TWO-COMPONENT AQUEOUS SEALING PRIMER FOR WOOD SUBSTRATE

Abstract

The present application is directed to a two-component waterborne wood sealing primer, including: Component A: a film-forming resin composition including an aqueous epoxy resin emulsion; and Component B: an aqueous curing system including an epoxy reactive curing agent, a filling slurry, and an additional additive; and wherein no organic solvent is added during the preparation process of the two-component waterborne wood sealing primer, and the two-component waterborne wood sealing primer has a solid content during application in the range of 45-50 wt % and a VOC content of 80 g/L or less.

Claims

1. A two-component waterborne wood sealing primer, comprising: Component A: a film-forming resin composition comprising an aqueous epoxy resin emulsion; and Component B: an aqueous curing system comprising an epoxy reactive curing agent, a filling slurry, and an additional additive; and wherein no organic solvent is added during the preparation process of the two-component waterborne wood sealing primer, and the two-component waterborne wood sealing primer has a solid content during application in the range of 45-50 wt % and a VOC content of 80 g/L or less.

2. The two-component waterborne wood sealing primer according to claim 1, wherein the aqueous epoxy resin emulsion has an epoxy equivalent in a range of 150-2000 g/eq.

3. The two-component waterborne wood sealing primer according to claim 1, wherein the film-forming resin composition comprises 100 wt % of aqueous epoxy resin emulsion relative to the total weight of the film-forming resin composition.

4. The two-component waterborne wood sealing primer according to claim 1, wherein the two-component waterborne wood sealing primer has a VOC content of 75 g/L or less.

5. The two-component waterborne wood sealing primer according to claim 1, wherein the aqueous curing system comprises, relative to the total weight of the aqueous curing system, 70-82 wt % of the epoxy reactive curing agent; 18-30 wt % of the filling slurry comprising water, a defoamer, a dispersant, and a filler; and 0-10 wt % of the additional additive comprising one or two of a wetting agent and a leveling agent.

6. The two-component waterborne wood sealing primer according to claim 5, wherein the filler is one or two of zinc stearate and talc.

7. The two-component waterborne wood sealing primer according to claim 5, wherein the filling slurry comprises, relative to the total weight of the filling slurry, 39-44 wt % of water; 0.1-0.5 wt % of the defoamer; 0.5-1 wt % of the dispersant; and 55-60 wt % of the filler.

8. The two-component waterborne wood sealing primer according to claim 1, wherein the epoxy reactive curing agent comprises an aliphatic polyamine, a fatty amine adduct, an amidoamine, an amino polyamide resin, a cycloaliphatic amine, an aromatic amine, an arylamine, a Mannich base, a ketimine, and a dicyandiamide or combinations thereof.

9. A wood article comprising: a wood substrate having at least one major surface; and a sealing primer layer formed from the two-component waterborne wood sealing primer of claim 1 which is directly applied on the major surface.

10. The wood product according to claim 9, wherein the wood substrate is selected from one or more of hardwood, chestnut, eucalyptus, red chestnut, camellia, eucalyptus, Douglas fir, Japanese cedar, American cypress, Japanese red pine, Japanese cypress, water walnut, black walnut, maple, Japan beech, Japanese paulownia, birch, Borneo, magnolia, ash, teak, Xylosma japonicum, Catalpa wood, Dryobalanops spp., fir, oak and rubber wood.

Description

DETAILED DESCRIPTION

[0027] The present application provides a two-component waterborne wood sealing primer, comprising:

[0028] Component A: a film-forming resin composition comprising an aqueous epoxy resin emulsion; and

[0029] Component B: an aqueous curing system comprising an epoxy reactive curing agent, a filling slurry, and an additional additive; and

[0030] wherein no organic solvent is added during the preparation process of the two-component waterborne wood sealing primer, and the two-component waterborne wood sealing primer has a solid content during application in the range of 45-50 wt % and a VOC content of 80 g/L or less.

[0031] Component A: Film-Forming Resin Composition

[0032] The term “film-forming resin composition” herein refers to the resin composition constituting the main body of the coating formed by the two-component waterborne wood sealing primer of the present application, and comprises an aqueous epoxy resin emulsion.

