Aqueous coating composition for reducing airborne contaminants

Abstract

An aqueous coating composition comprising a binder, a pigment, and a formaldehyde purifying urea compound; the coating composition is free of amine-based catalysts, and the urea compound is at least 1% by weight of the composition. When applied to a substrate, the coating composition absorbs formaldehyde and other air contaminants from passing air.

Description

[0001] References to earlier filed applications

[0002] This application claims priority to U.S. patent application No. 17 / 735,553, filed on May 3, 2022, the entire contents of which are incorporated herein by reference. Background Art

[0003] Individuals spend a great deal of time indoors, in homes, commercial spaces, and other public indoor areas. However, indoor air can sometimes contain pollutants from a variety of sources, including cleaning agents, combustion gases, cooking fumes, emissions from structural components (such as wood composites, flooring, carpets, and adhesives), and pollutants from occupants (such as personal care products and skin products). Recently, building practices have reduced the amount of outdoor air introduced into indoor spaces, preferring recirculated air to save energy costs. Therefore, the demand for solutions to improve indoor air quality has increased.

[0004] Indoor air pollutants can take many forms. These include VOCs (volatile organic compounds), such as formaldehyde; combustion byproducts, such as nitrogen oxides (NOx), sulfur oxides (SOx), and carbon monoxide (CO); ozone; radon, a naturally occurring carcinogenic gas from soil; particulates, such as tobacco smoke; and noxious and harmless odors from personal care products and food preparations.

[0005] Despite being identified as carcinogenic by the World Health Organization in 2004, formaldehyde is still widely used in many building materials such as particleboard, MDF, plywood, wood-based panels, adhesives, wallpaper and flooring. Formaldehyde can be released from such materials over long periods of time, many years.

[0006] Architectural paints and coatings are widely used to protect and decorate walls. The widespread use of architectural paints and other coatings in construction and building applications makes them particularly suitable for capturing and removing airborne pollutants such as formaldehyde in indoor spaces. Therefore, there is a need for coating compositions that can remove airborne formaldehyde and other pollutants. Summary of the invention

[0007] In a first aspect, an aqueous coating composition is disclosed that includes an aqueous carrier liquid, a polymeric binder, one or more additives, and a formaldehyde-scavenging urea compound.

[0008] The present invention may be combined with one or more optional additional features, either alone or in combination with any other additional features: wherein the coating composition is substantially free of an amine-based catalyst; wherein the amine-based catalyst is triethylenediamine; wherein the urea composition is present in an amount of at least 0.2 wt. % based on the weight of the aqueous coating composition; wherein the urea composition is present in an amount of at least 0.5 wt. % based on the weight of the aqueous coating composition; wherein the urea composition is present in an amount of at least 1.0 wt. % based on the weight of the aqueous coating composition; wherein the urea composition is present in an amount of up to 1.5 wt. % based on the weight of the aqueous coating composition; wherein the urea composition is present in an amount of up to 2.0 wt. % based on the weight of the aqueous coating composition; wherein the urea composition is present in an amount of up to 3.0 wt. % based on the weight of the aqueous coating composition.

[0009] Other optional additional features of the present invention that may be combined alone or in combination include the following: wherein the urea compound is urea; wherein the coating composition further comprises a pigment; wherein the coating composition has a VOC of less than 150 g / L; wherein the coating composition has a VOC of less than 100 g / L; wherein the coating composition has a VOC of less than 50 g / L; wherein the coating composition is substantially free of VOC; wherein the coating composition further comprises a surfactant; wherein the surfactant is a phosphate ester surfactant; wherein the coating composition is substantially free of alkylphenol ethoxylate surfactants; wherein the surfactant is a defoamer; wherein the aqueous coating composition further comprises at least one of a coalescing agent, a rheology modifier, a filler, an extender, a biocide, or a UV stabilizer; and / or wherein the coating composition has a pigment volume concentration (PVC) of about 25 to about 75.

[0010] Other optional additional features of the present invention that may be combined alone or in combination include the following: wherein the polymer binder comprises at least one of a (meth)acrylic latex, a vinyl acrylic latex, or a styrene acrylic latex; wherein at least one of the (meth)acrylic latex, the vinyl acrylic latex, or the styrene acrylic latex is formed from reactants comprising a seed latex; and / or wherein the polymer binder comprises a polyurethane.

[0011] In a second aspect, a coated article is disclosed that includes a substrate and a coating on the substrate, wherein the coating includes at least one layer formed from the aqueous coating composition of the present invention.

[0012] Other optional additional features of the present invention that may be combined alone or in combination include the following: wherein the substrate is drywall or comprises drywall; wherein the substrate is wood; wherein the substrate is brick or comprises brick; wherein the substrate is gypsum or comprises gypsum; wherein the substrate is cementitious fiberboard or comprises cementitious fiberboard; wherein the substrate is stucco or comprises stucco; wherein the substrate is vinyl siding or comprises vinyl siding, and / or wherein the substrate is cement or comprises cement.

[0013] In a third aspect, a coating formed from the aqueous coating composition of the present invention is disclosed.

[0014] In a fourth aspect, disclosed is a method of coating a substrate with a coating formed from the aqueous coating composition of the present invention.

[0015] In a fifth aspect, a method for reducing formaldehyde is disclosed comprising removing formaldehyde from air using the coated article of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 shows microscopic images of a coating composition of the present invention and a control coating composition applied to a substrate and cured.

[0017] definition

[0018] "Latex" polymer means a dispersion or emulsion of polymer particles formed in the presence of water and one or more dispersants or emulsifiers (e.g., surfactants, alkali-soluble polymers, or mixtures thereof), which need to be present to form the dispersion or emulsion. After the polymer is formed, the dispersant or emulsifier is typically separated from the polymer. In some methods, the reactive dispersant or emulsifier may become part of the polymer particles when formed.

[0019] The recitation of numerical ranges using endpoints includes all numbers subsumed within that range (eg, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0020] "A", "an", "the", "at least one", and "one or more" are used interchangeably. Thus, for example, an aqueous coating composition comprising "an" additive means that the aqueous coating composition comprises "one or more" additives.

[0021] The terms "comprises" and variations thereof do not have a limiting meaning when they appear in the description and claims.

[0022] The term "(meth)acrylic acid" includes either or both of acrylic acid and methacrylic acid, and the term "(meth)acrylate" includes either or both of acrylate and methacrylate.

