Low Emission, High Scrub VAE Latex Paints

Abstract

A water-based, low-emission latex paint formulation includes a vinyl acetate/ethylene (VAE) latex including a VAE resin with from 80 to 95 weight % vinyl acetate residue and from 5 to 20 weight % ethylene residue, optionally including additional monomers as well as a pigment composition including inorganic solids selected from inorganic pigments, inorganic fillers and mixtures thereof present in an amount such that the paint formulation has a pigment volume concentration (PVC) of from 25% to 85%. The formulations are suitable for eggshell and flat latex paints and exhibit surprising durability.

What is claimed is: 
     
         1 . A water-based, low-emission latex paint formulation comprising:
 (a) a vinyl acetate/ethylene (VAE) latex including a VAE resin consisting of (i) from 80 to 95 weight % vinyl acetate residue and (ii) from 5 to 20 weight % ethylene residue;   (b) a pigment composition including solids selected from the group consisting of inorganic pigments, inorganic fillers and mixtures thereof present in an amount such that the paint formulation has a pigment volume concentration (PVC) of from 25% to 85%; and   (c) one or more auxiliary components selected from the group consisting of wetting agents, dispersants, emulsifiers, protective colloids, thickeners, antifoams, dyes and preservatives;   wherein (i) the resin has a K-value of greater than 60, (ii) the paint formulation exhibits a relative scrub index of greater than 200% and up to 300%, and (iii) the ratio of the relative scrub index of the latex to the K-value of the resin is at least 2.25/1; and wherein the resin and the paint formulation are alkylphenol ethoxylate (APE)-free.   
     
     
         2 . The water-based, low-emission paint formulation according to  claim 1 , wherein the ethylene residue in the resin is from 10 to 15 weight %. 
     
     
         3 . The water-based, low-emission paint formulation according to  claim 1 , wherein the paint formulation has a volatile organic content less than 5 g/L. 
     
     
         4 . The water-based, low emission paint formulation according to  claim 1 , wherein the paint formulation further comprises a block-resistant additive. 
     
     
         5 . A water-based, low-emission latex paint formulation comprising:
 (a) a vinyl acetate/ethylene (VAE) latex including a VAE resin with (i) from 80 to 95 weight % vinyl acetate residue, (ii) from 5 to 20 weight % ethylene residue, and (iii) from 0.1 to 5 weight % silane residue, with the proviso that the sum of the weight % of the monomers equals 100;   (b) a pigment composition including solids selected from the group consisting of inorganic pigments, inorganic fillers and mixtures thereof present in an amount such that the paint formulation has a pigment volume concentration (PVC) of from 25% to 85%; and   (c) one or more auxiliary components selected from the group consisting of wetting agents, dispersants, emulsifiers, protective colloids, thickeners, antifoams, dyes and preservatives;   wherein (i) the resin has a K-value of greater than 60, a latex gel content value upon curing at 125° C. for 14 hours of greater than 50%, and a glass transition temperature (T g ) of from about minus 5° to about plus 20° C. measured at a transition midpoint, and (ii) the paint formulation exhibits a relative scrub index of greater than 200% and up to 300%; and   wherein the resin and the paint formulation are alkylphenol ethoxylate (APE)-free.   
     
     
         6 . The water-based, low-emission paint formulation according to  claim 5 , wherein the VAE resin has a gel content value upon curing at 125° C. for 14 hours of greater than 60%. 
     
     
         7 . The water-based, low-emission paint formulation according to  claim 5 , wherein the VAE resin has a gel content value upon curing at 125° C. for 14 hours of greater than 70%. 
     
     
         8 . The water-based, low-emission paint formulation according to  claim 5 , wherein the VAE resin has a gel content value upon curing at 125° C. for 14 hours of greater than 80%. 
     
     
         9 . The water-based, low-emission paint formulation according to  claim 5 , wherein the T g  of the resin is from minus 1° to plus 15° C. measured at a transition midpoint with a heating rate of 10 K per minute. 
     
     
         10 . The water-based, low emission paint formulation according to  claim 5 , wherein the VAE resin exhibits a swelling ratio (S r ) value, upon curing at 125° C. for 7.5 minutes, of 2.5 to 3.5 in THF. 
     
     
         11 . The water-based, low emission paint formulation according to  claim 5 , wherein the VAE resin exhibits an S r  value, upon curing at 125° C. for 7.5 minutes, of 2.5 to 3.5 in acetone. 
     
     
         12 . The water-based, low emission paint formulation according to  claim 5 , wherein the VAE resin exhibits an S r  value, upon curing at 125° C. for 14 hours, of 2.5 to 4.0 in THF. 
     