[0033] According to some embodiments of the present application, the aqueous epoxy resin emulsion comprises an epoxy resin having a specific epoxy equivalent. The term “epoxy resin” refers to a polymer or oligomer containing two or more epoxy groups per molecule. Preferably, each molecule in the epoxy resin may contain up to four epoxy groups. Preferably, each molecule in the epoxy resin may contain two or three epoxy groups. According to some embodiments of the present application, the epoxy resin may have an epoxy equivalent that varies within a wide range, wherein the epoxy equivalent refers to the mass of the epoxy resin containing 1 mol of epoxy groups. In the context of the present application, the aqueous epoxy resin emulsion contains an epoxy resin having an epoxy equivalent in a range of 150-2000 g/eq, preferably in a range of 200-1000 g/eq.

[0034] Suitable epoxy resins include, for example, diglycidyl ethers of polyphenols, such as resorcinol diglycidyl ether, catechol diglycidyl ether, hydroquinone diglycidyl ether, diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, diglycidyl ether of bisphenol S, diglycidyl ether of tetramethyl bisphenol; diglycidyl ether of polyhydric alcohols, such as diglycidyl ether of aliphatic glycol, diglycidyl ether of polyether glycols, such as diglycidyl ethers of C.sub.2-24 alkylene glycols, diglycidyl ethers of poly(ethylene oxide) glycols or diglycidyl ethers of poly(propylene oxide) glycols; polyglycidyl ethers of phenolic resins, such as polyglycidyl ethers of phenol-formaldehyde resins, polyglycidyl ethers of alkyl-substituted phenol-formaldehyde resins, polyglycidyl ethers of phenol-hydroxybenzaldehyde resins, or polyglycidyl ether of cresol-hydroxybenzaldehyde resin; or a combination thereof.

[0035] According to certain embodiments of the present application, the epoxy resin is a diglycidyl ether of polyphenol, and particularly preferably has the following structural formula (I):

##STR00001##

wherein, D represents —S—, —SS—, —SO—, —SO2-, —CO2—, —CO—, —O— or a divalent alkyl group having 1 to 10 carbon atoms, preferably 1 to 5 carbon atoms, more preferably 1 to 3 carbon atoms, such as —CH.sub.2— or —C(CH.sub.3).sub.2—;
each Y is independently halogen, such as F, Cl, Br, or I, or an optionally substituted monovalent C.sub.1-C.sub.10 hydrocarbon group, such as optionally substituted methyl, ethyl, vinyl, propyl, allyl or butyl;
each m is independently 0, 1, 2, 3, or 4; and
n is an integer from 0 to 4, such as 0, 1, 2, 3, or 4.

[0036] More preferably, the epoxy resin is a bisphenol A-type epoxy resin, a bisphenol S-type epoxy resin or a bisphenol F-type epoxy resin having the structural formula (I), wherein D represents—C(CH.sub.3).sub.2—, —SO2- or —CH.sub.2—, m represents 0, and n is an integer from 0 to 4.

[0037] Most preferably, the epoxy resin is a bisphenol A-type epoxy resin having the structural formula (I), wherein D each represents—C(CH.sub.3).sub.2—, m represents 0, and n is an integer from 0 to 4.

[0038] The epoxy resin disclosed above can be made, for example, by using epichlorohydrin technology well known to those skilled in the art. Alternatively, as an example of the epoxy resin, any suitable commercially available product can be used, such as E55, E51, E44, E20 available from Shanghai Kaiping Resin Co., Ltd.

[0039] Epoxy resins are used to provide resin components for aqueous epoxy resin emulsions. On the one hand, this resin component acts as an adhesive to provide adhesion between the coating and the substrate, and to keep the various components (such as fillers) in the epoxy resin component together and impart a certain cohesive strength to the paint film. On the other hand, such resin component has good reactivity with the curing agent, thereby obtaining a coating with high mechanical strength.

