TECHNICAL FIELD

[0001J In at least one aspect, the present invention is related to paint compositions that do not require a separate primer and topcoat.

BACKGROUND

[O002J Paint coatings are ubiquitous finding numerous applications for both aesthetic and functiona] applications, in many applications, paint coatings are applied to improve the aesthetic appeal of a surface by providing a uniform and pleasing appearance. 0003] In this regard, it is known that many coating compositions do not cover substrate well when the substrate is colored. In these situations, a primer and multiple coatings are frequently necessary leading to extra expense and significantly longer times to paint a surface. Moreover, many coatings formed from the prior art paint compositions are easily stained and difficult to clean once stained.

[00043 Accordingly, there is a need for paint compositions with improved hiding power and stain resistance when applied to a substrate

SUMMARY

[O005| In at least one aspect, the present invention provides a primer topcoat paint composition that can be applied to a surface with the need have applying separate primer and topcoat layer. The primer topcoat paint composition includes a first acrylic copolymer that is not a styrene acrylic copolymer, a second acrylic copolymer that Is a styrene acrylic copolymer, and water. Characteristically, the first acrylic copolymer is present in the primer topcoat paint composition in an amount by weight that is at least 5 times greater than that of the second acrylic copolymer. |0006] In another aspect, a method of coating a substrate with the primer topcoat paint composition set forth herein is provided. The method includes a step of applying the primer topcoat paint composition to a substrate surface to form a coated substrate and then allowing the coated substrate to dry at ambient temperature. Characteristically, the primer topcoat paint composition is applied with applying separate primer and topcoat coatings.

[0007] in another aspect, the paint composition provides a primer which does not need to be top-coated.

[0008] In another aspect, the paint composition delivers properties expected of a primer including sealing, adhesion, hiding, stain blocking, and tint ablil i ty .

[0009] In another aspect, the paint composition is scrabbable and washable with a tackiness level similar to opening price point level paint

[0010] In another aspect, the paint composition can be provided in a white base composition and a medium base composition.

10011} hi another aspect, the paint composition can be provided in three sheens flat, satin, semi-gloss sheens,

[0012] In still another aspect, the paint composition dries in about 30 minutes to the touch and in about an hour for recoating.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] For a further understanding of the nature, objects, and advantages of the present disclosure reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

[0014} FIGURES 1A and IB Table 2 provide a description of the test methods and abbreviations used in the tables of Figures 2 to 7. [0015| FIGURE 2 Table 3 which provides a summary' of the measured properties for the flat white compos i lion.

[OOKif FIGURE 3. Table 5 which provides a summary of the measured properties for the eggshell white composition.

[O01?f FIGURE 4. Table 7 which provides a summary of the measured properties for the semi gloss white composition

[00181 FIGURE 5. Table 9 which provides a summary of the measured properties for the deep flat paint composition

[00191 FIGURE 6. Table 11 which provides a summary of the measured properties for the eggshell deep paint composition

[00201 FIGURE 7 Table 13 which provides a summary of the measured properties for the semi -gloss deep paint composition.

DETAILED DESCRIPTION

[0021j Reference will now be made in detail to presently preferred compositions, embodiments an methods of the present invention, which constitute the best inodes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representati ve basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0022] Except in the examples, or where otherwise expressly indicated, all numerical quanti ties in this description indicating amoun ts of material or conditions of reaction and/or use are to be understood as modified by the word "about" in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: all R groups (e.g. Ri where i is an integer) include hydrogen, alkyl, lower alkyl, Ci- ₆ alkyl, CVJO ar l, CVio heteroaryi, -N<¼, -N¾, -N(R’R”), -N(R ^> R”R” ^> ) ^÷ L , Cl, F, Br, -CFn -CCh, -CN, - SOdS, -POdF>, -COOH, -C0 ₂ R\ -COR’, -CHO, -OH, -OR’, -0 MT, -SOyM", -POyKT, -COCTM\ - CF ₂ H, -CFiR’, -CFII2, and -CFR’R” where R’, R” and R” ⁵ are Ci- ₁₀ alkyl or Gs-is aryl groups; single letters (e.g,, "n" or "o") are 1, 2, 3, 4, or 5; in the compounds disclosed herein a CH bond can be substituted with alkyl, lower alkyl, Cj^ alkyl, G5-10 aryl, i io heteroaryi, - O ₂ , -NHj, -N(R’R”), -N(R’R”R’”) ^÷ L/, Cl, F, Br, -CFn -CCb, -CN, -SOM, -PO5H ₂ , -COOH, -Cf¾R\ -COR’, -CHO, -OH, -OR’, -0 M ^÷ , -SOfiM y -POyMk -COCrMF -CF _S H, -CF ₃ R ^; , -CFlH, and -CFR’R” where R’, R” and R”’ are C _MO alkyl or Ceeis aryl groups; percent, "parts of," and ratio values are by weight; the term "polymer" includes "oligomer," "copolymer," "terpolymer," and the like; molecular weight provided for any polymers refers to weight average molecular weight unless otherwise indicated; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein o the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later reference for the same property.