[0023] When the terms "free of," "not containing," "does not include," "does not include any," and similar phrases are used herein, such phrases are not intended to exclude the presence of trace amounts of related structures or compounds that may be present but not intentionally used, for example due to the presence of environmental contaminants.

[0024] The term "substantially free" means that the composition does not include any identified compound as a component intentionally added to the composition.

[0025] Test Method

[0026] Volatile organic compounds ("VOCs") are defined by the regulations of the United States Environmental Protection Agency as any carbon compound other than carbon monoxide, carbon dioxide, carbonic acid, metal carbides or carbonates, and ammonium carbonate, that participates in atmospheric photochemical reactions, other than the exempt compounds identified in 40 CFR 51.100. The amount of VOC present in the composition can be measured by gas chromatography via ASTM D6886-18, entitled "Standard Test Method for Determination of the Weight Percent of Individual Volatile Organic Compounds in Waterborne Air-Dry Coatings by Gas Chromatography". The amount of VOC is reported in grams per liter less exempt compounds (g / L).

[0027] Formaldehyde scavenging is a measure of the ability of a coating to capture formaldehyde from passing air. Formaldehyde scavenging is measured by the Formaldehyde Scavenging HPLC Test. In the Formaldehyde Scavenging HPLC Test, a small, measured amount of coating is sealed in a vial with a known amount of formaldehyde vapor. After equilibration for 24 hours, the amount of formaldehyde remaining in the vial is measured and compared to a control vial containing the same amount of formaldehyde vapor but without the coating. The specific steps of the test are as follows:

[0028] a) Part A: Generation of Standard Solutions. Seven standard solutions were prepared by mixing the following amounts of formaldehyde and acetonitrile carrier in a 2 mL HPLC autosampler vial in the following amounts (μL formaldehyde: mL acetonitrile): 5:1, 7:1, 10:1, 15:1, 20:1, 25:1, 5:2 to produce solutions containing the following concentrations (ppm) of formaldehyde, respectively: 1841, 2572, 3663, 5468,

[0029] 7255, 9024, 923. Three μL from each vial was then injected into a 20 mL vial and purged with nitrogen according to the method described in Part B, and the formaldehyde content was measured by the indicated HPLC conditions. A calibration curve was generated to correlate the area under the HPLC peak with the formaldehyde concentration in the headspace.

[0030] b) Part B: Nitrogen Purge and HPLC Measurement: The amount of formaldehyde in the headspace of the vials was measured by purging the headspace of each vial with nitrogen (using a double needle layout to pierce the vial septum) for 3 minutes, and then the nitrogen was flowed through a second sealed vial containing a 2,4-dinitrophenylhydrazine (DNPH) cartridge. Prior to testing, the DNPH cartridges were purchased and stored individually in an airtight sleeve in a refrigerator and then warmed to room temperature prior to testing. Any formaldehyde in the nitrogen reacted to form formaldehyde 2,4-dinitrophenylhydrazone (DNPH-FA). After the 3 minute nitrogen purge, the DNPH cartridge was removed from the vial and washed with 4 mL of acetonitrile into a clean 20 mL glass vial. The acetonitrile wash containing the DNPH-FA was then sealed using a septum and 1 mL of the solution was transferred to an autosampler vial. HPLC was run on the samples according to the following conditions:

[0031] ●Column: ODS Hypersil 5μm 200mm×4.6mm;

[0032] ●Protective parts: ODS Hypersil 5μm 10mm×4mm;

[0033] Flow rate: 1 mL / min

[0034] ●Mobile phase: 50% water, 50% acetonitrile;

[0035] Injection volume: 20 μL;

[0036] ●Column temperature: room temperature;

[0037] ● Column pressure: 60 bar;

[0038] UV detector: 365nm;

[0039] ●Retention time of DNPH-FA derivative: 6.5 minutes;

[0040] ●Running time: 10 minutes.

[0041] c) Part C: Coating composition sample preparation and measurement: The coating composition is applied to release paper using a 4 mil scraper and allowed to dry in air at room temperature for two days. A 6 mm circular coated release paper is obtained using a hole opener. The coated film is peeled off from the release paper and weighed. 7 standard solutions of formaldehyde are injected into a vial using an automatic analytical syringe, 3 μL each and 3 μL acetonitrile blank. One circle is added to each of 8 small (e.g., 20 mL) sealed vials and allowed to balance for 24 hours. The amount of formaldehyde in the headspace is then measured by the above-mentioned nitrogen purge and HPLC conditions, and the formaldehyde content is reported in ng / mL based on the calibration curve.

[0042] d) Part D: Analysis The difference between the headspace formaldehyde concentrations in the 7 standards and the 7 samples was then calculated and reported.

[0043] Washability refers to the relative ease with which soil, dirt, discoloration, etc., can be removed from a dry film applied to a substrate surface (usually an interior architectural surface such as a wall). Soil or dirt is typically removed by washing with an abrasive and / or non-abrasive cleaning composition. To measure washability, the standard test method ASTM D3450-00 (Standard Test Method for Washability Properties of Interior Architectural Coatings) is used.

[0044] Scrub or scrub resistance refers to the ability of the surface of a coating or paint film to resist wear or maintain its original appearance when rubbed with or against an abrasive surface, typically during cleaning. Scrub resistance can be evaluated by ASTM D2486-17 (Standard Test Method for Scrub Resistance of Wall Paints).

[0045] Finish refers to the ability of a coating to maintain its gloss value after being subjected to mechanical forces such as abrasion. Finish can be measured by ASTM D6736-08.

[0046] Blocking refers to the tendency or ability of a coating or paint film to adhere to itself after application and curing. Blocking can be measured by ASTM D4946-89 (2017), which is titled "Standard Test Method for Blocking Resistance of Architectural Paints". DETAILED DESCRIPTION

[0047] The coating compositions of the present invention contain an aqueous carrier liquid, a polymeric binder, and a formaldehyde scavenging urea compound. In some methods, the coating compositions of the present invention do not require and are substantially free of amine-based catalysts, such as triethylenediamine, for accelerating formaldehyde absorption.

