymer has a number of repeat units not less than 2,000, and 0% to 15% by weight of a cellulose-based filler, based on the total weight of the composition, wherein the weight ratio of second polymer to binder is in the range of from 1:100 to 1:1. The composition maybe used in various applications to form a decorative coating which has special visual and tactile effect.

Claims

1. A water borne coating composition, comprising: an emulsified binder, wherein the binder is a polymer selected from the group consisting of polymers prepared by emulsion polymerization of unsaturated vinyl, acrylate and/or methacrylate monomers, alkyd, polyurethane, and epoxy; 0.3% to 10% by weight of a second polymer selected from one or more of the group consisting of poly(vinyl alcohol) and water-soluble copolymers having repeat units of vinyl alcohol, wherein, if the second polymer is poly(vinyl alcohol), at least 85 wt % of the second polymer has a number of repeat units not less than 2,000; and 0.03% to 15% by weight of a cellulose-based filler; based on the total weight of the composition, wherein the weight ratio of second polymer to binder is in the range of from 1:100 to 1:1.

2. The water borne coating composition according to claim 1, wherein the weight percentage of the second polymer is within the range from 0.3% to 6% by weight based on the total weight of the composition.

3. The water borne coating composition according to claim 1, wherein the second polymer is a poly(vinyl alcohol) which has a number of repeat units of not less than 2,000.

4. The water borne coating composition according to claim 1, wherein the second polymer is a poly(vinyl acetate-co-vinyl alcohol) with a mole percentage of vinyl alcohol of less than 70%, and a number of repeat units of vinyl acetate and vinyl alcohol of at least 2,000.

5. The water borne coating composition according to claim 1, wherein the cellulose-based filler is selected from the group consisting of microcrystalline cellulose, regenerated cellulose, and lignocellulose.

6. The water borne coating composition according to claim 1, wherein the cellulose-based filler is a fibrous cellulose-based filler.

7. The water borne coating composition according to claim 1, wherein the weight percentage of the cellulose-based filler is not less than 0.5%, based on the total weight of the composition.

8. The water borne coating composition according to claim 6, wherein the weight percentage of the cellulose-based filler is within the range from 2% to 5%, based on the total weight of the composition.

9. The water borne coating composition according to claim 1, wherein the weight percentage of the binder is within the range from 10% to 40% based on the total weight of the composition.

10. The water borne coating composition according to claim 1, wherein the weight ratio of the second polymer to the binder is within the range from 1:50 to 1:2.

11. The water borne coating composition according to claim 1, which further comprises components selected from the group consisting of pigments, dyes, inorganic fillers, extenders, coalescent agents, surfactants, dispersants, biocides, neutralizing agents, defoaming agents, and anti-freeze agents.

12. A method for forming a fabric-like coating on a substrate, which comprises, providing a water borne coating composition according to claim 1; applying the water borne coating composition onto the substrate by spraying the coating composition onto the substrate through a nozzle with an internal diameter of 0.2 to 5.5 mm.

13. The method according to claim 12, wherein the distance from the substrate to the nozzle is kept within the range from 15 cm to 30 cm.

14. (canceled)

15. The coated substrate obtained by a method according to claim 12.

16. The water borne coating composition according to claim 9, wherein the weight percentage of the binder is within the range from 15% to 30% based on the total weight of the composition.

17. The water borne coating composition according to claim 10, wherein the weight ratio of the second polymer to the binder is within the range from 1:40 to 1:3.

18. The water borne coating composition according to claim 10, wherein the weight ratio of the second polymer to the binder is within the range from 1:10 to 1:4.

Description

DESCRIPTION OF DRAWINGS

[0036] The above and other objectives, features, and advantages of the present invention will become more apparent to those of ordinary skill in the art by being described in embodiments thereof with reference to the accompanying drawings.

[0037] FIG. 1a shows the pattern achieved with low density and uniform directional fibers as well as a completely hiding basecoat which plays a critical role in the final appearance.

[0038] FIG. 1b shows the pattern of the fibers fully covering the substrate and with a certain thickness.

[0039] FIGS. 2a and 2b show images of fibers overlaying in typical fabric-like coatings obtained from the present invention, taken by light microscopy and scanning electron microscopy, respectively.

EXAMPLES

[0040] The following examples are offered to illustrate, but not to limit the claimed invention.

Example 1

[0041] 40 grams of an aqueous binder emulsion (PRIMAL SF-500, ex. Dow Chemical Company,solid binder content approximately 50 wt %), 40 grams poly(vinyl alcohol) aqueous solution with solid content of 10% (NH-26, available from Nippon Gohsei), 4 grams plant fibers (lignocellulose fibers), 12.4 grams TiO.sub.2 slurry (Dupont A706, solid content 70 wt %), 0.67 grams Coasol 290 (Eastman Chemical Company), 1 gram polypropylene glycol, 1 g Vantex TA 496 (Taminco), and pigments were mixed at room temperature for 20 minutes. The composition is sprayed on a cement board with an air-assisted sprayer with a nozzle of 0.7 mm. A photo of the fabric coating formed taken by a digital camera is shown in FIG. 1b.

Example 2

[0042] 40 grams of an aqueous binder (vinyl acetate/ethylene) emulsion (EcoVAE 1603, ex. Celanesesolid binder content 53 wt %), 50 grams poly(vinyl alcohol)-co-poly(vinyl acetate) aqueous solution with solid content of 10% (GH-23, available from Nippon Gohsei), 4 grams wood fibers with a length smaller than 150 m, 6 grams TiO.sub.2 slurry (solid content 70 wt %), 5 grams CaCO.sub.3, 0.67 grams Coasol 290 (Eastman Chemical Company), 1 gram polypropylene glycol, 1 g Vantex TA 496 (Taminco), 2 grams water, and pigments were mixed at room temperature for 20 minutes. The composition is sprayed on a cement board with an air-assisted sprayer with a nozzle of 1.0 mm. A light microscope image of the coating formed is shown in FIG. 2a.

Example 3

[0043] 40 grams of an aqueous binder emulsion (Acronal Eco 702 ap, ex. BASFsolid binder content 50 wt %), 30 grams poly(vinyl alcohol)-co-poly(vinyl acetate) aqueous solution with solid content of 10% (NH-26, available from Nippon Gohsei), and 2 grams gold pearlescent pigment (Iriodin 9307, Merck) were mixed at room temperature for 20 minutes. The composition is sprayed on a plastic board with an air-assisted sprayer with a nozzle of 0.7 mm. A photo of the fabric coating formed taken by a digital camera is shown in FIG. 1a.