Water borne film-forming compositions

Abstract

The present invention provides a film_forming composition comprising a particulate polymer or emulsified liquid pre-polymer, water and a coalescent aid comprising an ester having the formula RCOOX wherein R and X are independently hydrocarbyl or substituted hydrocarbyl, and at least one of R and X contain at least two unsaturated carbon-carbon bonds. The coalescent aid helps lower the minimum film formation temperature of low glass transition temperature coatings and high glass transition temperature coatings and allows optimum film formation at ambient temperatures. The coalescent aid of this coating composition is not volatile like conventional coalescent aids by rather remains part of the film and air oxidizes to cure the film. This coating composition also exhibits properties of adhesion and gloss superior to that of coating compositions containing conventional coalescent aids. Additionally, this coalescent aid can be made from natural or synthetic oils.

What is claimed is:  
     
         1 . A film-forming composition comprising a continuous aqueous phase and a dispersed phase, the dispersed phase comprising (i) a particulate polymer or emulsified liquid prepolymer, and (ii) a coalescent aid comprising an ester having the formula RCOOX wherein R and X are independently hydrocarbyl or substituted hydrocarbyl and at least one of R and X comprises at least two unsaturated carbon-carbon bonds.  
     
     
         2 . The film-forming composition of  claim 1  wherein R and X independently comprise about 1 to about 30 carbon atoms.  
     
     
         3 . The film-forming composition of  claim 1  wherein R and X independently comprise about 1 to about 30 carbon atoms and, in combination, contain no more than about 35 carbon atoms.  
     
     
         4 . The film-forming composition of  claim 1  wherein R and X each contain an unsaturated carbon-carbon bond.  
     
     
         5 . The film-forming composition of  claim 1  wherein R comprises at least two unsaturated carbon-carbon bonds in conjugation.  
     
     
         6 . The film-forming composition of  claim 1  wherein R or X is substituted hydrocarbyl and the hydrocarbyl substituent is selected from the group consisting of ketones, esters, alcohols, amides, halogens, urea, urethane, and nitrile substituents.  
     
     
         7 . The film-forming composition of  claim 1  wherein the ester is prepared by the transesterification reaction between a fatty acid and a glycol.  
     
     
         8 . The film-forming composition of  claim 1  wherein the ester is an ester derived from a fatty acid of soybean oil, canola oil, or linseed oil.  
     
     
         9 . The film-forming composition of  claim 1  wherein the ester is an ethylene glycol monoester derived from a fatty acid of soybean oil.  
     
     
         10 . The film-forming composition of  claim 1  wherein the ester is an diethylene glycol monoester derived from a fatty acid of soybean oil.  
     
     
         11 . The film-forming composition of  claim 1  wherein the ester is a propylene glycol monoester derived from a fatty acid of soybean oil.  
     
     
         12 . The film-forming composition of  claim 1  wherein the ester is a dipropylene glycol monoester derived from a fatty acid of soybean oil.  
     
     
         13 . The film-forming composition of  claim 1  wherein the ester is a methyl ester derived from a fatty acid of soybean oil.  
     
     
         14 . The film-forming composition of  claim 7  wherein the fatty acid is a fatty acid derived from soybean oil.  
     
     
         15 . The film-forming composition of  claim 1  wherein the weight of the ester is about 0.1% to about 50% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         16 . The film-forming composition of  claim 1  wherein the weight of the ester is about 0.1% to about 4% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         17 . The film-forming composition of  claim 1  wherein the continuous aqueous phase constitutes at least about 20 wt. % of the film-forming composition.  
     
     
         18 . The film-forming composition of  claim 17  wherein the ester is an ester derived from a fatty acid of soybean oil, canola oil, or linseed oil.  
     
     
         19 . The film-forming composition of  claim 1  wherein the dispersed or continuous aqueous phase further comprises an additive selected from the group consisting of wetting aids, dispersants, thickeners, defoaming agents, biocides, algicides, ultra-violet inhibitors, flow agents, levelling agents, reology modifiers, freeze thaw stabilizing agents, pH modifiers, flash rust inhibitors, and biocides.  
     