[0048] The compounds of the present invention having urea functionality have the following structure:

[0049]

[0050] Wherein R1, R2, R3 and R4 are identical or different, and comprise straight or branched alkyl group, aromatic group, straight or branched alcohol or hydrogen.Compound with urea functional group is preferably urea, 2-hydroxyethyl urea, bis(hydroxymethyl) urea or their combination.In some methods, urea compound is present in coating composition with the total weight of component in coating composition at least 0.2 weight %, or preferably at least 0.5 weight %, 1.0 weight %, 1.5 weight %, 2.0 weight % or 2.5 weight % concentration based on the total weight of component in coating composition.In some methods, urea compound is present in coating composition with the total weight of component in coating composition at most 3.0 weight %, preferably at most 2.0 weight % based on the total weight of component in coating composition, or even more preferably at most 1.0 weight % concentration based on the total weight of component in coating composition.Including urea compound in coating composition makes coating can surprisingly remove formaldehyde and other pollutants from passing air and trap such pollutants in coating, without comprising amine-based absorption catalyst such as diethylenetriamine.

[0051] Without being bound by theory, it is believed that formaldehyde passing through the air is absorbed into the coating formed from the coating composition where it reacts with the urea compound to produce monomethyl urea, which then polymerizes via a condensation reaction to form a urea-formaldehyde resin as shown in the following reaction mechanism, thereby producing a compound that is stable and entrained in the coating.

[0052]

[0053] The non-gaseous urea-formaldehyde reaction product is thus trapped in the coating, thereby removing formaldehyde from the passing air. It is also believed that the excess urea in the coating relative to the amount of passing formaldehyde drives the production of urea-formaldehyde resin, which promotes further absorption of formaldehyde from the passing air.

[0054] Conventional solutions to reduce formaldehyde through coatings rely on including a binder in the coating that contains monomers believed to react with formaldehyde. For example, Formashield (R) Sold as a binder in paints that "actively and reversibly removes formaldehyde from ambient air...". While conventional solutions can provide some formaldehyde reduction from passing air, the formaldehyde absorption capacity of such solutions tends to be limited at higher concentrations of formaldehyde. In other words, the amount of formaldehyde that can be reduced by these conventional solutions tends to be limited to an upper limit above which no additional formaldehyde will be reduced from passing air.

[0055] In contrast, the formaldehyde absorption of the present invention is surprisingly not limited to higher concentrations. While not wishing to be bound by theory, it is believed that the inclusion of relatively abundant urea compounds relative to the formaldehyde passing through allows the formaldehyde absorption of the coating composition of the present invention to be substantially unconstrained by the stoichiometry of the formaldehyde-reactive compounds in the coating composition. As an additional benefit, some of the urea compounds in the present invention are relatively simple organic molecules, as opposed to the more complex molecules required as monomers in conventional solutions.

[0056] Furthermore, in contrast to prior art solutions, coatings formed from the aqueous coating compositions of the present invention in some processes surprisingly do not require amine-based absorption catalysts to accelerate absorption of passing contaminants into the coating, and are therefore substantially free of absorption catalysts comprising amine structural units, such as triethylenediamine.

[0057] The coating compositions of the present invention may include, for example, paints, clearcoats, stains, aerosols, sealant formulations, and the like.

[0058] In some embodiments, the present invention includes a method for preparing a coating composition. Typically, one or more aqueous resins are combined and blended to form a binder, and the coating composition is prepared by further adding a liquid, an additive, and any other diluent to dilute the binder. Conventional preparation methods typically involve four or more stages, which include a pre-dilution stage, a grinding stage, a washing stage, and a dilution stage. In the pre-dilution stage, one or a binder resin can be mixed with a liquid in a dilution tank. Low shear mixing can be applied in the dilution tank to form a pre-dilution mixture. In the grinding stage, pigments and other additives that will not be homogenized under low shear mixing can be dispersed into a carrier liquid under high shear conditions. The grinding stage can be carried out in a high shear mixing device such as a mill. The high shear applied in the grinding stage breaks the agglomerates of particles and the wet particles with liquid. The composition of the liquid added when diluting the ground material can be the same or different from the composition of the carrier liquid used when preparing the ground material. Next, in the washing stage, the washing liquid (which can have a composition that is the same or different from the composition of the carrier liquid) can be pumped into the high shear mixing device to move the grinding slurry to the dilution tank. Finally, in the dilution stage, the mill slurry, carrier liquid, wash liquid, and pre-dilution mixture may be blended together under low shear conditions in a dilution tank. In this stage, the coating composition concentrate may be further diluted by the addition of further liquid, which may have the same composition as the carrier liquid or a different composition. The process may employ these conventional stages, or the coating composition may be prepared by other suitable methods. For example, the process may employ a continuous preparation using component slurries.

[0059] In the present invention, the urea compound can be added alone or together with another liquid or solid component at any stage of the process. The urea compound is preferably added alone to the grind in the grinding stage, but can also be mixed with a liquid before adding to the grind. The urea compound can be added to the liquid or binder resin in the dilution stage, or added alone to the mixture in the dilution stage. The urea compound can be added alone or together with a liquid in the washing stage.

[0060] The aqueous coating composition of the present invention also includes a polymer binder and a carrier. In some methods, the aqueous coating composition may include at least 20 wt %, at least 25 wt %, or at least 30 wt % of the polymer binder based on the total weight of the coating composition. In some methods, the aqueous coating composition may include up to 45 wt %, up to 40 wt %, or up to 35 wt % of the polymer binder based on the total weight of the coating composition.

[0061] The polymeric binder may be any suitable polymeric binder. Prior to addition to the coating composition, the polymeric binder may be in the form of a latex, may be dispersed in a carrier liquid (e.g., in a colloidally stabilized emulsion or using a surfactant), or may be present as a solute in a carrier liquid (e.g., in a solution polymer).

[0062] In some methods, the polymer binder can be a waterborne polyurethane polymer, a (meth)acrylate, an acetate (eg, ethylene vinyl acetate), or a vinyl acrylic polymer.