[0040] As an example of the aqueous epoxy resin emulsion, any suitable commercially available product can be used, such as Allnex 387 from Allnex, 3907 from Huntsman, 900 and 1600 from Nanya, and 484R from Aditya Birla Chemical. Preferably, the aqueous epoxy resin emulsion has a solid content of 45-65% by weight.

[0041] According to an embodiment of the present application, relative to the total weight of the film-forming resin composition, the film-forming resin composition contains 100% of the aqueous epoxy resin emulsion. In other words, the film-forming resin composition consists of an aqueous epoxy resin emulsion.

[0042] Component B: An Aqueous Curing System

[0043] In some embodiments of the present application, the aqueous curing system comprises, relative to the total weight of the aqueous curing system, [0044] 70-82 wt % of the epoxy reactive curing agent; [0045] 18-30 wt % of the filling slurry; and [0046] 0-10 wt % of the additional additive comprising one or two of a wetting agent and a leveling agent.

[0047] In some embodiments of the present application, the filling slurry comprises water, a defoamer, a dispersant and a filler.

[0048] The filling slurry according to the present application may optionally comprise a defoamer to reduce foam in the system. Suitable defoamers include one or more of organosiloxane defoamers, grease defoamers, polyether defoamers and polyether modified silicone defoamers. All types of defoamers are commercially available products. As examples of defoamers, BYK024 available from BYK, TEGO-902W or TEGO-810 available from Tego, Germany can be used.

[0049] The filling slurry according to the present application may optionally comprise a dispersant to improve the dispersibility of the waterborne wood sealing primer. As an example of the dispersant, any dispersant suitable for formulating waterborne wood paint can be used, for example, BYK 190 from BYK and TEGO DISPERS 735W from Tego, Germany can be used.

[0050] The filling slurry according to the present application may optionally comprise fillers. According to the present application, “filler” refers to any volume extender suitable for a two-component waterborne wood primer, which may be inorganic, for example, in the form of particles. There is no particular limitation on the shape of the particles, and they can have any appropriate shape. The average particle size of the filler can vary within a wide range, for example within a range of about 10 nanometers to about 50 microns. Some fillers, in addition to functioning as volume extenders, also impart one or more desired properties to the composition and/or the coating formed from the composition. For example, some fillers can improve the chemical and/or physical properties, especially the mechanical properties of the coating obtained from the composition. In this case, such filler is also called “reinforcing filler”. Suitable fillers may include, for example, zinc stearate, china clay, wollastonite, barite, calcium carbonate, diatomaceous earth, talc, barium sulfate, magnesium aluminum silicate, silicon dioxide, and any combination thereof. Preferably, the filler is one or two of zinc stearate and talc.

[0051] In one embodiment of the present application, the filling slurry comprises, relative to the total weight of the filling slurry, [0052] 39-44 wt % of water; [0053] 0.1-0.5 wt % of the defoamer; [0054] 0.5-1 wt % of the dispersant; and [0055] 55-60 wt % of the filler.

[0056] The filling slurry is prepared separately under high-speed stirring, for example, stirring at a speed of 2000-3000 rpm. Under such high-speed stirring, the uniform dispersion and fineness of each component can be achieved, so that the problem of anti-settling does not need to be considered before mixing with the film-forming resin composition, and the storage stability is better.

[0057] The epoxy reactive curing agent comprises an aliphatic polyamine, a fatty amine adduct, an amidoamine, an amino polyamide resin, a cycloaliphatic amine, an aromatic amine, an arylamine, a Mannich base, a ketimine, and a dicyandiamide or combinations thereof.

[0058] In some embodiments of the present application, the epoxy reactive curing agent is well-known in the art, for example, it is disclosed in “Coating Technology” edited by Liu Dengliang, fourth edition, 2010, No. 275-280, which is incorporated herein by reference to its entirety.

[0059] According to the embodiments of the present application, the weight ratio of the epoxy reactive curing agent to the film-forming resin composition can be adjusted according to actual needs.

