VOC containment coating, methods and articles

Abstract

VOC components are retained within a substrate by coating the substrate with a composition to form an ionically crosslinked polymer matrix in a coating. Methods, compositions, coatings and articles that are coated are described.

1 . A method for retaining VOC components within a substrate, comprising 
 a) Providing a substrate comprising VOC components;    b) Applying an aqueous coating composition comprising 
 i. an ionomerically crosslinkable polymer;  
 ii. water  
   to the substrate at a dry coating weight of at least about 2.4 g/sq yard; and    c) allowing said coating composition to cure, thereby forming a continuous coating layer having ionomeric crosslinks, said coating being capable of retaining said VOCs.    
     
     
         2 . The method of  claim 1 , wherein the coating composition comprises 
 i. a polymer having a plurality of ionic functionalities;    ii. an ionomeric crosslinking counterion capable of ionically crosslinking said polymer, and    iii. water.    
     
     
         3 . The method of  claim 2 , wherein the polymer has acid or acid precursor groups, and said polymer has an acid number of at least about 3.  
     
     
         4 . The method of  claim 3 , wherein the polymer is a vinyl chloride/(meth)acrylate copolymer emulsion.  
     
     
         5 . The method of  claim 3 , wherein the polymer is an acrylonitrile/(meth)acrylate copolymer emulsion.  
     
     
         6 . The method of  claim 3 , wherein the polymer is ethylene/vinyl chloride copolymer.  
     
     
         7 . The method of  claim 3 , wherein the polymer is a polycarbonate urethane polymer.  
     
     
         8 . The method of  claim 7  wherein the polymer is crosslinked with melamine.  
     
     
         9 . The method of  claim 3 , wherein the polymer is vinylidene chloride.  
     
     
         10 . The method of  claim 3 , wherein the polymer is a carboxylic acid functional polymer prepared from polymerization of one or more unsaturated aliphatic carboxylic acids with one or more reactive monomers selected from the group consisting of acrylamide, acrylonitrile, vinyl chloride, allyl chloride, vinyl acetate, and ethylenically unsaturated groups.  
     
     
         11 . The method of  claim 2 , wherein the coating composition comprises a blend of polymers that comprise ionically crosslinkable functionality.  
     
     
         12 . The method of  claim 2 , wherein the coating composition comprises blends of polymers that comprise ionically crosslinkable functionality, together with polymers that do not comprise ionically crosslinkable functionality.  
     
     
         13 . The method of  claim 2 , wherein the ionomeric crosslinking counterion is zinc.  
     
     
         14 . The method of  claim 1 , wherein the continuous coating layer is incompatible with a mono-component solution made from of at least one member of the group consisting of phenol, formaldehyde, dodecane, hexane and N-methyl-2-pyrrolidone.  
     
     
         15 . The method of  claim 1 , wherein the continuous coating layer is incompatible with a mono-component solution made from all members of the group consisting of phenol, formaldehyde, dodecane, hexane and N-methyl-2-pyrrolidone.  
     
     
         16 . The method of  claim 1 , wherein the substrate is a chloride-containing vinyl polymer film.  
     
     
         17 . The method of  claim 1 , wherein the substrate comprises a polyvinyl chloride film.  
     
     
         18 . The method of  claim 1 , wherein the substrate is an article comprising a plurality of materials and a plurality of surfaces, and the coating compositions are applied to all surfaces of the substrate.  
     
     
         19 . The method of  claim 1 , wherein the substrate is an article having a first major surface and a second major surface, wherein the coating composition is applied to the first major surface.  
     
     
         20 . An aqueous coating composition for containment of VOC components comprising the following ingredients: 
 a) A polymer having a plurality of ionic functionalities;    b) an ionomeric crosslinking counterion capable of ionically crosslinking said polymer; and    c) water    wherein said ingredients are present in an amount such that, when applied to a substrate at a coating weight of at least about 2.4 g/sq yard forms a continuous coating layer having ionomeric crosslinks that is capable of retaining said VOCs.    
     
     
         21 . The composition of  claim 20 , wherein the polymer has acid or acid precursor groups, said polymer having an acid number of at least about 3.  
     
     
         22 . A coating in place on a substrate, said coating being an ionically crosslinked matrix formed from a polymer having a plurality of ionic functionalities that has been ionically crosslinked; wherein said substrate emits no more than about 90% of the VOC emissions level of a like substrate without said coating.  
     
     
         23 . The coating of  claim 22 , said coating overlying a substrate comprising a polyvinyl chloride film.  
     
     
         24 . The coating of  claim 22 , said coating overlying pressboard.  
     
     
         25 . The coating of  claim 22 , said coating overlying a powder coated surface.  
     
     
         26 . A process of reducing VOC emissions of an article comprising: 
 a) providing the article;    b) applying a coating composition of  claim 20  in a manner and amount sufficient so that said substrate emits no more than about 90% of the VOC emissions level of a like article without said coating.    
     
     
         27 . The process of  claim 26 , wherein prior to application of the coating composition to the article, the article is ventilated to remove a portion of available VOCs from the article.  
     
     
         28 . A system for providing a low VOC releasing printed vinyl film, comprising 
 a) a chloride-containing vinyl polymer film    b) an ink comprising zinc;    c) ionically cross-linkable coating composition for overcoating printed film said ionically cross-linkable coating composition being capable of interacting with the zinc present in the ink.    
     
     
         29 . A method of treating a decorated interior wall of a building comprising an essentially flat structural material with at least one surface covered by an ionically crosslinked polymer-containing decorative material, wherein said wall emits no more than about 90% of the VOC emissions level of a like wall without said coating.  
     
     
         30 . The method of  claim 1 , wherein the coating composition, when coated on the substrate at a coating weight of between about 2.4 g./sq. yard to about 20 g./sq. yard, emits no more than about 90% of the VOC emissions level of a like substrate without said coating.  
     
     
         31 . The method of  claim 1 , wherein the coating composition, when coated on the substrate at a coating weight of between about 20 g./sq. yard and about 40 g./sq. yard, emits no more than about 90% of the VOC emissions level of a like substrate without said coating.  
     
     
         32 . The method of  claim 1 , wherein the substrate is a resin-containing component.  
     
     
         33 . The method of  claim 1 , wherein the substrate comprises plastic.  
     
     
         34 . The method of  claim 1 , wherein the substrate is a vinyl film.  
     
     
         35 . The method of  claim 1 , wherein the substrate comprises pressboard.  
     
     
         36 . The method of  claim 1 , wherein the substrate comprises a powder coated surface.  
     
     
         37 . The method of  claim 1 , wherein the coating composition is an aqueous coating composition comprising 
 i) an ionomerically crosslinkable polymer; and    ii) water.