|0023j It is also to be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.

|0(124| it must also be noted that, as used in the specification and the appended claims, the singular form "a," "an," and "the" comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components. [O025J The term “comprising'’ is synonymous with ‘including,” “having,” “containing,” or

“characterized by.” These terms are inclusive and open-ended and do not exclude additional unrecited elements or method steps 0026| The phrase “consisting of’ excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole

[002?! The phrase “consisting essentially of’ limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characieristic(s) of the claimed subject matter.

[0028| With respect to the terms “comprising,” “consisting of” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

[tHi29| It should also be appreciated that: integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10, Simi larly , the range I to 100 includes 1,2, 3,4. . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, .1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits in the specific examples set forth herein, concentrations, temperature, and reaction conditions (e.g. pressure, pH, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to three significant figures. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to three significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pH, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to three significant figures of the value provided in the examples. [0030] In the examples set forth herein, concentrations, temperature, and reaction conditions

(e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In a refinement, concentrations, temperature, and reaction conditions (e.g,, pressure, pH, flow rates, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g , pressure, pH, flow rates, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples,

[00 1 I Throughout this application, where publications are referenced, the disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains

[00321 T hroughout this application, the amounts of all components of the primer topcoat paint compositions are weight percentages of the total weight of the primer topcoat paint composition, Moreover, all weights of polymeric or copoly meric components are solids weights.

[0033} in an embodiment, a primer topcoat paint composition with improved hiding and stain resistance is provided. The primer topcoat paint composition includes a first acrylic copolymer that is not a styrene acrylic copolymer, a second acrylic copolymer that is a styrene acrylic copolymer, and water. In a refinement, the primer topcoat paint composition is a latex paint (i,e., an emulsion) The first acrylic copolymer In a refinement, the first acrylic copolymer is a nearly 100 percent acrylic copolymer (e.g , greater than 95% acrylic copolymer. In another refinement, the first acrylic copolymer has a minimum film forming temperature less than about 20 °C. In this context, an acrylic copolymer is any polymer formed from at least one acrylate monomer.

[0034| Characteristically, ihe first acrylic copolymer is present in the primer topcoat paint composition in an amount by weight that is at least 5 times greater than that of the second acrylic copolymer. In a refinement, the first acrylic copolymer is present in the primer topcoat paint composition in an amount by weight that is at least, in increasing order of preference 3, 4, 5, 7, or 10 times greater than that of the second acrylic copolymer. In a further refinement, the first acrylic copolymer is present in the primer topcoat paint composition in an amount by weight that is at most, in increasing order of preference 20, 15, 12, 10, or 8 times greater than that of the second acrylic copolymer.

[0035] In a variation, the first acrylic copolymer and second acrylic copolymer are independently added to the primer topcoat paint composition as an emulsion copolymer. In a refinement, the first acr lic copolymer nearly 100% acrylic and is formed from one or more or any combination of monomers selected from the group consisting of methacrylate, methyl acrylate, ethyl acrylate, 2-chloroethyl vinyl ether, 2-ethylhexyi acrylate, hydroxyeihyl methacrylate, butyl acrylate, butyl methacrylate, trimeihylolpropane triacrylate, penlafluorophenyl methacrylate, pentafluorophenyl acrylate, 1,1 , 1 ,3,3,3-hexafhioroisopiOpylacry late, bis-(2,2,2-tri fluoroeihyl) itaeonate, bis-( 1,1 , 1,3.3, 3 -hexafl uoroi so propy 1), lH,lH,3H-hexafhiorobuiyl acrylate, 111,111.711- dodecafl uorohepty 1 methacrylate, 2,2,2-tri fluoroeihyl acrylate, 2,2,2 -trifluoroethyl methacrylate, aliphatic, fluorinated aliphatic, .1 H , 1 H,2H,2 H~Heptadecafl uorodec I methacrylate 532,2 acrylic, 1 H, 1 H,2H,2H-hepiadecafluorodecyl aeiylate, 1 H, lH,5H-octafluoropentyl aeiylate, 1 H, 1 H,3H- tetrafiuoropropyl methacrylate, hexailuoro-iso-propyl methacrylate, 1 H, 1 H,3H-hexafluorobutyl methacrylate, lH,lH,5H-octa£hioropentyl methacrylate, ethylene, propylene, 1 -butylene, 2 butylene, vinyl acetate, functional monomers (e,g,, phosphorous-containing monomers), acid group monomers, and combinations thereof. Specific examples of phosphorus-containing functional monomers are disclosed In U.S. Pal. Nos. 5,385,960; 6,080,802; 7,488,534; and 8,318,8483; the entire disclosures of which are hereby incorporated by reference. Examples of acidic group monomers are disclosed in U.S. Pat. No, 6,080,802.

