Gel-Phase Colorant Dispersions for Coating Compositions

Abstract

The present invention is a novel gel-phase colorant dispersion comprising (a) a gel-phase colorant comprising the reaction product of (1) a reactive material component, (2) a reactive colorant, and (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and (b) a dispersion medium, wherein the dispersion medium can be an aqueous or non-aqueous-based dispersion. The gel-phase colorant dispersion of this invention can then be mixed or blended with typical coating materials. This invention is also directed to a method of preparing coating compositions comprising a binder phase of an aqueous or non-aqueous-based dispersion and a gel-phase colorant dispersion, and in particular, a method comprising the steps of (1) preparing at least one gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of (a) a reactive material component, (b) a reactive colorant, and (c) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; dispersed in a dispersion medium; and (2) mixing or blending the gel-phase colorant dispersion with typical coating materials. The coating composition can also comprise one or more independent gel-phase colorant dispersions. This invention is also directed to a process for achieving a multicolor faux finish pattern on a surface utilizing a gel-phase colorant dispersion-based one-pack multiphase coating composition. This invention is also directed to a two-layer coating system comprising a topcoat and an undercoat, wherein the topcoat is a waterborne dispersion comprising a gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of: (1) a reactive material component, (2) a reactive colorant, and (3) a crosslinker having reactive groups capable of forming a bond with the reactive material (a) component and the reactive colorant; and (b) a dispersion medium and wherein the undercoat is a waterborne dispersion comprising one or more highly water-absorbent pigments.

1 . A gel-phase colorant dispersion comprising a gel-phase colorant comprising: 
 (a) a reaction product of: 
 (1) a reactive material component,  
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) a dispersion medium.    
   
   
       2 . A coating composition comprising: 
 (a) a gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of: 
 (1) a reactive material component,  
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) a dispersion medium, wherein said dispersion medium optionally comprises a tinting colorant.    
   
   
       3 . The coating composition in accordance with  claim 2  wherein the gel-phase colorant dispersion is present in a quantity up to 95 weight percent, based on total coating composition weight.  
   
   
       4 . The coating composition in accordance with  claim 2 , wherein the reactive material component is a polyol, and the crosslinker contains isocyanate functionality.  
   
   
       5 . The coating composition in accordance with  claim 2 , wherein the gel-phase colorant dispersion comprises an admixture of two or more gel phases, each of which contains a different colorant component.  
   
   
       6 . A process for producing a coating composition comprising: 
 (a) preparing at least one gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of    (1) a reactive material component, 
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) dispersing the gel-phase colorant dispersion in a binder phase.    
   
   
       7 . An article having applied on its surface a coating composition comprising: 
 (a) a gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of: 
 (1) a reactive material component,  
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) a dispersion binder phase, wherein said dispersion binder phase optionally comprises a tinting colorant.    
   
   
       8 . A process for achieving a multicolor pattern on a surface which comprises: applying to a surface a coating composition comprising a gel-phase colorant dispersion comprising a gel-phase colorant comprising a reaction product of: 
 (a) a reactive material component,    (b) a reactive colorant, and    (c) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant.    
   
   
       9 . A gel-phase colorant comprising a reaction product of: 
 (a) a reactive material component,    (b) a reactive colorant, and    (c) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant.    
   
   
       10 . A two-layer coating system comprising a topcoat and an undercoat, wherein the topcoat is a waterborne dispersion comprising a gel-phase colorant dispersion comprising a gel-phase colorant comprising: 
 (a) a reaction product of: 
 (1) a reactive material component,  
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) a dispersion medium and wherein the undercoat is a waterborne dispersion comprising one or more highly water-absorbent pigments.    
   
   
       11 . The composition of  claim 10 , wherein the topcoat comprises a colorant having a color different than the gel-phase colorant whereby a multi-tone appearance is effectuated.  
   
   
       12 . The composition of  claim 10 , wherein the undercoat has a pigment volume concentration (PVC) of at least 55.  
   
   
       13 . The coating system in accordance with  claim 10  wherein the gel-phase colorant dispersion is present in a quantity up to 95 weight percent, based on total topcoat weight.  
   
   
       14 . The coating composition in accordance with  claim 10  wherein the gel-phase colorant is present up to 50% by weight of the gel-phase colorant dispersion  
   
   
       15 . The composition of  claim 10  wherein the topcoat has a non-volatile materials content in the range of 15 to 75%.  
   
   
       16 . The composition of  claim 10  wherein the topcoat has a non-volatile materials content in the range of 35 to 50%.  
   
   
       17 . The composition of  claim 10  wherein the highly water-absorbing pigment is selected from aluminum silicate and calcium carbonate.  
   
   
       18 . The composition of  claim 10  wherein the highly water-absorbing pigment is aluminum silicate.  
   
   
       19 . The composition of  claim 10  wherein the PVC of the undercoat is between 55 and 80 for the total undercoat formulation.  
   
   
       20 . The composition of  claim 10  wherein the PVC of the undercoat is in the range of 65 to 75.  
   
   
       21 . The method of obtaining a multi-tone coating on a surface comprising: 
 (a) applying an undercoat, wherein the undercoat is a waterborne dispersion comprising one or more highly water absorbent pigments; 
 applying a topcoat over the undercoat wherein the topcoat waterborne dispersion comprising a gel-phase colorant dispersion comprising a gel-phase colorant comprising:  
 (1) a reaction product of: 
 (i) a reactive material component,  
 (ii) a reactive colorant, and  
 (iii) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
 
 (2) a dispersion medium.  
   
   
   
       22 . The method of  claim 21  wherein the undercoat or topcoat is applied to a surface using brush, drawdown, roller, or spray application, and allowed to dry.  
   
   
       23 . A coated surface comprising a two-layer coating system comprising a topcoat and an undercoat, wherein the topcoat is a waterborne dispersion comprising a gel-phase colorant dispersion comprising a gel-phase colorant comprising: 
 (a) a reaction product of: 
 (1) a reactive material component,  
 (2) a reactive colorant, and  
 (3) a crosslinker having reactive groups capable of forming a bond with the reactive material component and the reactive colorant; and  
   (b) a dispersion medium and wherein the undercoat is a waterborne dispersion comprising one or more highly water-absorbent pigments.