[0063] In some methods, the latex copolymer may include (meth) acrylic acid, vinyl acrylic latex or styrene acrylic latex polymer. The latex copolymer may be formed from reactants including methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, propyl methacrylate, 2-ethylhexyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxybutyl acrylate, hydroxybutyl methacrylate, glycidyl methacrylate, 4-hydroxybutyl acrylate glycidyl ether, 2-(acetoacetoxy)ethyl methacrylate (AAEM), diacetone acrylamide (DAAM), acrylamide, methacrylamide, hydroxymethyl (meth) acrylamide, styrene, α-methylstyrene, vinyl toluene, vinyl acetate, vinyl propionate, allyl methacrylate and mixtures thereof. Some preferred monomers include styrene, methyl methacrylate, methacrylic acid, acetoacetoxyethyl methacrylate, butyl acrylate, butyl methacrylate and the like. Some monomers, such as AAEM, may be optionally included to provide the coating composition with an additional mechanism for scrubbing formaldehyde from the passing air.

[0064] The polymer binder may be synthetic, or may be a naturally occurring polymer, a biopolymer or a bio-based polymer, such as a polysaccharide, polypeptide, lipid, nucleic acid based polymer, whether cross-linked or non-cross-linked.

[0065] In some methods, the binder may be poly(ethylene vinyl acetate) "PEVA", a vinyl ester homopolymer or copolymer, or a silane or fluoro latex emulsion.

[0066] In some methods, the reactants that form the latex copolymer also include an ethylenically unsaturated polar component. For example, the ethylenically unsaturated polar component may include an ethylenically unsaturated monomer having at least one alcohol group, an ethylenically unsaturated ionic monomer, an at least partially neutralized ethylenically unsaturated ionic monomer, etc. The at least partially neutralized ethylenically unsaturated ionic monomer may be in the form of a salt of the ethylenically unsaturated ionic monomer, and the salt form may be formed before, during, or after the ethylenically unsaturated ionic monomer reacts with other monomers in the reactants to form the latex copolymer.

[0067] In some methods, the ethylenically unsaturated polar monomer can include an acid or anhydride functional ethylenically unsaturated monomer or an at least partially neutralized acid or anhydride functional ethylenically unsaturated monomer. For example, the ethylenically unsaturated polar monomer can include acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, anhydride variants thereof, at least partially neutralized variants thereof, or combinations thereof.

[0068] The aqueous coating compositions of the present invention may also contain one or more additives, including coalescing agents, rheology modifiers, surfactants, pigments, fillers, extenders, biocides, and UV stabilizers, in amounts and concentrations known to those skilled in the art. Preferably, all additives and the latex binder of the coating composition are selected so that the coating composition will have less than 150 g / L VOC, preferably less than 100 g / L VOC, even more preferably less than 50 g / L VOC.

[0069] The aqueous coating composition may contain one or more optional coalescing agents to facilitate film formation. Coalescing agents suitable for use in aqueous coating compositions will be known to those of ordinary skill in the art, or can be determined using standard methods. Exemplary coalescing agents include glycol ethers, such as those sold under the trade name EASTMAN TM EP, EASTMAN TM DM, EASTMAN TM DE, EASTMAN TM DP, EASTMAN TM DB and EASTMAN TMPMs are those sold by Eastman Chemical Company, Kingsport, Tennessee, and ester alcohols such as those sold under the trade name TEXANOL TM Ester alcohols are those sold by Eastman Chemical Company. The optional coalescing agent may be a low VOC coalescing agent such as described in US Pat. No. 6,762,230 B2.

[0070] In some methods, the latex copolymers disclosed above can be formed and / or stabilized with one or more emulsifiers (e.g., surfactants) used alone or together. Suitable nonionic emulsifiers include tert-octylphenoxyethyl poly (39)-ethoxyethanol, dodecyloxy poly (10) ethoxyethanol, nonylphenoxyethyl-poly (40) ethoxyethanol, polyethylene glycol 2000 monooleate, ethoxylated castor oil, fluorinated alkyl esters and alkoxylates, polyoxyethylene (20) sorbitan monolaurate, sucrose monococoate, di (2-butyl) phenoxy poly (20) ethoxyethanol, Hydroxyethylcellulose polybutyl acrylate graft copolymer, dimethyl silicone polyoxyalkylene graft copolymer, poly(ethylene oxide) poly(butyl acrylate) block copolymer, block copolymer of propylene oxide and ethylene oxide, 2,4,7,9-tetramethyl-5-decyne-4,7-diol ethoxylated with ethylene oxide, N-polyoxyethylene (20) lauramide, N-lauryl-N-polyoxyethylene (3) amine and poly (10) ethylene glycol dodecyl sulfide. Suitable anionic emulsifiers include sodium lauryl sulfate, sodium dodecylbenzene sulfonate, potassium stearate, sodium dioctyl sulfosuccinate, sodium dodecyl diphenyl ether disulfonate, nonylphenoxyethyl poly (1) ethoxyethyl ammonium sulfate, sodium styrene sulfonate, sodium dodecyl allyl sulfosuccinate, linseed oil fatty acid, sodium, potassium or ammonium salts of phosphate esters of ethoxylated nonylphenol or tridecyl alcohol, sodium octylphenol polyether-3-sulfonate, sodium cocoyl sarcosinate, sodium 1-alkoxy-2-hydroxypropyl sulfonate, α-olefin (C 14 -C 16 ) sulfonate, hydroxyalkanol sulfate, tetrasodium N-(1,2-dicarboxyethyl)-N-octadecyl sulfosuccinamate, disodium N-octadecyl sulfosuccinate, disodium alkylamidopolyethoxysulfosuccinate, disodium ethoxylated nonylphenol half ester of sulfosuccinic acid, and sodium salt of tert-octylphenoxyethoxypoly (39) ethoxyethyl sulfate.

[0071] The aqueous coating composition of the present invention may include a rheological package comprising one or more thickeners or rheological modifiers to produce a coating composition having suitable low, medium and high shear flow characteristics. Suitable rheological packages are described in U.S. Published Patent Application 2020 / 0291249. Thickeners may include hydroxyethyl cellulose (HEC), xanthan gum, alginates, guar gum and other cellulose derivatives. Other rheological agents include aqueous clays; hydrophobically modified alkali swellable emulsions (HASE); or associative thickeners, such as hydrophobically enhanced urethanes (HEUR), polyether polyols (PEPO) or hydrophobically modified ethoxylated aminoplast thickeners (HEAT).

[0072] Waterborne clays include, for example, magnesium aluminum phyllosilicates such as attapulgite ((Mg,Al)2Si4O 10 (OH)·4(H2O)), hectorite (Na 0.3 (Mg,Li)3Si4O 10 (OH)2), organically modified hectorite, synthetic hectorite, etc. Examples of trade names 400 was purchased from Active Minerals International, LLC, Sparks, Maryland; and 40 and 50 was purchased from BASF SE, Ludwigshafen, Germany.

