Polyurethane coating cure enhancement using zirconium carbonate

Abstract

Zirconiun carbonates can initiate hardening of polyurethane coatings and decrease the coating tack-free time. The decreased tack-free times facilitate earlier application of additional polyurethane layers and earlier return of a coated article to service, and can provide improved floor finishes.

1 . An autohardenable polyurethane coating comprising sufficient zirconium carbonate to decrease the coating tack-free time.  
     
     
         2 . A coating according to  claim 1  wherein the zirconium carbonate comprises sodium zirconium carbonate.  
     
     
         3 . A coating according to  claim 1  wherein the zirconium carbonate comprises potassium zirconium carbonate.  
     
     
         4 . A coating according to  claim 1  wherein the zirconium carbonate comprises ammonium zirconium carbonate.  
     
     
         5 . A coating according to  claim 1  comprising sufficient zirconium carbonate to decrease the coating tack-free time by at least about 10%.  
     
     
         6 . A coating according to  claim 1  comprising sufficient zirconium carbonate to decrease the coating tack-free time by at least about 30%.  
     
     
         7 . A coating according to  claim 1  comprising sufficient zirconium carbonate to decrease the coating tack-free time by at least about 50%.  
     
     
         8 . A coating according to  claim 1  containing about 0.01 to about 15 wt. % zirconium carbonate.  
     
     
         9 . A coating according to  claim 1  containing about 0.1 to about 10 wt. % zirconium carbonate.  
     
     
         10 . A coating according to  claim 1  wherein the polyurethane comprises a polyisocyanoate and a polyester polyol, polyether polyol, acrylic polyol, polyurethane polyol or combination thereof.  
     
     
         11 . A coating according to  claim 1  wherein the polyurethane comprises a waterborne multicomponent polyurethane.  
     
     
         12 . A coating according to  claim 1  atop a flooring substrate.  
     
     
         13 . A method for applying a polyurethane finish comprising applying to a substrate a layer of an autohardenable polyurethane coating comprising sufficient zirconium carbonate to decrease the coating tack-free time.  
     
     
         14 . A method according to  claim 13  wherein the zirconium carbonate comprises sodium zirconium carbonate.  
     
     
         15 . A method according to  claim 13  wherein the zirconium carbonate comprises potassium zirconium carbonate.  
     
     
         16 . A method according to  claim 13  wherein the zirconium carbonate comprises ammonium zirconium carbonate.  
     
     
         17 . A method according to  claim 13  wherein the coating comprises sufficient zirconium carbonate to decrease the coating tack-free time by at least about 10%.  
     
     
         18 . A method according to  claim 13  wherein the coating comprises sufficient zirconium carbonate to decrease the coating tack-free time by at least about 30%.  
     
     
         19 . A method according to  claim 13  wherein the coating comprises sufficient zirconium carbonate to decrease the coating tack-free time by at least about 50%.  
     
     
         20 . A method according to  claim 13  wherein the coating contains about 0.01 to about 15 wt. % zirconium carbonate.  
     
     
         21 . A method according to  claim 13  wherein the coating contains about 0.1 to about 10 wt. % zirconium carbonate.  
     
     
         22 . A method according to  claim 13  comprising forming the polyurethane by combining a polyisocyanate and a polyester polyol, polyether polyol, acrylic polyol, polyurethane polyol or combination thereof  
     
     
         23 . A method according to  claim 13  wherein the polyurethane comprises a waterborne multicomponent polyurethane.  
     
     
         24 . A method according to  claim 13  wherein the substrate comprises a floor.  
     
     
         25 . A method according to  claim 24  further comprising walking on the polyurethane after it has become tack-free to apply a further polyurethane layer or a layer of another film-forming material.  
     
     
         26 . A jobsite-renewable point of use floor finish system comprising a substantially isocyanatefree undercoat, an autohardenable polyurethane topcoat and instructions for jobsite application of the undercoat to a floor and the topcoat to the undercoat, wherein the undercoat or topcoat comprise sufficient zirconium carbonate to decrease the topcoat tack-free time.  
     
     
         27 . A system according to  claim 26  wherein the zirconium carbonate comprises sodium zirconium carbonate.  
     
     
         28 . A system according to  claim 26  wherein the zirconium carbonate comprises potassium zirconium carbonate.  
     