100361 1° another refinement, the second copolymer is formed from substituted or unsubstituted styrene (e,g,, for example Cl -10 alkyl, halogen, etc. as set forth above) and one or more or any combination of monomers selected from the group consisting of methacrylate, methyl acrylate, ethyl acrylate, 2-chloroethyl vinyl ether, 2~ethylhexyl aeiylate, hydroxyeihyl methacrylate, butyl acrylate, butyl melhacrylaie, trimeihylolpropane triacrylaie, pentafluorophenyl methacrylate. pentafluorophenyl acrylate, 1,1,1 ,3,3,3-hexafluoroisop.ropylacrylale, bis-(2,2,2-trifluoroethyl) itaconate, bis-(i,l , 1 ,3,3,3-hexafluo.roisoprop I), lH,lH,3H-hexafluorobuiyl acrylate, 1H,1H,7H- dodecafluoroheptyl meihacrylate, 2,2,2-tnf!uoroethyi acrylate, 2,2,2-trifluoroetbyl methacrylate, aliphatic, iluorinated aliphatic, lH,lH ₅ 2H,2H-Heptadecafluorodecyl methacrylate 532,2 acrylic, 111, i H _f 2H,2H-heptadeca†luorodecyl acrylate, 1 H, 1 H,5H-octafiuoropentyl acrylate, 111, i H,3 H- tetrafluoropropyl methacrylate, hexafluoro-iso-propyl methacrylate, 1H,111 , 3 E -hexafi uorobut i methacrylate, 1H, 1 H,5 H-octailuoropent I meihacrylate, ethylene, propylene, 1 -butylene, 2 butylene, vinyl acetate, functional monomers (e.g., phosphorous-containing monomers), acid group monomers, and combinations thereof.

[§037] In some variations, the paint composition optional ly further includes a combination of paint additives selected from the group consisting of matting agents, rheology modifiers, surfactants, defoamers, organic solvents, pH adjusters, UV stabilizers, dispersants, coalescents, biocides, matting agents, opaque polymers, miklewcides. and the like, and combinations thereof. It should be appreciated that any combination of these paint additives an be used. In should also be appreciated that each specific additi ve may refer to a combination of such additi ves. Typically, the paint additives other than the matting agent are each independently present in an amount from about 0.01 to 10 weight percent. In a refinement, the primer topcoat paint composition independently includes 0 1 to 5 weight percent rheology modifiers. 0.01 to 3 weight percent surfactants, 0 1 to 5 weight percent defoamers, 0.01 to 3 weight percent dispersants, 0.1 to 3 weight percent coalescents, 0.01 to 5 weight percent biocides. 0.01 to 3 weight miklewcides, 0,01 to 3 weight pH adjusters, 0.1 to 10 weight percent opaque polymer, 0.2 to 40 matting agents, and combinations thereof. Typically, the additives are present in a comb tried total amount fro about 0.1 to 50 weight percent of the total weight of the paint composition