[0073] Example HASE rheological agents include those sold under the trade name ACRYSOL TM TT-935 was purchased from Dow Chemical Company, Midland, Michigan; TR-116 is available from Arkema Inc., King, Prussia, Pennsylvania; TM 3800 was purchased from Arkema Inc., King, Prussia, Pennsylvania; sold under the trade name POLYPHOBE TM PP 102 was purchased from Arkema Inc., King, Prussia, Pennsylvania; 1 Available from Elementis Specialties, Inc., East Windsor, New Jersey; sold under the trade name ACRYSOL TM ASE-60 is available from Dow Chemical Company, Midland, Michigan; TMTT-615 is available from Dow Chemical Company, Midland, Michigan; TM DR-300 was purchased from Dow Chemical Company, Midland, Michigan; TR-117 is available from Arkema Inc., King, Prussia, Pennsylvania; and ACRYSOL TM RM-5 was purchased from Dow Chemical Company, Midland, Michigan.

[0074] Exemplary associative thickeners include those sold under the trade name ACRYSOL TM RM-2020NPR was purchased from Dow Chemical Company, Midland, Michigan; it is sold under the trade name ACRYSOL TM SCT-275 is available from Dow Chemical Company, Midland, Michigan; TM RM-825 is available from Dow Chemical Company, Midland, Michigan; TM RM-8W is available from Dow Chemical Company, Midland, Michigan; TM RM-12W was purchased from Dow Chemical Company, Midland, Michigan; 350 was purchased from Elementis Specialties, Inc., East Windsor, New Jersey; TM NHS-310 was purchased from Ashland, Inc., Covington, Kentucky; TM NHS-350 was purchased from Ashland, Inc., Covington, Kentucky; L100 was purchased from Byk GmbH, Wesel, Germany; H3300 VF was purchased from Byk GmbH, Wesel, Germany; and H370 was purchased from Byk GmbH, Wesel, Germany.

[0075] The aqueous coating composition may include a surfactant (e.g., a surfactant) as part of a rheological package, as part of an aqueous coating composition, or both. The surfactant may change the dispersion of the rheological package in the aqueous coating composition, change the interaction of the coating composition with the substrate or with a previously applied coating, or both. The surfactant affects the quality of the aqueous coating composition, including how to handle the aqueous coating composition, how to spread it on the surface of the substrate, and how to bond it to the substrate. The surfactant may change the ability of the aqueous coating composition to wet the substrate and may also be referred to as a wetting agent. The surfactant may also provide leveling, defoaming or flow control properties, etc. If the aqueous coating composition includes a surfactant, the surfactant is preferably present in an amount of less than 5% by weight based on the total weight of the aqueous coating composition. Surfactants suitable for use in coating compositions will be known to those of ordinary skill in the art, or may be determined using standard methods. Some suitable surfactants include those listed below: TM KK-95H, STRODEX TM PLF100, STRODEX TM PK0VOC、STRODEX TM LFK70、STRODEX TM SEK50D and DEXTROL TM OC50 is available from Dexter Chemical L.LC, Bronx, New York; TM 100. HYDROPALAT TM 140. HYDROPALAT TM 44. HYDROPALAT TM 5040 and HYDROPALAT TM 3204 was purchased from Cognis Corporation, Cincinnati, Ohio; TM A. DISPERS TM 660C, DISPERS TM 715W and DISPERS TM 750W was purchased from Degussa Corporation, Parsippany, New Jersey.; TM 156. BYK TM 2001 and ANTI-TERRA TM 207 was purchased from Byk Chemie, Wallingford, Connecticut;TM A40, DISPEX TM N40, DISPEX TM R50, DISPEX TM G40, DISPEX TM GA40, EFKA TM 1500, EFKA TM 1501, EFKA TM 1502, EFKA TM 1503, EFKA TM 3034, EFKA TM 3522, EFKA TM 3580, EFKA TM 3772, EFKA TM 4500, EFKA TM 4510, EFKA TM 4520, EFKA TM 4530, EFKA TM 4540, EFKA TM 4550, EFKA TM 4560, EFKA TM 4570, EFKA TM 6220, EFKA TM 6225, EFKA TM 6230 and EFKA TM 6525 was purchased from Ciba Specialty Chemicals, Tarrytown, New York; under the trade name SURFYNOL TM CT-111, SURFYNOL TM CT-121, SURFYNOL TM CT-131, SURFYNOL TM CT-211, SURFYNOL TM CT231, SURFYNOL TM CT-136, SURFYNOL TM CT-151, SURFYNOL TM CT-171, SURFYNOL TM CT-234, CARBOWET TM DC-01, SURFYNOL TM 104, SURFYNOL TM PSA-336, SURFYNOL TM 420, SURFYNOL TM 440, ENVIROGEM TMAD-01 and ENVIROGEM AE01 were purchased from Air Products & Chemicals, Inc., Allentown, Pennsylvania.; TM 1124、TAMOL 850、TAMOL 681、TAMOL TM 731 and TAMOL TM SG-1 was purchased from Rohm and Haas Co., Philadelphia, Pennsylvania; TM CO-210、IGEPAL TM CO-430、IGEPAL TM CO-630、IGEPAL TM CO-730 and IGEPAL TM CO-890 was purchased from Rhodia Inc., Cranbury, New Jersey; TM and T-MULZ TM Products are available from Harcros Chemicals Inc., Kansas City, Kansas; polydimethylsiloxane surfactants (such as those sold under the trade name SILWET TM L-760 and SILWET TM L-7622 was purchased from OSI Specialties, South Charleston, West Virginia, or under the trade name BYK TM 306 available from Byk-Chemie) and fluorinated surfactants (such as those sold under the trade name FLUORAD TM FC-430 is commercially available from 3M Co., St. Paul, Minnesota). Preferably, the surfactant is free of alkylphenol ethoxylates (APEO).

