TOPCOAT COMPOSITION, METHOD OF COATING SUBSTRATES WITH THE SAME, AND SUBSTRATE

Abstract

The present invention relates to a flame retardant and iodine stain resistant topcoat composition comprising: a thermoplastic component including one or both of ethylene vinyl acetate resin and chloride vinyl acetate resin; and a radiation curable component including one or more acrylic oligomers and one or more acrylic monomers. The present invention further relates a method of coating at least a portion of a substrate with the topcoat composition and a substrate being at least partially coated with the topcoat composition. The present invention further discloses a flame retardant topcoat composition, comprising an alumina pigment; and a radiation curable component including one or more acrylic oligomers and one or more acrylic monomers.

Claims

1. A high solid content flame retardant and iodine stain resistant radiation curable topcoat composition comprising: (a) a thermoplastic component including one or both of ethylene vinyl acetate resin and chloride vinyl acetate resin; and (b) a radiation curable component including: (b-1) one or more acrylic oligomers; and (b-2) one or more acrylic monomers.

2. The topcoat composition of claim 1, wherein the ethylene vinyl acetate resin or the chloride vinyl acetate has a weight average molecular weight ranging from 5,000 to 50,000.

3. The topcoat composition of claim 1, wherein the ethylene vinyl acetate resin or the chloride vinyl acetate comprises 5-45% of vinyl acetate units in its backbone.

4. The topcoat composition of claim 1, wherein the ethylene vinyl acetate resin or the chloride vinyl acetate is unmodified or modified.

5. The topcoat composition of claim 4, wherein the ethylene vinyl acetate resin is modified with polyvinyl chloride.

6. The topcoat composition of claim 4, wherein the chloride vinyl acetate resin is modified with styrene maleic anhydride.

7. The topcoat composition of claim 1, wherein the radiation curable component further comprises one or more photo initiators.

8. The topcoat composition of claim 1, further comprising: at least one pigment.

9. The topcoat composition of claim 8, wherein the pigment is alumina or silica.

10. The topcoat composition of claim 1, wherein the one or more acrylic monomers comprise isobornyl acrylate and isodecyl acrylate.

11. The topcoat composition of claim 8, comprising, based on the total weight of the topcoat composition: (a) 1-95% by weight of the thermoplastic component; (b) 5-99% by weight of the radiation curable component; and (c) 0-60% by weight of the pigment.

12. A method of coating at least a portion of a substrate comprising the steps of: coating the substrate with the radiation curable topcoat composition in accordance with claim 1; and curing the topcoat composition under UV radiation.

13. A substrate being at least partially coated with the topcoat composition in accordance with claim 1. any one of claims 1 to 11.

14. The substrate of claim 13, wherein the substrate comprises wood.

15. The substrate of claim 13, wherein the substrate comprises plastic.

16. A flame retardant radiation curable topcoat composition, comprising: (a) an alumina pigment; and (b) a radiation curable component comprising: (b-1) one or more acrylic oligomers; and (b-2) one or more acrylic monomers.

17. A substrate comprising the radiation curable topcoat composition of claim 16 applied to at least a portion of the substrate.

Description

EXAMPLES

[0060] The following examples are presented to demonstrate the general principles of the invention. The Examples describe the preparation and test of the high solids content topcoat composition having good iodine stain resistance and flame retardance of the present invention. All amounts as listed are described in parts by total weight, and all percentages as listed are based on weight, unless otherwise indicated. The invention should not be construed as limited to the specific examples presented.

Preparation Examples

[0061] The topcoat compositions 1-6 comprising components as described hereinafter were prepared generally by taking 800 g sample for preparing each topcoat composition. That is, in the preparation of each of those topcoat compositions, acrylic oligomer(s) and acrylic monomer(s) (i.e., the radiation curable component), as well as solvent(s) were added into a 1 L stainless steel container. The mixture was stirred at 600 to 800 rpm with an IKA high speed dispersion equipment (1500 rpm) for 10 min. Then, an EVA and/or a chloride vinyl acetate resin (i.e., the thermoplastic) was added, and the mixture was stirred at 1000-1200 rpm until the thermoplastic was totally dissolved into the radiation curable component to achieve a viscosity of 8000-15000 cps (Brookfield RVT #3 Spindle 20 RPM @25 C.). Next, pigment or pigments were added into the mixture, and stirred at a temperature below 70 C. with a high speed mixer for less than 60 min. Finally, the remaining components of the topcoat composition (including, but not limited to, photo initiator(s), and other monomers, as well as other additive(s), if used, were added, and the mixture was stirred until a homogeneous mixture was formed, thereby producing the desired topcoat composition.

[0062] Here are the topcoat compositions prepared as described above.

Topcoat Composition Example-1:

[0063]

TABLE-US-00001 EVA: DuPont ELVAX 150W 5% VINISOL: lu'ou T32 EVA vinisol resin 10% Acrylic oligomer: PPG URETHANE ACRYLATE 20% Acrylic oligomer: Guangdong Wuxing EA8204 20% Acrylic monomer: isobornyl acrylate (IBOA) 5% Acrylic monomer: isodecyl acrylate (IDA) 15% Solvent: propylene glycol methyl ether acetate (pma) 20% photo initiators: IRGACURE 184-BASF 3% photo initiators: IHT-PI-BP 2%

Topcoat Composition Example-2:

[0064]

TABLE-US-00002 Vinisol: Wacker vinnol E22/48 8% EVA: DuPont ELVAX 150W 8% Acrylic oligomer: ETERNAL 6196-100 10% Acrylic oligomer: Jiangsu Sanmu SM6105-75Y 20% Acrylic oligomer: Guangdong JESIDA DSP-552F 15% Acrylic monomer: trimethylolpropane triacrylate 35% (TMPTA) photo initiators: IRGACURE 1173-BASF 2% photo initiators: IHT-PI TPO 2%