[0038] As set forth above, the primer topcoat paint composition can include a matting agent to adjust the gloss to a lower sheen, The matting agent can be any extender pigment, such as silicas, zinc oxide, nepheSine syenite, calcined kaolin, diatomaeeous earth, mica, calcium carbonate, and the like. In a refinement, the matting agent is present in an amount from about 02 to 40 weight percent of the dry weight of the paint composition . |0039J In another variation, the primer topcoat paint composition includes one or more pigments. Suitable pigments are azo dyes, phthalocyanine, anthraquinone dyes, inorganic pigments and carbon black, powdered metals, metal compounds (e.g , zinc phosphate), and combinations thereof. Examples of inorganic pigments include, but are not limited to, titanium oxide, calcium carbonate, iron oxides (black, yellow and red), zinc oxide, and the like, and combinations thereof In a refinement, the primer topcoat paint composition includes about 1 to 40 weight percent titanium dioxide (TiCfi) hi a refinement, the primer topcoat paint composition includes about 20 to 30 weight percent titanium dioxide <Ti(V). f0040| In another variation, the primer topcoat paint composition includes the first acrylic copolymer in an amount from about 10 to 50 weight percent; and the second acrylic copolymer in an amount from about 1 to 10 weight percent with the balance being water and a combination of paint additives as set forth above. j IN 1411 In another embodiment, a method of coating a substrate with the primer topcoat paint composition set forth above is provided, The method includes a step of applying a primer topcoat paint composition to a substrate surface to form a coated substrate. The primer topcoat paint composition includes a first acrylic copolymer that is not a styrene acrylic copolymer, a second acrylic copolymer that is a styrene acrylic copolymer, and water. As set forth above, the first acrylic copolymer is present in the primer topcoat paint composition in an amount by weight that is at least 5 times greater than that of the second acrylic copolymer. Additional details of the primer topcoat paint composition are set forth above. The coated substrate is allowed to dry (i.e., dried) at ambient temperature. Typically, ambient temperature is from about 15 °C to about 30 °C. Characteristically, the primer topcoat paint composition is applied without having to apply separate primer and topcoat layers. lf.M)42| In a variation, the paint composition is formed by a formulation process that includes a grind step and a letdown step. During the grind step, solvent (w'ater), dispersant, defoamer, titanium oxide, and extender pigments are mixed together. During the letdown, the binder polymer, the mildeweide, the rheology modifier, and the biocide are added to the grind product. |0043J The following examples illustrate the various embodiments of the present invention.

Those skilled in the art will recognize many variations that are within the spirit of the present invention and scope of the claims. 0044 j The experimental compositions set forth below demonstrate the superior properties of the embodi ents and variation set forth above with respect to sealing, adhesion, hiding, stain bl cki g, tintablility, scrubhable and washable.

[0045J 1. Flat White Primer topcoat paint composition

[0046J Table 1 provides an example of a flat white paint composition formed i accordance with the present invention. Figures 1 A and 1 B provides Fable 2 which is a summary" of the test methods and abbreviations used in the properties tables of Figures 2-7. Table 3 (Figure 2) provides a summary of the measured properties for a pai nt coating formed from the fiat white composition.

100471 Table 1. Flat white composition weight percentages.

10048! 2. Eggshell White Primer topcoat paint composition

(0049J Table 4 provides an example of an eggshell white paint composition formed in accordance with the present invention. Table 5 (Figure 3) provides a summary of the measured properties for a paint coating formed from the eggshell white composition. 005l)| Table 4 Eggshell white composition weight percentages. 00511 3. Semi-gloss Primer Topcoat White

100521 Table 6 provides an example of a semi-gloss white paint composition formed in accordance with the present invention. Table 7 (Figure 4) provides a summary of the measured properties of a paint coating formed from the semi-gloss white composition

|0053| Table 6 Semi-gloss white composition weight percentages.

|00S4| 4. Deep Flat Faint composition

[0055J Table 8 provides an example of a deep Oat paint composition formed in accordance with the present invention. Table 9 (Figure 5) provides a summary of the measured properties for a paint coating formed from the deep fiat paint composition

|0056| Table 8 Deep Fiat paint composition weight percentages.

|0057| 5. Eggshell Deep

[0058J Table 10 provides an example of an eggshell deep paint composition formed in accordance with the present invention. Table 11 (Figure 6) provides a summary of the measured properties for a paint coating formed front the eggshell deep paint composition. jOOSdJ Table 10. Eggshell deep paint composition weight percentages.

[0060J 6. Semi-gloss Deep

[0061 J Table 12 provides an example of a semi-gloss deep paint composition formed in accordance with the present invention. Table 13 (Figure 7) provides a summary of the measured properties for a paint coating formed from the semi-gloss deep paint composition.

|0(162| Table 12. Semi-gloss deep paint composition weight percentages.

[0063 J While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of die invention. Additionally, the features of various implementing embodiments maybe combined to form further embodiments of the invention.