     
         13 . The water-based, low emission paint formulation according to  claim 5 , wherein the VAE resin exhibits an S r  value, upon curing at 125° C. for 14 hours, of 2.0 to 3.5 in acetone. 
     
     
         14 . The water-based, low emission paint formulation according to  claim 5 , wherein the VAE resin exhibits an S r  value, upon curing at 125° C. for 14 hours, of 2.0 to 3.5 in ethyl acetate. 
     
     
         15 . A water-based, low-emission latex paint formulation containing a blend of a vinyl acetate/ethylene (VAE) latex and an acrylic latex, wherein the blend comprises:
 (a) 70 to 80 weight % of a vinyl acetate/ethylene (VAE) latex, based upon the total weight of the acrylic latex and the vinyl acetate/ethylene latex, including a VAE resin comprising (i) from 80 to 95 weight % vinyl acetate residue, (ii) from 5 to 20 weight % ethylene residue, and (iii) optionally from 0.1 to 5 weight % silane residue, with the proviso that the sum of the weight % of the monomers equals 100;   (b) 20 to 30 weight % of an acrylic latex, based upon the total weight of the acrylic latex and the vinyl acetate/ethylene latex;   wherein the paint formulation further comprises:   (c) a pigment composition including solids selected from the group consisting of inorganic pigments, inorganic fillers and mixtures thereof present in an amount such that the paint formulation has a pigment volume concentration (PVC) of from 25% to 85%; and   (d) one or more auxiliary components selected from the group consisting of wetting agents, dispersants, emulsifiers, protective colloids, thickeners, antifoams, dyes and preservatives;   wherein the paint formulation exhibits a relative scrub index of greater than 200% and up to 300% and the formulation is characterized in that (i) the VAE resin exhibits a glass transition temperature (T g ) of from about minus 5° to about plus 20° C. measured at a transition midpoint and a K-value of greater than 60; and wherein the resin and the paint formulation are alkylphenol ethoxylate (APE)-free.   
     
     
         16 . The water-based, low-emission latex paint formulation according to  claim 15 , wherein the acrylic latex comprises the emulsion polymerization product of at least one monomer selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethyl hexyl acrylate, decyl acrylate, methyl methacrylate, butyl methacrylate, iso-butyl methacrylate, iso-bornyl methacrylate hydroxy ethyl acrylate and hydroxy ethyl methacrylate. 
     
     
         17 . The water-based, low-emission latex paint formulation of  claim 15 , wherein the acrylic latex includes vinyl acetate residue. 
     
     
         18 . A water-based, low-emission latex paint formulation comprising:
 (a) a vinyl acetate/ethylene (VAE) latex including a VAE resin with from 80 to 95 weight % vinyl acetate residue and from 5 to 20 weight % ethylene residue, optionally including additional monomers;   (b) a pigment composition including inorganic solids selected from inorganic pigments, inorganic fillers and mixtures thereof present in an amount such that the paint formulation has a pigment volume concentration (PVC) of from 25% to 85%; and   (c) one or more auxiliary components selected from the group of wetting agents, dispersants, emulsifiers, protective colloids, thickeners, antifoams, dyes and preservatives;   wherein the latex, pigment composition, and auxiliary components are selected and utilized in amounts such that the paint formulation exhibits a relative scrub index of greater than 200% and up to 300%; and wherein the resin and the paint formulation are alkylphenol ethoxylate (APE)-free.   
     
     
         19 . The water-based, low-emission paint formulation according to  claim 18 , wherein the VAE resin incorporates from 0.1 to 5 weight % of the residue of at least one monomer selected from the group consisting of silane monomers, glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, vinyl glycidyl ether, vinylcyclohexene oxide, limonene oxide, myrcene oxide, caryophyllene oxide, vinyltoluenes and styrenes substituted with a glycidyl radical in the aromatic moiety, vinylbenzoates substituted with a glycidyl radical in the aromatic moiety, acetoacetoxyethyl acrylate, acetoacetoxypropyl methacrylate, acetoacetoxyethyl methacrylate, acetoacetoxybutyl methacrylate, 2,3-di (acetoacetoxy)propyl methacrylate, and allyl acetoacetate. 
     
     
         20 . The water-based, low-emission paint formulation according to  claim 18 , wherein the VAE resin incorporates from 0.1 to 5 weight % of the residue of at least one monomer selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, vinyl glycidyl ether, vinylcyclohexene oxide, limonene oxide, myrcene oxide, caryophyllene oxide, vinyltoluenes and styrenes substituted with a glycidyl radical in the aromatic moiety, and vinylbenzoates substituted with a glycidyl radical in the aromatic moiety.