[0076] In some methods, the surfactant can be a defoamer. The aqueous coating composition can include a single surfactant or multiple surfactants, such as a first surfactant and a second defoamer. Some suitable defoamers include those sold under the trade name BYK TM 018. BYK TM 019. BYK TM 020, BYK TM 022. BYK TM 025. BYK TM 032. BYK TM 033. BYK TM 034. BYKTM 038. BYK TM 040, BYK TM 051. BYK TM 060, BYK TM 070, BYK TM 077 and BYK TM 500 sold by Byk Chemie; under the trade name SURFYNOL TM DF-695、SURFYNOL TM DF-75、SURFYNOL TM DF-62、SURFYNOL TM DF-40 and SURFYNOL TM DF-110D is sold by Air Products & Chemicals, Inc. under the trade name DEEFO TM 3010A、DEEFO TM 2020E / 50、DEEFO TM 215.DEEFO TM 806-102 and AGITAN TM 31BP is sold by Munzing Chemie GmbH, Heilbronn, Germany; EFKA 2526, EFKA 2527 and EFKA 2550 are sold by Ciba Specialty Chemicals; and FOAMAX TM 8050、FOAMAX TM 1488, FOAMAX TM 7447、FOAMAX TM 800、FOAMAX TM 1495 and FOAMAX 810 are sold by Degussa Corp.; under the trade name FOAMASTER TM 714. FOAMASTER TM A410, FOAMASTER TM 111. FOAMASTER TM 333. FOAMASTER TM 306. FOAMASTER TM SA-3, FOAMASTER TM AP, DEHYDRAN TM 1620, DEHYDRAN TM 1923 and DEHYDRAN TM 671 sold by Cognis Corp.

[0077] The aqueous coating composition can also include one or more pigments, which provide decorative and protective features for the paint. Pigment is a solid particle for providing various qualities for the paint, and this quality includes but is not limited to color, opacity and durability. Pigment and other solids increase the volume of the paint, and their content is relevant to the glossiness or flatness of the paint. Some suitable pigments include titanium dioxide white, carbon black, lamp black, black iron oxide, red iron oxide, yellow iron oxide, brown iron oxide (a blend of red and yellow oxides and black), phthalocyanine green, phthalocyanine blue, organic red (such as naphthol red, quinacridone red and toluidine red), quinacridone magenta, quinacridone violet, DNA orange or organic yellow (such as Hansa yellow). The aqueous coating composition can also include gloss control additives or optical brighteners, such as those sold under the trade name UVITEX. TM OB are those commercially available from Ciba-Geigy. In some methods, the coating composition can have a pigment volume (PVC) ratio of about 25 to about 75.

[0078] In some examples, the aqueous coating composition may include optional fillers or inert ingredients. The fillers or inert ingredients extend the aqueous coating composition, reduce the cost of the aqueous coating composition, change the appearance of the aqueous coating composition, or provide desired features for the aqueous coating composition before and after curing. Fillers and inert ingredients suitable for use in aqueous coating compositions will be known to those of ordinary skill in the art, or standard methods can be used to measure. Some suitable fillers or inert ingredients include, for example, clay, glass beads, calcium carbonate, talc, silica, feldspar, mica, barite, ceramic microspheres, calcium metasilicate, organic fillers, etc.

[0079] In certain applications, it may also be desirable to include a biocide in the aqueous coating composition that provides wet and / or dry film preservation. Suitable wet biocides are known in the art and include isothiazolinones such as 2-methyl-4-isothiazolin-3-one (MIT), 5-chloro-2-methyl-4-isothiazolin-3-one (CMIT), benzisothiazolinone (BIT), butylbenzisothiazolinone (BBIT), and dichlorooctylisothiazolinone (DCOIT), methyl-benzimidazolyl-2-yl carbamate, 3-iodo-2-propynyl-butyl carbamate (IPBC), propiconazole, zinc pyrithione, sodium pyrithione, and zinc oxide. Some suitable biocides or fungicides include those sold under the trade name ROZONE TM 2000、BUSAN TM 1292 and BUSAN 1440 are sold by Buckman Laboratories, Memphis, Tennessee; under the trade name POLYPHASE TM 663 and POLYPHASE TM678 sold by Troy Chemical Corp., Florham Park, New Jersey; and under the trade name KATHON TM The LX is sold by Rohm and Haas Co.

[0080] In certain applications, it may also be desirable to include an optional UV stabilizer in the aqueous coating composition. UV stabilizers may include encapsulated hydroxyphenyl triazine compositions and other compounds known to those of ordinary skill in the art, such as TINUVIN commercially available from BASF Corporation. TM 477DW.

[0081] The aqueous coating composition may also contain other ingredients that modify the properties of the aqueous coating composition when the aqueous coating composition is stored, handled or applied, and at other or subsequent stages. Waxes, matting agents, wear additives and other similar performance enhancing additives may be used as needed in amounts effective to improve the properties of the cured coating and aqueous coating composition. Some suitable wax emulsions for improving the physical properties of the coating include those sold under the trade name MICHEM TM Emulsions 32535, 21030, 61335, 80939M and 7173MOD are sold by Michelman, Inc. Cincinnati, Ohio, and under the trade name CHEMCOR TM 20N35, 43A40, 950C25 and 10N30 are those sold by ChemCor, Chester, New York. Desirable performance characteristics of the coating include chemical resistance, wear resistance, hardness, gloss, reflectivity, appearance, or a combination of these characteristics, and other similar characteristics. For example, the composition may include a wear-resistant promoting adjuvant such as silica or alumina (e.g., sol-gel treated alumina).

[0082] Other optional additives for use in the aqueous coating compositions herein are described in Kissuke et al., Paint and Coatings Industry, April 2003, pp. 12-86. Some performance enhancing additives that may be optionally used include coalescing solvents, dispersants, amines, preservatives, biocides, mildewcides, fungicides, glycols, pigments, colorants, dyes, heat stabilizers, leveling agents, anti-cratering agents, cure indicators, plasticizers, fillers, precipitation inhibitors, ultraviolet light absorbers, optical brighteners, and the like to modify the properties of the aqueous coating composition.

[0083] Aqueous coating compositions can be used for coating substrates, for example, as a primer, a finish or a combination of a primer and a finish. For example, aqueous coating compositions can be used for building materials, including bricks, concrete, plaster, wood, gypsum board, drywall, hardboard, etc. For another example, aqueous coating compositions can be used for coating other materials, such as metals or alloys, polymeric materials used in automobiles or other machines, etc. The coating composition can be applied by any suitable method, including roller coating, brushing or air spraying. Can be by making the coating composition dry, or by heat, UV or chemical crosslinking to cure the coating composition.