[0060] In certain embodiments of the present application, the aqueous curing system may further comprises additional additives commonly used in aqueous epoxy resin primers, and these additives will not adversely affect the coating composition or the cured coating obtained therefrom. Suitable additives include, for example, those that can be used to improve the processability or manufacturability of the composition, enhance composition aesthetics, or improve a particular functional property or characteristic of the coating composition or the cured composition resulting therefrom, such as adhesion to a substrate. Suitable examples of the additive include, such as dispersants, leveling agents, bactericides, antifungal agents, chain extenders, lubricants, biocides, plasticizers, defoamers, vehicles, waxes, antioxidants, adhesion promoters, UV stabilizers, or any combination thereof. Each optional ingredient can be included in a sufficient amount to serve its intended purpose, but preferably not in such an amount to adversely affect the coating composition or cured coating obtained therefrom. In a preferred embodiment of the present application, suitable additional additives include dispersants, wetting agents, leveling agents, or any combination thereof.

[0061] The dispersant is an agent used to assist the dispersion of the epoxy resin in an aqueous medium. Suitable dispersants may include ionic dispersing agents, non-ionic dispersing agents, or multifunctional dispersing agents. As examples of commercially available dispersing agents, Dispers 715 W, Dispers 740W, Dispers 760W, Disperbyk 194 from Tego, Germany, and BYK 190 from BYK can be used.

[0062] The leveling agent is an agent that can promote the film-forming resin composition to form a flat, smooth and uniform coating film during the film-forming process. Suitable leveling agents include polysiloxane leveling agents, polyacrylic leveling agents or any combination thereof. As an example of a commercially available leveling agent, BYK420 available from BYK Company in Germany can be used.

[0063] The aqueous curing system according to the present application may optionally include a wetting agent to improve the wettability of the substrate. Suitable wetting agents may include one or more of anionic wetting agents, cationic wetting agents, non-ionic wetting agents, and amphoteric wetting agents. All types of wetting agents are commercially available products, and BYK3455 available from BYK and 104-BC available from SURFYNOL can be used.

[0064] The content of each optional ingredient is sufficient to achieve the intended purpose, but preferably, such content does not adversely affect the aqueous curing system or the cured coating obtained therefrom. According to some embodiments of the present application, the total amount of additional additives is in the range of about 0-10 wt %, preferably in the range of about 0.5-2 wt %, relative to the total weight of the aqueous curing system.

[0065] Since no organic solvents such as cosolvents and coalescing agents are used, in some embodiments of the present application, the obtained two-component waterborne wood sealing primer has a VOC content of 80 g/L or lower, preferably a VOC content of 75 g/L or lower, more preferably a VOC content of 70 g/L or lower.

[0066] During the formulation of the two-component waterborne wood sealing primer according to the present application, the aqueous curing system containing epoxy reactive curing agent, the filling slurry and additional additives is combined with the film-forming resin composition. A synergistic effect is produced therebetween, so the waterborne wood sealing paint thus obtained has suitable viscosity, higher solid content during application and excellent sealing performance, thus during application the waterborne wood sealing primer of the present application can be used after being diluted by adding 0-10 wt % of water relative to the total weight of the waterborne wood sealing primer. Preferably, the waterborne wood sealing paint according to the present application can be used after being diluted by adding 0-5 wt % of water relative to the total weight of the waterborne wood sealing paint during application. More preferably, the waterborne wood sealing primer according to the present application can be used without adding water for dilution during application. Therefore, the waterborne wood sealing primer according to the present application has a higher solid content during application. In one embodiment of the present application, the waterborne wood sealing primer has a solid content of 40 wt % or higher, preferably a solid content in the range of 45 wt % to 50 wt %. In this embodiment, the waterborne wood sealing primer has a solid content during application of 40 wt % or higher, preferably a solid content during application in the range of 45 wt % to 50 wt %.

