Opaque wet, see-through dry weather-resistive barriers and methods for making

Abstract

The present invention provides aqueous self-inspecting wet coatings or films that dry to form translucent to clear weather-resistive barriers on a substrate, preferably a building substrate such as sheathing. The coatings comprise, as a wet film, one or more aqueous emulsion or dispersion polymer that can form a film in use conditions and less than 6% pigment volume concentration (% PVC), of one or more opacifier, one or more extender in amounts up to critical % pigment volume concentration (CPVC), optionally, one or more pigment, and substantially no void, hollow core, or hollow sphere containing pigment. The coatings or films enable one to apply the correct amount of coating to make a weather barrier that dries to a see-through coating or film.

1 . A self-inspecting wet coating or film that dries to form a translucent to clear weather-resistive barrier comprising a composition applied to a substrate, the applied composition comprising one or more aqueous emulsion or dispersion polymer that can form a film in use conditions and less than 6% pigment volume concentration (% PVC) of one or more opacifier, one or more extender in amounts up to critical % pigment volume concentration (CPVC), optionally, one or more pigment, and substantially no void, hollow core, or hollow sphere containing pigment. 
     
     
         2 . The coating or film as claimed in  claim 1 , consisting essentially of the emulsion or dispersion polymer, pigment, extender and/or opacifier and up to 2% PVC of one or more colorant. 
     
     
         3 . The coating or film as claimed in  claim 1 , wherein the one or more opacifier is present in the amount of 4% PVC or less. 
     
     
         4 . The coating or film as claimed in  claim 1 , wherein the total % PVC of the wet coating is up to 45% PVC. 
     
     
         5 . The coating or film as claimed in  claim 1 , wherein the emulsion or dispersion polymer has a weight average particle size of from 20 to 500 nm, wherein when the emulsion or dispersion polymer has a weight average particle size of 100 nm or less, the composition has a % pigment volume concentration (% PVC) of 10 to 50. 
     
     
         6 . The coating or film as claimed in  claim 1 , wherein the emulsion or dispersion polymer has a weight average particle size of 160 nm or more. 
     
     
         7 . The coating or film as claimed in  claim 1 , wherein the self-inspecting wet aqueous coating comprises an opaque film at a thickness ranging from 100 μm to 1800 μm. 
     
     
         8 . The coating or film as claimed in  claim 1  on a building substrate chosen from wood sheathing, gypsum sheathing, cement sheathing, foam sheathing, masonry, wood roofing, flooring and subflooring. 
     
     
         9 . A method of making a weather-resistive barrier film comprising applying self-inspecting aqueous emulsion or dispersion polymer coating compositions to a building substrate until the substrate is no longer visible to form the wet coating as claimed in  claim 1 , and drying. 
     
     
         10 . The method as claimed in  claim 9 , further comprising applying a foamed aqueous composition of an emulsion or dispersion polymer with a Tg less than 25° C., a surfactant, water and a blowing agent to any gaps within the building substrate prior to applying the coating composition to the substrate.