[0084] The present invention includes, but is not limited to, the following embodiments.

[0085] Embodiment 1: An aqueous coating composition comprising: an aqueous carrier liquid; a polymeric binder; one or more additives; and a formaldehyde-scavenging urea compound.

[0086] Embodiment 2: The aqueous coating composition according to any preceding embodiment, wherein the coating composition is substantially completely free of amine-based catalysts.

[0087] Embodiment 3: The aqueous coating composition of Embodiment 2, wherein the amine-based catalyst is triethylenediamine.

[0088] Embodiment 4: The aqueous coating composition according to any preceding embodiment, wherein the urea compound is urea.

[0089] Embodiment 5: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of at least 0.2 weight percent, based on the weight of the aqueous coating composition.

[0090] Embodiment 5: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of at least 0.5 wt %, based on the weight of the aqueous coating composition.

[0091] Embodiment 6: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of at least 1.0 wt %, based on the weight of the aqueous coating composition.

[0092] Embodiment 7: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of up to 1.5 wt %, based on the weight of the aqueous coating composition.

[0093] Embodiment 8: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of up to 2.0 wt %, based on the weight of the aqueous coating composition.

[0094] Embodiment 9: The aqueous coating composition of any preceding embodiment, wherein the urea composition is present in an amount of up to 3.0 wt %, based on the weight of the aqueous coating composition.

[0095] Embodiment 10: The aqueous coating composition according to any preceding embodiment, wherein the urea compound is urea.

[0096] Embodiment 11: The aqueous coating composition according to any preceding embodiment, further comprising a pigment.

[0097] Embodiment 12: The aqueous coating composition of any preceding claim, wherein the coating composition has a VOC of less than 150 g / L.

[0098] Embodiment 13: The aqueous coating composition of any preceding claim, wherein the coating composition has a VOC of less than 100 g / L.

[0099] Embodiment 14: The aqueous coating composition of any preceding claim, wherein the coating composition has a VOC of less than 50 g / L.

[0100] Embodiment 15: The aqueous coating composition of any preceding claim, wherein the coating composition is substantially free of VOCs.

[0101] Embodiment 16: The aqueous coating composition of any preceding embodiment, wherein the coating composition further comprises a surfactant.

[0102] Embodiment 17: The aqueous coating composition of Embodiment 16, wherein the surfactant is a phosphate ester surfactant.

[0103] Embodiment 18: The aqueous coating composition of any preceding embodiment, wherein the coating composition is substantially free of alkylphenol ethoxylate surfactants.

[0104] Embodiment 19: The aqueous coating composition of Embodiment 16, wherein the surfactant is a defoaming agent.

[0105] Embodiment 20: The aqueous coating composition of any preceding embodiment, wherein the aqueous coating composition further comprises at least one of a coalescing agent, a rheology modifier, a filler, an extender, a biocide, or a UV stabilizer.

[0106] Embodiment 21: The aqueous coating composition according to any preceding embodiment, wherein the pigment volume concentration (PVC) of the aqueous coating composition is from about 25 to about 75.

[0107] Embodiment 22: The aqueous coating composition of any preceding embodiment, wherein the polymer binder comprises at least one of a (meth)acrylic latex, a vinyl acrylic latex, or a styrene acrylic latex.

[0108] Embodiment 23: The aqueous coating composition of Embodiment 22, wherein at least one of the (meth)acrylic latex, vinyl acrylic latex, or styrene acrylic latex is formed from reactants comprising a seed latex.

[0109] Embodiment 24: The aqueous coating composition of any preceding embodiment, wherein the polymeric binder comprises a polyurethane.

[0110] Embodiment 25: A coated article comprising a substrate; and a coating on the substrate, wherein the coating comprises at least one layer formed from the aqueous coating composition according to any preceding embodiment.

[0111] Embodiment 26: The coated article of Embodiment 25, wherein the substrate is drywall.

[0112] Embodiment 27: The coated article of Embodiment 25, wherein the substrate is wood.

[0113] Embodiment 28: The coated article of Embodiment 25, wherein the substrate is a brick.

[0114] Embodiment 29: The coated article of Embodiment 25, wherein the substrate is cement.

[0115] Embodiment 30: The coated article of Embodiment 25, wherein the substrate is gypsum.

[0116] Embodiment 31: The coated article of Embodiment 25, wherein the substrate is cementitious fiberboard.

[0117] Embodiment 32: The coated article of Embodiment 25, wherein the substrate is stucco.

[0118] Embodiment 33: The coated article of Embodiment 25, wherein the substrate is vinyl siding.

[0119] Embodiment 34: A method comprising coating a substrate with a coating formed from the aqueous coating composition according to any one of Embodiments 1 to 24.

[0120] Embodiment 35: A method for reducing formaldehyde from air comprising using the coated article according to any one of Embodiments 25 to 33 to remove formaldehyde from air.

[0121] The present disclosure is illustrated by the following examples, which are provided for purposes of explanation and are not intended to limit the scope of the invention. Unless otherwise noted, all paints identified by trade names are available from The Sherwin-Williams Company, Cleveland, Ohio.

[0122] Example

[0123] Example 1

[0124] Each sample is a conventional acrylic latex paint 200Zero VOC EggShell EW Base 1 was thoroughly mixed with 1 wt %, 2 wt % and 3 wt % urea based on the total weight of the coating. These samples, along with a control sample of ProMar 200Zero VOC EggShell EW Base (no urea added) and ProMar 200Zero VOC EggShell EW Base available from The Sherwin-Williams Company, Cleveland OH, were tested according to the Formaldehyde Scavenging HPLC Test described herein. EggShell EW Paint 2 The formaldehyde scavenging properties of . No absorption catalyst, such as an amine-based catalyst, was added to any sample or control. The data was recorded and plotted as follows.

[0125] Table 1. Formaldehyde removal HPLC test results

[0126]

[0127] Figure 1. Formaldehyde removal HPLC test results

[0128]

[0129] The data show that coating compositions containing 1 wt%, 2 wt%, or 3 wt% urea unexpectedly remove more urea than the same conventional acrylic latex without urea. The data also show that although The ability of the paint to remove formaldehyde from the passing air tends to decline above a passing formaldehyde concentration of 600 ng / mL, but the composition of the invention containing urea continues to absorb additional formaldehyde. Thus, the data indicate that The paint becomes saturated, whereas the coating composition of the present invention comprising urea does not become saturated, the The paint contains a binder marketed as removing formaldehyde from the air.