[0067] According to some embodiments of the present application, the two-component waterborne wood sealing primer can be prepared by mixing the epoxy reactive curing agent, the additional additives, and the filling slurry to obtain an aqueous curing system, and then the film-forming resin composition and the aqueous curing system are simply mixed in a mixing device at a predetermined weight ratio. The mixed waterborne wood sealing primer can be applied using various methods familiar to those skilled in the art, including spraying (for example, air-assisted, airless or electrostatic spraying), brushing, roller coating, overflow coating, and dipping. In one embodiment of the present application, the mixed wood sealing primer is applied by spraying. Epoxy resin primer can be applied to various wet film thicknesses. In an embodiment of the present application, the wet film thickness preferably provides a dry film thickness of about 45 to about 200 μm, and more preferably about 45 to about 100 μm. The applied coating can be cured by air-drying or by using various drying devices (for example, an oven) familiar to those skilled in the art to accelerate the curing. The preferred heating temperature for curing the epoxy resin primer is from about 25° C. to about 80° C., and more preferably from about 25° C. to about 55° C., and the preferred heating time is at least three minutes to less than 60 minutes, less than 45 minutes, or less than 40 minutes. The heating time will tend to decrease with the increase of temperature or airflow.

[0068] Wood Article

[0069] Another aspect of the present application provides a wood article, which comprises: a wood substrate having at least one major surface; and a sealing primer layer formed by the two-component waterborne wood sealing primer according to the present application which is directly coated on the major surface.

[0070] As the wood substrate used to manufacture the wood article of the present application, any suitable wood substrate known in the art can be used. In the present application, the term “wood substrate” refers to any cellulose/lignin material derived from the hard, fibrous structural organization of the stems and roots of trees or other woody plants. Wood includes, for example, hardwood and softwood wood cut directly from trees, and engineered wood composite materials made of wood strips, wood chips, wood fibers, or wood veneers. Examples of wood composite materials include, but are not limited to, plywood, oriented strand board (OSB), medium density fiberboard (MDF), particle board, and the like.

[0071] The wood article of the present application comprises a wood substrate containing an acidic substance. As an example, the acidic substance includes tannins, aldehydes and/or hemiacetals. In some embodiments of the present application, the wood substrate has a tannin content of at least 0.1% by weight, preferably a tannin content of at least 1% by weight, more preferably a tannin content of at least 5% by weight, and even more preferably a tannin content of at least 10% by weight, even more preferably a tannin content of 30% by weight, as determined by CNS4716-2005. As exemplary wood substrates, hardwood, chestnut, eucalyptus, red chestnut, camellia, eucalyptus, Douglas fir, Japanese cedar, American cypress, Japanese red pine, Japanese cypress, water walnut, black walnut, maple, Japan beech, Japanese paulownia, birch, Borneo, magnolia, ash, teak, Xylosma japonicum, Catalpa wood, Dryobalanops spp., fir, oak and rubber wood.

[0072] According to the present application, the wood substrate has at least one, preferably two major surfaces facing each other. As used herein, the “major surface” is the surface for decoration formed by the length and width dimensions of the wood substrate.

[0073] According to the present application, the wood article can be prepared, for example, by the following steps: (1) providing a polished wood substrate; (2) using a coating and curing process to sequentially coat the wood substrate and form one or more of two-component waterborne wood sealing primer layers of the present application, to provide the wood substrate with the required sealing performance.

[0074] According to the present application, the wood articles thus obtained can be used in the following applications, including, but not limited to: household furniture, such as tables, chairs, cabinets, etc.; bedroom and bathroom furniture; office furniture; custom furniture, such as school and children's furniture, hospitals furniture, restaurant and hotel furniture, kitchen cabinets and furniture; panels for interior design; indoor and outdoor windows and doors; indoor and outdoor window and door frames; outdoor and indoor wall panels and wooden floors.

[0075] The present disclosure is more particularly described in the following examples that are intended as illustrations only, since numerous modifications and variations within the scope of the present disclosure will be apparent to those skilled in the art. Unless otherwise noted, all parts, percentages, and ratios reported in the following examples are on a weight basis, and all reagents used in the examples are commercially available and used directly without further treatment.

Examples

[0076] Testing Methods

[0077] Viscosity during application: as required, a certain amount of water was used to dilute the sample to be tested, and then an Iwata 2# cup was used to test its viscosity.

[0078] Solid content: The amount of remaining components after the sample was baked in an atmospheric oven at 150° C. for 1 hour was measured to determine the solid content.

