Stain resistant water-borne coating composition

Abstract

Aqueous coating compositions are described where the binder includes an anionically stabilised addition polymerised polymeric dispersion. The monomers used to prepare the dispersion are acrylic acid and methacrylic acid as a carboxylic monomer and styrene, alpha methyl styrene or vinyl toluene as a hydrophobic high Tg aromatic monomer and an alkyl acrylate ester as a low Tg monomer. The relative weight proportions of the monomers are required to satisfy a formula. Blends of high and low Tg dispersions are also described. Paints formulated with the binders exhibit an excellent balance of stain resistance, tint strength and viscosity stability.

1 . An aqueous coating composition, comprising an anionically stabilized dispersion polymerized from a carboxylic acid containing ethylenically unsaturated monomer selected from the group consisting of acrylic acid and methacrylic acid, said hydrophobic aromatic ethylenically unsaturated monomer being in the range of from 8-70%, a hydrophobic aromatic ethylenically unsaturated high Tg monomer selected from the group consisting of styrene and alpha methyl styrene, and an C 2 -C 12  acrylate ester monomer whereby the relative proportions of ethylenically unsaturated monomers are selected such that the following Equation I is satisfied:  
       
         
           
             
               
                 
                   
                     a 
                     = 
                     
                       
                         5 
                         + 
                         b 
                       
                       
                         
                           ( 
                           
                             c 
                             + 
                             
                               d 
                               / 
                               2.4 
                             
                           
                           ) 
                         
                         2 
                       
                     
                   
                 
                 
                   I 
                 
               
             
           
           
           
               
           
         
       
       where 
 a=2-13  
 b=weight percent hydrophobic aromatic high Tg monomer with respect to all monomers  
 c=weight percent acrylic acid with respect to all acrylic acid  
 d=weight percent methacrylic acid with respect to all methacrylic acid  
 and whereby the polymeric dispersion has a maximum Tg of 30° C.  
 
     
     
         2 . (Canceled)  
     
     
         3 . The aqueous coating composition of  claim 1 , wherein the hydrophobic aromatic ethylenically unsaturated monomer is in the range of from 15-50%.  
     
     
         4 . The aqueous coating composition of  claim 1 , wherein the hydrophobic aromatic ethylenically unsaturated monomer is styrene.  
     
     
         5 . An aqueous coating composition, comprising an anionically stabilized dispersion polymerized from a carboxylic acid containing ethylenically unsaturated monomer selected from the group consisting of acrylic acid and methacrylic acid, a hydrophobic aromatic ethylenically unsaturated high Tg monomer selected from the group consisting of styrene, alpha methyl styrene and vinyl toluene and an C 2 -C 12  acrylate ester monomer whereby the relative proportions of ethylenically unsaturated monomers are selected such that the following Equation I is satisfied:  
       
         
           
             
               
                 
                   
                     a 
                     = 
                     
                       
                         5 
                         + 
                         b 
                       
                       
                         
                           ( 
                           
                             c 
                             + 
                             
                               d 
                               / 
                               2.4 
                             
                           
                           ) 
                         
                         2 
                       
                     
                   
                 
                 
                   I 
                 
               
             
           
           
           
               
           
         
       
       where 
 a=2-13  
 b=weight percent hydrophobic aromatic high Tg monomer with respect to all monomers  
 c=weight percent acrylic acid with respect to all acrylic acid  
 d=weight percent methacrylic acid with respect to all methacrylic acid and wherein the polymeric dispersion has Tg 30° C. maximum.  
 
     
     
         6 . The aqueous coating composition of  claim 1 , wherein “a” in Equation I is in the range of from 2.5 to 9.5.  
     
     
         7 . The aqueous coating composition of  claim 5 , wherein the weight percent of acrylic acid is greater than the weight percent of carboxylic acid monomer excluding acrylic acid.  
     
     
         8 . The aqueous coating composition of  claim 5 , wherein the Tg of the polymeric dispersion is at least −15° C.  
     
     
         9 . The aqueous coating composition of  claim 8 , wherein the Tg of the polymeric dispersion is in a range of from −5 to 30° C.  
     
     
         10 . The aqueous coating composition of  claim 5 , wherein the particle size of the polymeric dispersion is a maximum of 200 nanometers (number average).  
     
     
         11 . The aqueous coating composition of  claim 10 , wherein the particle size of the polymeric dispersion is a maximum of 150 nanometers.  
     
     
         12 . The aqueous coating composition of  claim 10 , wherein the particle size of the polymeric dispersion is a maximum of 120 nanometers.  
     
     
         13 . (Previously Canceled)  
     
     
         14 . The aqueous coating of  claim 23 , wherein the low Tg polymer dispersion is non-ionically stabilised.  
     
     
         15 . The aqueous coating composition of  claim 23 , wherein the low Tg polymer dispersion is as defined in  claim 1  such that vinyl toluene is included in  claim 1  as a further hydrophobic aromatic ethylenically unsaturated high Tg monomer.  
     
     
         16 . The aqueous polymeric dispersion of  claim 5 .  
     
     
         17 . The aqueous polymeric dispersion of  claim 5 , wherein the polymeric dispersion has a Tg greater than 30° C. but not more than 60° C. and wherein the weight majority of carboxylic acid containing ethylenically unsaturated monomer is acrylic acid.  
     
     
         18 . The aqueous coating composition of  claim 1 , wherein “a” in Equation I is in the range of from 2.5 to 9.5.  
     
     
         19 . The aqueous coating composition of  claim 1 , wherein the weight percent of acrylic acid is greater than the weight percent of carboxylic acid monomer excluding acrylic acid.  
     
     
         20 . The aqueous coating composition of  claim 1 , wherein the particle size of the polymeric dispersion is a maximum of 150 nanometers.  
     
     
         21 . The aqueous polymeric dispersion of  claim 1 .  
     
     
         22 . An aqueous coating composition, comprising an anionically stabilized dispersion polymerized from a carboxylic acid containing ethylenically unsaturated monomer selected from the group consisting of acrylic acid and methacrylic acid, a hydrophobic aromatic ethylenically unsaturated high Tg monomer selected from the group consisting of styrene, alpha methyl styrene, and vinyl toluene, and an C 2 -C 12  acrylate ester monomer whereby the relative proportions of ethylenically unsaturated monomers are selected such that the following Equation I is satisfied:  
       
         
           
             
               
                 
                   
                     a 
                     = 
                     
                       
                         5 
                         + 
                         b 
                       
                       
                         
                           ( 
                           
                             c 
                             + 
                             
                               d 
                               / 
                               2.4 
                             
                           
                           ) 
                         
                         2 
                       
                     
                   
                 
                 
                   I 
                 
               
             
           
           
           
               
           
         
       
       where 
 a=2-13  
 b=weight percent hydrophobic aromatic high Tg monomer with respect to all monomers  
 c=weight percent acrylic acid with respect to all acrylic acid  
 d=weight percent methacrylic acid with respect to all methacrylic acid.  
 
     
     
         23 . The aqueous polymeric dispersion of  claim 22 , comprising a blend of low Tg and high Tg aqueous polymeric dispersions wherein the polymer dispersion with low Tg has a Tg less than 0° C., the polymer dispersion with high Tg has a Tg of at least 25° C., and the volume ratio of low Tg to high Tg polymer dispersion is in the range of from 0.4:1 to 3:1.