[0130] Example 2: Application quality test.

[0131] Samples A (control), B (1 wt% urea), C (2 wt% urea), and D (3 wt% urea) of Example 1 were applied to an aluminum substrate via a 10 mil 8-pass drawdown bar. The coatings were cured for 24 hours at ambient room conditions (approximately 70°F and 50% relative humidity) and examined under a 200x optical microscope with reflected illumination.

[0132] Inspection results indicated that the applied surface quality of the coatings made with urea (Samples B, C and D) was indistinguishable from that of the control. More specifically, all samples lacked significant grit (agglomeration of particles) and appeared smooth.

[0133] Example 3: Coating property testing.

[0134] The coatings formed from the coating composition of Example 1 were evaluated for coating performance characteristics.

[0135] Washability : Coatings formed from compositions A, B, C, D and E of Example 1 were applied using a 7 mil Dow Film Caster and evaluated for cleanability according to the ASTM method described herein after 100 cycles with 10 mL of an all-purpose cleaner saturated in a sponge.

[0136] Table 2: Washability

[0137]

[0138] scrub : Test method using ASTM D2486-17 Test Method B, using Sherwin- The interior acrylic latex, Low Luster Enamel, Extra White was used as a reference, and the coating compositions from compositions A, B, C, D and E were tested for scrub resistance.

[0139] Table 3: Scrub resistance

[0140]

[0141] The data show that Sample B (ProMar 200 paint with 1% urea) maintains approximately equal scrub resistance to the same paint without urea and The coating compositions containing 2% urea (Sample C) and 3% urea (Sample D) showed reduced scrub resistance.

[0142] Dry Finish : Dry finishing measurements were made by 85° gloss after 5 abrasion cycles and 25 abrasion cycles.

[0143] Table 4: Dry finishing

[0144]

[0145] The data show that Sample B (ProMar 200 paint with 1% urea) maintains approximately equal scrub resistance to the same paint without urea and Slightly better scrub resistance than the ULTRA brand paints. For the compositions containing 2% (Sample C) and 3% (Sample D) urea, the polishing (abrasion) resistance is slightly significantly reduced.

[0146] Blocking: Blocking measurements were performed according to ASTM D4946-89 (2017) based on the following scale. A rating of 3 or higher was considered a "pass".

[0147] Rating Separation type performance 5 No stickiness Excellent 4 Slightly sticky good 3 Sticky; no seal Difference 2 5% to 25% sealing fail 1 26% to 50% sealed fail 0 50% to 100% sealed fail

[0148] Adhesion measurement data is shown below.

[0149] Table 5: 24-hour adhesion

[0150]

[0151] The data shows that the compositions containing 2% and 3% urea performed better than the sample containing 1% urea.

Claims

1. An aqueous coating composition comprising: an aqueous carrier fluid; polymer binder; one or more additives; and Formaldehyde purifying urea compounds.

2. The aqueous coating composition of claim 1, wherein the coating composition is substantially completely free of amine-based catalysts.

3. The aqueous coating composition of claim 1, wherein the urea compound is urea.

4. The aqueous coating composition of claim 2, wherein the amine-based catalyst is triethylenediamine.

5. The aqueous coating composition of any one of claims 1 to 4, wherein the urea compound is present in an amount of at least 0.2 wt. %, based on the weight of the aqueous coating composition.

6. The aqueous coating composition of claim 5, wherein the urea compound is present in an amount of at least 0.5 weight percent, based on the weight of the aqueous coating composition.

7. The aqueous coating composition of claim 6, wherein the urea compound is present in an amount of at least 1.0 wt. %, based on the weight of the aqueous coating composition.

8. The aqueous coating composition of any one of claims 1 to 7, wherein the urea compound is present in an amount of up to 1.5 wt. %, based on the weight of the aqueous coating composition.

9. The aqueous coating composition of claim 8, wherein the urea compound is present in an amount of up to 2.0 wt. %, based on the weight of the aqueous coating composition.

10. The aqueous coating composition of claim 9, wherein the urea compound is present in an amount of up to 3.0 wt. %, based on the weight of the aqueous coating composition.

11. The aqueous coating composition of any one of claims 1 to 10 further comprising a pigment.

12. The aqueous coating composition of any one of claims 1 to 11, wherein the coating composition has a VOC of less than 150 g / L.

13. The aqueous coating composition of claim 12, wherein the coating composition has a VOC of less than 100 g / L.

14. The aqueous coating composition of claim 13, wherein the coating composition has a VOC of less than 50 g / L.

15. The aqueous coating composition of claim 14, wherein the coating composition is substantially free of VOCs.

16. The aqueous coating composition of any one of claims 1 to 15, wherein the coating composition further comprises a surfactant.

17. The aqueous coating composition of claim 16, wherein the surfactant is a phosphate ester surfactant.

18. The aqueous coating composition of any one of claims 1 to 17, wherein the coating composition is substantially free of alkylphenol ethoxylate surfactants.

19. The aqueous coating composition of claim 16, wherein the surfactant is a defoamer.

20. The aqueous coating composition of any one of claims 1 to 19, wherein the additive is a coalescing agent, a rheology modifier, a filler, an extender, a biocide or a UV stabilizer.

21. The aqueous coating composition of any one of claims 11 to 20, wherein the aqueous coating composition has a pigment volume concentration (PVC) of about 25 to about 75.

22. The aqueous coating composition of any one of claims 1 to 21, wherein the polymer binder comprises at least one of a (meth)acrylic latex, a vinyl acrylic latex, or a styrene acrylic latex.

23. The aqueous coating composition of any one of claims 1 to 21, wherein the polymeric binder comprises a polyurethane.

24. A coated article, include: substrate; and a coating on said substrate; wherein the coating comprises at least one layer formed from an aqueous coating composition according to any preceding claim.

25. The coated article of claim 24, wherein the substrate comprises drywall.

26. The coated article of claim 24, wherein the substrate comprises wood.

27. The coated article of claim 24, wherein the substrate comprises brick.

28. The coated article of claim 24, wherein the substrate comprises cement.

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