     
         29 . A system according to  claim 26  wherein the zirconium carbonate comprises ammonium zirconium carbonate  
     
     
         30 . A system according to  claim 26  comprising sufficient zirconium carbonate to decrease the polyurethane tack-free time by at least about 10%.  
     
     
         31 . A system according to  claim 26  comprising sufficient zirconium carbonate to decrease the polyurethane tack-free time by at least about 30%.  
     
     
         32 . A system according to  claim 26  comprising sufficient zirconium carbonate to decrease the polyurethane tack-free time by at least about 50%.  
     
     
         33 . A system according to  claim 26  wherein the polyurethane contains about 0.01 to about 15 wt. % zirconium carbonate.  
     
     
         34 . A system according to  claim 26  wherein the polyurethane contains about 0.1 to about 10 wt. % zirconium carbonate.  
     
     
         35 . A system according to  claim 26  wherein the undercoat contains about 1 to about 50 wt. % zirconium carbonate.  
     
     
         36 . A system according to  claim 26  wherein the undercoat contains about 2 to about 30 wt. % zirconium carbonate.  
     
     
         37 . A system according to  claim 26  wherein the topcoat and undercoat comprise zirconium carbonate.  
     
     
         38 . A system according to  claim 26  wherein the polyurethane comprises a waterborne multicomponent polyurethane.  
     
     
         39 . A system according to  claim 38  wherein the polyurethane components comprise (a) a polyisocyanate and (b) a polyester polyol, polyether polyol, acrylic polyol, polyurethane polyol or combination thereof.  
     
     
         40 . A system according to  claim 26  further comprising a waterborne maintenance coat composition.  
     
     
         41 . A system according to  claim 26  further comprising a stripper.  
     
     
         42 . A system according to  claim 26  wherein the hardened polyurethane and undercoat can be removed from the floor by applying a stripper composition comprising at least one polar solvent, allowing the stripper composition to contact the polyurethane for sufficient time to soften the polyurethane and undercoat, and removing the softened polyurethane and undercoat without removing substantial portions of the floor  
     
     
         43 . A method for applying a jobsite-renewable finish to a floor comprising applying to the floor a multilayer coating system comprising a layer or layers of a substantially isocyanate-free undercoat and a layer or layers of an autohardenable polyurethane topcoat, wherein the undercoat or topcoat comprise sufficient zirconium carbonate to decrease the topcoat tack-free time.  
     
     
         44 . A method according to  claim 43  wherein the zirconium carbonate comprises sodium zirconium carbonate.  
     
     
         45 . A method according to  claim 43  wherein the zirconium carbonate comprises potassium zirconium carbonate.  
     
     
         46 . A method according to  claim 43  wherein the zirconium carbonate comprises ammonium zirconium carbonate  
     
     
         47 . A method according to  claim 43  wherein the undercoat or topcoat comprise sufficient zirconium carbonate to decrease the polyurethane tack-free time by at least about 10%.  
     
     
         48 . A method according to  claim 43  wherein both the undercoat and polyurethane comprise zirconium carbonate.  
     
     
         49 . A method according to  claim 43  wherein the undercoat comprises zirconium carbonate and the topcoat does not.  
     
     
         50 . A method according to  claim 43  comprising applying a layer of undercoat that comprises zirconium carbonate, a layer of undercoat that does not contain zirconium carbonate, and a layer of topcoat.  
     
     
         51 . A method according to  claim 50  wherein the topcoat also comprises zirconium carbonate.  
     
     
         52 . A method according to  claim 43  wherein the polyurethane comprises a waterborne multicomponent polyurethane.  
     
     
         53 . A method according to  claim 52  wherein the polyurethane components comprise (a) a polyisocyanate and (b) a polyester polyol, polyester polyol, acrylic polyol, polyurethane polyol or combination thereof.  
     
     
         54 . A method according to  claim 43  wherein the hardened polyurethane and undercoat can be removed from the floor by applying a stripper composition comprising at least one polar solvent, allowing the stripper composition to contact the polyurethane for sufficient time to soften the polyurethane and undercoat, and removing the softened polyurethane and undercoat without removing substantial portions of the floor.  
     
     
         55 . A method according to  claim 43  wherein the floor comprises wood, vinyl or vinyl composite.  
     
     
         56 . A method according to  claim 43  further comprising walking on the polyurethane after it has become tack-free to apply a further polyurethane layer or a layer of another film-forming material.