     
         20 . The film-forming composition of  claim 1  wherein the film-forming composition comprises a mixture of coalescent aids and the ester comprises at least about 5 wt. % of the mixture.  
     
     
         21 . The film-forming composition of  claim 1  wherein the ester is derived from a fatty acid contained in an oil obtained from a plant or animal and the unsaturated fatty acid comprises at least about 25 wt. % of the fatty acid content of the oil.  
     
     
         22 . The film-forming composition of  claim 1  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil obtained from a plant or animal, and the unsaturated fatty acid comprises at least about 25 wt. % of the fatty acid content of the oil.  
     
     
         23 . The film-forming composition of  claim 1  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil obtained from a plant or animal, and the unsaturated fatty acid comprises at least about 50 wt. % of the fatty acid content of the oil.  
     
     
         24 . The film-forming composition of  claim 23  wherein the film-forming composition contains at least about 20 wt. % water.  
     
     
         25 . The film-forming composition of  claim 23  wherein the film-forming composition contains at least about 20 wt. % water, at least about 10 wt. % particulate polymer or liquid pre-polymer, and the weight of the ester is about 0.1% to about 50% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         26 . The film-forming composition of  claim 1  wherein the film-forming composition contains at least about 20 wt. % water, at least about 10 wt. % particulate polymer or liquid pre-polymer, and the weight of the ester is about 0.1% to about 50% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         27 . The film-forming composition of  claim 26  wherein at least 95 wt. % of the ester is dissolved in the particulate polymer or liquid pre-polymer.  
     
     
         28 . The film-forming composition of  claim 1  wherein at least 95 wt. % of the ester is dissolved in the particulate polymer or liquid pre-polymer.  
     
     
         29 . The film-forming composition of  claim 1  wherein the continuous aqueous phase contains less than about 10 wt. % organic solvent.  
     
     
         30 . The film-forming composition of  claim 1  wherein at least 95 wt. % of the ester is dissolved in the particulate polymer or liquid pre-polymer and the continuous aqueous phase contains less than about 10 wt. % organic solvent.  
     
     
         31 . The film-forming composition of  claim 30  wherein the film-forming composition contains at least about 20 wt. % water, at least about 10 wt. % particulate polymer or liquid pre-polymer, and the weight of the ester is about 0.1% to about 50% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         32 . The film-forming composition of  claim 31  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil found in a plant or animal, and the unsaturated fatty acid comprises at least about 50 wt. % of the fatty acid content of the oil.  
     
     
         33 . The film-forming composition of  claim 30  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil found in a plant or animal, and the unsaturated fatty acid comprises at least about 50 wt. % of the fatty acid content of the oil.  
     
     
         34 . A film-forming composition comprising at least about 10 wt. % of a continuous aqueous phase and a dispersed phase, the dispersed phase comprising (i) a particulate polymer or emulsified liquid prepolymer, and (ii) a coalescent aid comprising an ester derived from a fatty acid contained in an oil found in a plant or animal, the ester having the formula RCOOX wherein R and X are independently hydrocarbyl or substituted hydrocarbyl and at least one of R and X comprises at least two unsaturated carbon-carbon bonds.  
     
     
         35 . The film-forming composition of  claim 34  wherein at least 95 wt. % of the ester is dissolved in the particulate polymer or liquid pre-polymer and the continuous aqueous phase contains less than about 10 wt. % organic solvent, based upon the weight of the continuous phase.  
     
     
         36 . The film-forming composition of  claim 35  wherein the film-forming composition contains at least about 20 wt. % water, at least about 10 wt. % particulate polymer or liquid pre-polymer, and the weight of the ester is about 0.1% to about 50% of the weight of the particulate polymer or liquid pre-polymer.  
     
     
         37 . The film-forming composition of  claim 35  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil found in a plant or animal, and the unsaturated fatty acid comprises at least about 50 wt. % of the fatty acid content of the oil.  
     
     
         38 . The film-forming composition of  claim 34  wherein the film-forming composition comprises a mixture of coalescent aids, the ester comprises at least about 5 wt. % of the mixture, the ester is derived from a fatty acid contained in an oil found in a plant or animal, and the unsaturated fatty acid comprises at least about 50 wt. % of the fatty acid content of the oil.