Topcoat Composition Example-3:

[0065]

TABLE-US-00003 EVA: DuPont ELVAX 150W 5% Acrylic oligomer: PPG URETHANE ACRYLATE 34% Acrylic oligomer: Guangdong JESIDA DSP-552F 10% Acrylic monomer: isobornyl acrylate (IBOA) 10% Acrylic monomer: isodecyl acrylate (IDA) 10% AL2O3: MICROGRIT WCA 3S-MICRO 10% ABRASIVES CORPORATION Ground silica: TREMIX958-600EST-SIBELCO 10% Silica matt agent: SYLOID ED 80-GRACE DAVISON 5% photo initiators: IRGACURE 1173-BASF 6%

Topcoat Composition Example-4:

[0066]

TABLE-US-00004 Unmodified vinisol: wacker vinnol E22/48 A 5% modified vinisol: lu'ou T32 EVA vinisol resin 5% Unmodified eva: DuPont ELVAX 150W 5% Solvent: N-BUTYL ACETATE 10% Acrylic oligomer: PPG URETHANE ACRYLATE 10% Acrylic oligomer: Jiangsu Sanmu SM6105-75Y 9.8% Acrylic monomer: trimethylolpropane triacrylate 30% (TMPTA) Acrylic monomer: isobornyl acrylate (IBOA) 5% Silica matt agent: SYLOID ED 80-GRACE 3% DAVISON Al2O3: MICROGRIT WCA 35-MICRO 10% ABRASIVES CORPORATION Ground silica: TEGO AIREX 920-EVONIK 0.2% INDUSTRIES photo initiators: IHT-PI-BP 2% photo initiators: IHT-PI TPO 2% photo initiators: IRGACURE 184-BASF 3%

Topcoat Composition Example-5 Without Photo Initiator:

[0067]

TABLE-US-00005 EVA: DuPont ELVAX 150W 5% Acrylic oligomer: PPG URETHANE ACRYLATE 34% Acrylic oligomer: Guangdong JESIDA DSP-552F 13% Acrylic monomer: isobornyl acrylate (IBOA) 10% Acrylic monomer: isodecyl acrylate (IDA) 13% AL2O3: MICROGRIT WCA 3S-MICRO 10% ABRASIVES CORPORATION Ground silica: TREMIX958-600EST-SIBELCO 10% Silica matt agent: SYLOID ED 80-GRACE DAVISON 5%

[0068] Here are two comparative examples

Comparative Example-1 (Without EVA or Vinisol)

[0069]

TABLE-US-00006 Acrylic oligomer: ALLNEX EB 809 50% Acrylic monomer: Eternal ETERMER 2211 18% Acrylic monomer: MIWON Miramer M130 15% Silica matt agent: SYLOID ED 80-GRACE DAVISON 8% AL2O3: MICROGRIT WCA 3S-MICRO 5% ABRASIVES CORPORATION Pigment: IRGACURE 1173-BASF 2.5% Pigment: IHT-PI-BP 1.5%

[0070] Comparative Example-2 (Using Different Thermoplastic Component)

TABLE-US-00007 Acrylic oligomer: ALLNEX EB 809 15% Acrylic monomer: Eternal ETERMER 2211 35% Acrylic monomer: MIWON MIRAMER M3190 20% thermoplastic component: TEGO ADDBOND LTH 10% Silica matt agent: SYLOID ED 30-GRACE DAVISON 5% Pigment: Sibelco silverBond 602 5% Pigment: IHT-PI TPO 3% Pigment: IRGACURE 184-BASF 2%

Tests

[0071] The topcoat compositions 1-6 as prepared in the aforesaid examples and the aforesaid comparative examples were tested for their respective flame retardance in accordance with the method of EN 13501-1:2007+A1:2009, and for their respective iodine stain resistance in accordance with the method of EN 438-2:2005. The results are listed, respectively, in the Table-1 and Table -2 below.

TABLE-US-00008 TABLE 1 Example No. 1 2 3 4 5 Flame Level B or Level B or Level B or Level B or Level B or Retardance Level C Level C Level C Level C Level C Iodine Stain Rating 4 Rating 5 Rating 5 Rating 5 Rating 5 Resistance

TABLE-US-00009 TABLE 2 Example No. Comparative Comparative Example-1 Example-2 Flame Retardance Level D Level D Iodine Stain Resistance Rating 3 Rating 3
Note 1: Flame Retardance level under EN13501-1:2007+A1:2009:
Level A is the highest, then Level B, Level C, Level D, and so on.
Note 2: Stain rating under EN 438-2:2005 are as follows:
Rating 5: no visible change;
Rating 4: slight change of gloss and/or color, only visible at certain viewing angles;
Rating 3: moderate change of gloss and/or color;
Rating 2: marked change of gloss and/or color; and
Rating 1: surface distortion and/or blistering.

[0072] It can be seen from the above examples and tests that the topcoat compositions of the present invention exhibit good flame retardance and excellent iodine stain resistance, while the comparative compositions do not.

[0073] The particular aspects of this invention have been described above for the purposes of illustration, and it will be evident to those skilled in the art that numerous variations of certain details of the present invention may be made without departing from the invention as defined in the appended claims. It is understood, therefore, that this invention is not limited to the particular aspects disclosed and stated hereinabove, but it is intended to cover modifications that are within the spirit and scope of the invention, as defined by the appended claims.