Water-based coating compositions and systems with improved sag resistance and related methods

a coating composition and water-based technology, applied in the direction of drying machines, process and machine control, drying machines, etc., can solve the problems of increasing operating costs, adversely affecting the appearance of painted containers, and typically not cost-effective to extend the length of the drying chamber or significantly increase the air flow capacity of the system. , to achieve the effect of increasing the level of cas agents, increasing the viscosity, and increasing the drying tim

Inactive Publication Date: 2013-05-02
VALSPAR SOURCING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0022]Increasing the levels of CAS agents beyond conventional levels for use in a humid drying environment can be counterintuitive for several reasons. For example, conventional wisdom holds that the viscosity will increase when excessive amounts of CAS agents are used to a degree such that the release of water from the composition may be inhibited and the dry time will thereby be undesirably increased. As yet another example, increasing the levels of CAS agents beyond conventional levels (e.g., above one pound of CAS agent per 100 pounds (0.12 kg of CAS agents per 100 L) of aqueous coating composition) is counterintuitive because hydrophilic clay-based materials are hygroscopic and they may further inhibit the release of water from the composition and thereby increase dry time to an undue degree.
[0023]Surprisingly, increasing the level of CAS agents beyond conventional levels prevents undue sagging in a humid environment, yet allows water to be released from the coating and does not impact dry time to an undue degree.
[0024]In addition to controlling sag resistance using specific agents or thickeners, it is possible to improve sag resistance of the primer composition using other types of thickeners or rheology agents, if the system used to apply and dry / cure the coating includes measures to control humidity. By controlling the humidity conditions in the spray booth when the coating is applied, and in the oven during drying / cure of the coating, a wet film of the coating is allowed to dry uniformly in a way that eliminates problems associated with sag caused by high humidity environments (i.e. the shear forces acting on a wet film applied to a vertically positioned substrate).

Problems solved by technology

If a conventional drying chamber is used to dry shipping containers to which a water-based paint has been applied, the paint on the container does not adequately dry in a reasonable amount of time, which increases operating costs and adversely affects the appearance of the painted container.
It is typically not cost-effective to extend the length of the drying chamber or significantly increase the air flow capacity of the system that applies the heated air to the drying chamber.

Method used

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  • Water-based coating compositions and systems with improved sag resistance and related methods
  • Water-based coating compositions and systems with improved sag resistance and related methods
  • Water-based coating compositions and systems with improved sag resistance and related methods

Examples

Experimental program
Comparison scheme
Effect test

example 1a

[0169]The following ingredients are charged to a high speed mixing vessel. All listed amounts are parts by weight unless otherwise noted.

TABLE 1ARaw materialVendorRun 1Run 2Run 3A1PO3Various6.056.05Ammonium Ashland0.00260.00260.0026HydroxideBentone LTElementis0.0860.0860.086BYK 024BYK0.130.130.13BYK 155BYK0.520.520.52Dynol 604Air Products0.170.170.17Epi-rez 3510Hexion3.4EB solventEastman 1.441.441.44ChemicalsMonolite Heubauch0.850.850.85carbonblackPluronic F87 BASF5.15.15.1(30%)in WaterShieldexGrace6.05Sodium nitrite Shiwu0.810.810.81(10%)in waterSurfynol 104Air Products0.460.460.46TalcSpecialty 20.3720.3720.37MineralsTexanolEastman 0.09370.09370.0937ChemicalsWater15.4110.610.6

[0170]The mixture is dispersed at high speed to a grind of 5-6 Hegman, then letdown with the following mixture of Table 1b. In some modes of practice, it may be desirable to pre-disperse the Bentone LT material in a portion of the water.

TABLE 1BAmmonium HydroxidepH control0.160.160.16Haloflex 202DSM Neoresins4...

example 1b

[0173]The procedure of Example 1A, Run 3 is followed except that the Epi-rez 3510 epoxy resin is added with the ingredients of Table 1c instead of with the ingredients of Table 1a.

example 2

Waterborne Topcoat Formulations

[0174]The following ingredients are charged to a high speed mixing vessel. All listed amounts are parts by weight unless otherwise noted.

TABLE 2ARaw materialVendorRun 1Run 2Aerosil 200Evonik0.40.4ASP 170BASF11.611.6Cimbar ExCimbar11.611.6Disperbyk 190 BYK1.21.2EB SolventEastman0.90.9ChemicalsFoamaster SA-3Cognis0.30.3Red OxideChemik1.8Tiona 595Cristal0.55Water4.34.3Yellow OxideChemik2.6

[0175]The mixture is dispersed at high speed to a grind of 6.5 Hegman, then letdown with the following mixture of Table 2b.

TABLE 2BAcrysol RM-8WRohm & Haas1.41.4Ammonium HydroxideAshland0.50.5EPS2568E.P.S.43.343.3Foamaster SA-3Cognis0.40.4TexanolEastman2.22.2ChemicalsWater1716.9

[0176]The top coat of Run 1 has relatively high pigment to binder ratio and is a brown color. The top coat of Run 2 had relatively high pigment to binder ratio and is a white color.

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Abstract

The present invention provides a water-based coating and/or coating system that can be used to form sag resistant wet layers or coatings on a wide range of substrates. The coating system is particularly effective for protecting metal-containing substrates, such as intermodal cargo containers, against corrosion. As an overview, the present invention provides water-based compositions suitable to form primer coats on substrates. Desirably, the primer incorporates a high level of one or more CAS agents for excellent sag resistance while drying in a broad range of relative humidity environments. Alternatively, modifications can be made to control temperature and humidity during spray application and drying as a way to increase sag resistance of the coating.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)[0001]This application is a continuation of PCT Application No. PCT / US2011 / 057010, filed 20 Oct. 2011, which claims priority to U.S. Provisional Application Ser. No. 61 / 450,481, filed 8 Mar. 2011.FIELD OF THE INVENTION[0002]The present invention relates to water-based coating systems and methods used to form protective coatings on substrates and in particular metal containing substrates. More particularly, the present invention relates to coating compositions, methods, and coating systems involving an aqueous coating composition. These coatings are typically used as a primer coat (also referred to as a base coat) or as a direct-to-metal coat (“DTM”), wherein the aqueous coating composition preferably has a sufficiently high loading of one or more clay anti-sag agents (hereinafter “CAS agents”), and / or the coating is applied in a controlled humidity environment, to promote enhanced performance of the resultant coatings with respect to sag resi...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B65D88/12B65D90/02
CPCB65D88/121B05D3/0486C09D7/002C09D5/04C09D5/024B05D2520/00B05D7/14B05D7/227B05D1/02C09D127/08B05D2504/00C08K3/346C08L63/00B05D3/0413C09D7/43B05B12/085Y02P20/141B05D1/00B65D1/22B65D25/14B65D25/34B05D2401/20F26B15/16B65D23/02B05D3/12B65D23/08B05D7/56B65D7/06F26B2210/12F26B21/006B65D90/02B65D88/123B05D3/007G05D7/0688
Inventor BEAUDRY, CHANNING C.NOWACK, WILLIAM C.PREVOST, JAMES A.ZHANG, FENG
Owner VALSPAR SOURCING INC
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