[0079] Solid content during application: a certain amount of water was used to dilute the sample to be tested, and then the sample to be tested was measured according to the test method used to test the solid content.

[0080] VOC content was measured according to the standard HJ2537-2014.

[0081] Storage stability was measured according to the standard GB/T23999-2009.

[0082] Sandability was measured according to the standard GB/T23999-2009.

[0083] Application performance: manual judgments was made based on whether the gun was blocked during spraying, atomization effect, wetting effect and leveling after spraying.

[0084] Sealing property: a “hot steaming method” was used to apply the sealing primer on the wood substrate, to apply a white topcoat on top of the sealing primer layer, and then the sample was put in hot steam for 48 hours to observe whether the topcoat was colored, i.e. whether the color and oil quality of the wood substrate had penetrated the sealing primer layer or not.

[0085] Preparation of Two-Component Waterborne Wood Sealing Primer

[0086] First, according to the amounts shown in Table 1, the defoamer, dispersant, filler and water were pre-mixed, then grinded and dispersed with a grinder at high speed (about 2400-2800 rpm) to obtain a uniform system to prepare a filling slurry.

TABLE-US-00001 TABLE 1 Raw materials Weight percentage (wt %) Water 40 Defoamer 0.3 Dispersant 0.7 Filler (tal, zinc stearate) 59

[0087] Then, according to the amounts shown in Table 2, the system was mixed with a commercially available epoxy-reactive curing agent and additional additives to obtain an aqueous curing system as Component B. Then a commercially available 100% aqueous epoxy resin emulsion was used as Component A. Then, the obtained Component A and Component B were mixed to form the two-component waterborne wood sealing primer of Example 1-2. The comparative example did not contain any filling slurry, and was prepared according to the components shown in Table 2.

TABLE-US-00002 TABLE 2 Comparative Example 1 Example 2 Example Raw materials (wt %) (wt %) (wt %) Component Aqueous epoxy 100 100 80 A resin emulsion Defoamer / / 0.3 Dispersant / / 0.8 Filler (talc, zinc / / 10 stearate) Additional additives / / 5.7 (wetting agent, leveling agent, anti-settling agent, etc.) Cosolvent / / 1 (propylene Glycol Methyl Ether) Coalescing agent / / 1 (diethylene glycol monobutyl ether) Rheological / / 0.2 additives (PUR 40, MÜNZING, Germany) Water / / 1 Component Epoxy reactive 75 80 100 B curing agent Filling slurry 23.1 18.1 / Wetting agent 0.9 0.9 / Water 1 1 / Weight ratio of Component 100:55 100:52 100:33 A to Component B Performance Solid content during 49% 48% 47% application Viscosity during 55 s 55 s 55 s application VOC content (g/L) 73 75.2 109 Storage stability 5 5 3 Activation period 3 h 3 h 2 h Sandability 4 3 4 Application 5 5 3 performance Sealing property 5 5 5

[0088] Then, the performance of the two-component waterborne wood sealing primers of Examples 1-2 and Comparative Examples was tested, including solid content during application, viscosity during application, VOC content, storage stability, pot life, sandability, application performance and sealing property, The results are shown in Table 2. Among them, storage stability, sandability, application performance and sealing property were evaluated on a scale of 1-5, with 1 being the worst and 5 being the best.

[0089] It can be seen from the results in Table 2 that the aqueous curing system containing epoxy reactive curing agent, filling slurry and additional additives was combined with the film-forming resin composition, and they undergone a chemical crosslinking reaction to form a dense paint film having high mechanical properties, the resulting sealed primer coating had good sealing properties, efficient filling effect and good anti-collapse properties; at the same time, the addition of a filling slurry into the curing agent solved the problem of storage stability (it was easy to stratify in the emulsion to form a hard precipitate), and simplified the production process, reduced the production cost, and shortened the production cycle. In addition, since the system according to the present application did not use any organic solvents such as cosolvents and coalescing agents, the obtained two-component waterborne wood sealing primer had a VOC content of 80 g/L or lower.

[0090] While the invention has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the invention as disclosed herein.