Floor coating compositions

Abstract

The invention relates to the use of Real Michael Addition (RMA) crosslinkable composition for the preparation of a floor coating, to special RMA crosslinkable compositions with long working time and very short service time and low VOC and to specific floor compositions, in particular for use in high build floor coating applications.

What is claimed is: 
     
         1 . Use of a Real Michael Addition (RMA) crosslinkable composition for the preparation of a floor coating, said RMA crosslinkable composition comprising at least one crosslinkable component comprising reactive components A and B each comprising at least 2 reactive groups wherein the at least 2 reactive groups of component A are acidic protons (C—H) in activated methylene or methine groups, and the at least 2 reactive groups of component B are activated unsaturated groups (C═C) which reactive groups react to achieve crosslinking by RMA reaction between said at least one crosslinkable components in the presence of a base catalyst (C), preferably comprising a reactivity moderator D comprising an X—H group that is also a Michael addition donor reactable with component B under the action of catalyst C, wherein X is C, N, P, O or S to improve open time and preferably an alcohol with 2 to 12 carbon atoms to improve potlife. 
     
     
         2 . The use according to  claim 1  for direct coating on concrete floors without a sealing layer, for application of a top-coating over a conventional sealer layer which is based on one or more resins including epoxy, phenolic, silane, acrylics, polyurethane, polyurea, polyaspartic resins and their hybrids or for coating wood floors, in particular gymnasium floors, vinyl floors, terrazo floors, cork floors, phenolic floors or metal floors. 
     
     
         3 . The use according to  claim 1  or  2  for coating surfaces in out-door applications, in particular when temperatures are lower than 15° C. or the relative humidity higher than 85% RV or when the coating substrate surface is moist. 
     
     
         4 . A RMA crosslinkable composition for the preparation of a floor coating composition, said RMA crosslinkable composition comprising at least one crosslinkable component comprising reactive components A and B each comprising at least 2 reactive groups wherein the at least 2 reactive groups of component A are acidic protons (C—H) in activated methylene or methine groups, and the at least 2 reactive groups of component B are activated unsaturated groups (C═C) which reactive groups react to achieve crosslinking by Real Michael Addition (RMA) reaction between said at least one crosslinkable components in the presence of a base catalyst (C) wherein the amount of volatile solvent is between 0 and 20, 15, 10, 5 and preferably even less than 1 wt % relative to the total of the crosslinkable components A and B and preferably further comprising a reactivity moderator D comprising an X—H group that is also a Michael addition donor reactable with component B under the action of catalyst C, wherein X is C, N, P, O or S and preferably also an alcohol with 2 to 12 carbon atoms. 
     
     
         5 . The RMA crosslinkable composition of  claim 4  comprising one or more reactive solvents which react with crosslinkable components A or B, which are preferably selected from the group of monomeric or dimeric components A, monomeric or dimeric components B, compounds A′ having only 1 reactive acidic protons (C—H) in activated methylene or methine groups, compounds B′ having only 1 reactive unsaturated groups (C═C), most preferably acetoacetate, malonate or an acryloyl. 
     
     
         6 . The RMA crosslinkable composition of  claim 4  or  5  wherein the total amount of volatile organic solvent plus reactive solvents is between 0 and 30 wt % and the volatile organic solvent is less than 5 wt % tot the total weight of the RMA composition. 
     
     
         7 . The RMA crosslinkable composition of  claims 4 - 6  wherein the one or more crosslinkable components are one or more polymers chosen from the group of polyesters, alkyds, polyurethanes, polyacrylates, epoxy resins, polyamides and polyvinyl resins which contains components A or B in the main chain, pendant, terminal or combinations thereof preferably polymeric components with a weight average molecular weight II, of at least 250 g/mol, preferably a polymer having M w  between 250, 300 and 15000, more preferably between 400 and 10000 or 500 and 10000 g/mol. 
     
     
         8 . The RMA crosslinkable composition of  claims 4 - 7  wherein reactive component A is malonate or acetoacetate and reactive component B is acryloyl 
     
     
         9 . The RMA crosslinkable composition of  claims 4 - 8  wherein reactive component A in the crosslinkable component predominantly comprises one type of reactive components, predominantly meaning preferably more than 50, 75, 90 and most preferably 100% of the C—H reactive groups in crosslinkable component A are from one type of reactive component, preferably malonate or acetoacetate and most preferably consisting predominantly of malonate and acetoacetate or acetylacetone as remainder. 
     
     
         10 . The RMA crosslinkable composition of  claims 4 - 9  wherein the X—H group in component D, preferably an N—H group containing component, has a pKa (defined in aqueous environment) of at least one unit, preferably two units, less than that of the C—H groups in predominant component A and preferably the pKa of the X—H group in component D is lower than 13, preferable lower than 12, more preferably lower than 11, most preferably lower than 10; it is preferably higher than 7, more preferably 8, more preferably higher than 8.5. 
     
     
         11 . A floor coating composition comprising the RMA crosslinkable composition of  claims 4 - 10  not including the catalyst C, for use in combination with a catalyst C, and further floor coating additives, which can be a clear floor coating composition without pigments or filler, a pigmented floor coating composition or a high build floor coating composition comprising particulate filler (having course particles other than pigments). 
     
     
         12 . A floor coating composition for high build floor coatings comprising
 a. 50-95, preferably 55, 60 65 or 70 up to 95, 90, 85 or 80 wt % of a solid particulate filler,   b. 5-50, preferably 10, 15 or 20 up to 50 wt % of a resin from a RMA crosslinkable composition of  claims 4 - 10 ,   c. less than 100, preferably less than 75, 50 or 25 gr/ltr volatile organic solvents,   d. 0-20 wt % of a reactive solvent,
 wherein wt % is relative to the total weight of components a-d, 
 wherein wt % b) is the sum of resin forming components A and B not including components a), c) or d). 
   
     
     
         13 . The floor coating composition of  claim 12  wherein at least 50 wt % of the solid particulate filler has a diameter of between 0.5 and 20 mm and the solid filler preferably are one or more selected from the group of inorganic, wood, metal or polymer particles, for example sand, saw dust, gravel, pebbles, PVC chips, plastic waste recycle, sea shells, glass, gypsum. 
     
     
         14 . The floor coating composition of  claims 11 - 13  wherein catalyst C is a carbon dioxide blocked strong base catalyst, preferably a quaternary alkyl ammonium bi- or alkylcarbonate (as described in EP2556108), for use in coating layers with a thickness up to 500, 400, 300, 200 or 150 micrometer or catalyst C is a homogeneously active strong base catalyst (i.e. not of the surface deblocking type as in claim  26 ) for use in coating layers with a thickness from 150, 200 or 300 up to 2000, 1500, 1000 or 10,000 micrometer. 
     
     
         15 . A kit of parts for preparation of a floor coating composition comprising
 a. One or more filler parts, comprising the solid filler particles,   b. One or more parts comprising components of the RMA coating composition of  claims 4 - 10  not containing catalyst C   c. One or more parts containing catalyst C.