# US 11,999,867 B2 · Coating composition and coated substrate

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- Number: US 11,999,867 B2
- Document ID: US11999867B2
- Status: Granted
- Kind: B2
- Application number: 16/858,647
- Filed: 2020-04-26
- Published: 2020-12-03
- Granted: 2024-06-04
- Earliest claimed: 2019-05-31
- Assignees: Sika Technology AG
- Applicants: Sika Technology AG
- Inventors: Gail D. Winterbottom; Aditi Chavannavar; Sarah Kay O' Boyle; Monica Santos-Verbrick
- Web page: https://patentgrep.com/patent/US11999867B2

## CPC

- C09D 125/14: with unsaturated esters
- C09D 175/04: Polyurethanes
- C08F 220/20: of polyhydric alcohols or phenols {, e.g. 2-hydroxyethyl (meth)acrylate or glycerol mono-(meth)acrylate}
- C08G 18/0866: {the dispersing or dispersed phase being an aqueous medium}
- C08G 18/10: Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G 18/6229: {Polymers of hydroxy groups containing esters of acrylic or methacrylic acid with aliphatic polyalcohols}
- C08G 18/73: acyclic
- C08L 25/14: with unsaturated esters
- E04B 2/00: Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls (connections for building structures in general E04B1/38; insulation for buildings in general E04B1/62; building elements of relatively thin form for parts of buildings E04C2/00)
- E04C 2/205: {of foamed plastics, or of plastics and foamed plastics, optionally reinforced}
- C08L 33/066: {containing -OH groups}
- C08L 2201/52: Aqueous emulsion or latex, e.g. containing polymers of a glass transition temperature (Tg) below 20°C
- C08L 2201/54: Aqueous solutions or dispersions
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)

## Abstract

A two-component water-based coating composition that exhibits good adherence to the surface of substrates such as polyurethane foam boards. The two-component water-based coating composition is based on acrylic urethane chemistry. Coated substrates, including polyurethane foam boards coated with the two-component water-based acrylic urethane coating composition, wall cladding systems, and building walls incorporating the coated polyurethane foam boards are also disclosed. The coated polyurethane foam boards are water resistant, mold resistant, mildew resistant, UV radiation resistant, lightweight and thermally insulative.

## Claims

### Claim 1

A two-component water-based acrylic urethane coating composition that is able to adhere to polyurethane foam board, the composition comprising:
a first component comprising about 40 to about 80 weight percent of a hydroxyl functional acrylic polymer emulsion, and (ii) from about 2.5 to about 15 weight percent of pigment; and
a second component comprising a water-emulsifiable isocyanate,
wherein the first component and the second component are provided in respective volumes that correspond to a volume mixing ratio in a range of from 4:1 to 8:1.

### Claim 2 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein said acrylic polymer emulsion comprises a styrene-acrylic copolymer.

### Claim 3 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein said acrylic polymer emulsion comprises an ammonia salt of a styrene-acrylic copolymer.

### Claim 4 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, water-emulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 5 (depends on 4)

The two-component water-based polyurethane coating composition of claim 4, wherein said water-emulsifiable isocyanate is an aliphatic isocyanate.

### Claim 6 (depends on 2)

The two-component water-based polyurethane coating composition of claim 2, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, water-emulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 7 (depends on 6)

The two-component water-based polyurethane coating composition of claim 6, wherein said water-emulsifiable isocyanate is an aliphatic isocyanate.

### Claim 8 (depends on 3)

The two-component water-based polyurethane coating composition of claim 3, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, water-emulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 9 (depends on 8)

The two-component water-based polyurethane coating composition of claim 8, wherein said water-emulsifiable isocyanate is an aliphatic isocyanate.

### Claim 10 (depends on 1)

A coated polyurethane foam board comprising:
a base polyurethane foam board comprising first and second opposite facing major surfaces and a thickness extending between said first and second opposite facing major surfaces; and
the urethane coating composition of claim 1, which is applied to at least a portion of at least one of said first and second opposite facing surfaces of said polyurethane foam board.

### Claim 11 (depends on 10)

The coated polyurethane foam board of claim 10, wherein said acrylic polymer comprises a styrene-acrylic copolymer.

### Claim 12 (depends on 11)

The coated polyurethane foam board of claim 11, wherein said acrylic polymer comprises an ammonia salt of said styrene-acrylic copolymer.

### Claim 13 (depends on 10)

The coated polyurethane foam board of claim 10, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, wateremulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 14 (depends on 13)

The coated polyurethane foam board of claim 13, wherein said water-emulsifiable is an aliphatic isocyanate.

### Claim 15 (depends on 11)

The coated polyurethane foam board of claim 11, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, wateremulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 16 (depends on 15)

The coated polyurethane foam board of claim 15, wherein said water-emulsifiable aliphatic isocyanate.

### Claim 17 (depends on 12)

The coated polyurethane foam board of claim 12, wherein said water-emulsifiable isocyanate is selected from water-emulsifiable aliphatic isocyanates, wateremulsifiable cycloaliphatic isocyanates, water-emulsifiable araliphatic isocyanates and mixtures thereof.

### Claim 18 (depends on 17)

The coated polyurethane foam board of claim 17, wherein said water-emulsifiable is an aliphatic isocyanate.

### Claim 19 (depends on 1)

A building wall comprising:
a frame and a coated polyurethane foam board attached to said frame,
said coated polyurethane foam board having opposite facing first and second surfaces and a thickness extending between said first and second opposite facing surfaces, and the urethane coating composition of claim 1, which is adhered to at least a portion of at least one of said first and second opposite facing major surfaces of said polyurethane foam board.

### Claim 20 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the second component comprises at least one water-emulsifiable isocyanate in solvent.

### Claim 21 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the solids content of the first component composition is from about 45 to about 55 percent by weight.

### Claim 22 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the solids content of a mixture of the first and second component compositions is from about 40 to about 45 percent by volume.

### Claim 23 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the solids content of a mixture of the first and second component compositions is from about 50 to about 55 percent by weight.

### Claim 24 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the density of the first component composition is in the range of about 1 to about 1.5 kg/L.

### Claim 25 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the density of a mixture of the first and second component compositions is in the range of about 1 to about 1.3 kg/L.

### Claim 26 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the volatile organic content (VOC) of the first component composition is less than 100 g/L.

### Claim 27 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the first component comprises from about 5 to about 25 weight percent water.

### Claim 28 (depends on 1)

The two-component water-based polyurethane coating composition of claim 1, wherein the first component comprises from about 7.5 to about 15 percent by weight of the pigment.

### Claim 29 (depends on 1)

The two-component colored water-based acrylic polyurethane coating composition of claim 1, wherein the first component further comprises from about 5 to about 25 weight percent of filler.

### Claim 30 (depends on 1)

The two-component colored water-based acrylic polyurethane coating composition of claim 1, wherein the first component further comprises from about 10 to about 20 weight percent of filler.

### Claim 31 (depends on 1)

The two-component colored water-based acrylic polyurethane coating composition of claim 1, wherein the water-emulsifiable isocyanate is an oligomeric isocyanate.