Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF THE INVENTION
The present invention relates to acrylic binders, and
more particularly to acrylic emulsions having a wide variety of
applications in coating of substrates, and the method of
producing same.
Acrylic emulsions used as binders have previously been
widely investigated and used. Such emulsions have
conventionally been used in the form of water-based emulsions
for example as latex paints), or sycupy solutions of acrylic
solids in aromatic solvents. All such acrylic emulsions are
inherently subject to manifestations of instability common to
all colloidal systems. As well, all are very sensitive to
freezing, excessive shear and also to bacterial attack. When
used as coatings, acrylic emulsions have restricting
limitations when it comes to-
l. choice of substrate
2. condition of substrate
3. high humidity environment
4. freezing temperatures
In conventional acrylic binder systems, powders,
beads, granules, flakes or even solid blocks of the acrylic
composition are either dissolved or compounded in wa~er or
aromatic solvents, with or without heat, to produce the desired
resin solution or suspension.
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It i6 an object of the present invention to erovide a
series of ac~ylic emulsion solutions which are easily
compounded and can ~e adapted to a wide variety of end uses as
coatings. It is a further object of the present invention to
erovide acrylic resin solutions that are unaffected by extreme
temeerature changes and remain clear and stable over long
periods of time. It is a further object of the present
invention to p~oduce resin binder solutions that are immune to
bacterial attack, thus providing for longer shelf life than
conventional acrylic binder solutions.
SUMMARY OF THE INVENTION
In accordance with the present invention there is
provided an hydroxilic bonding resin which is the reaction
product between any one or a blend of two or more acrylic
emulsions and any one or a blend of two or more primary or
secondaLy alcohols. The alcohol or blend thereof is specific
to dissolve the selected acrylic emulsion.
The alcohol or blend thereof is ereferably selected
from the group consisting of ethyl, n-butyl, 2-butyl, n-eropyl,
iso-eropyl, and diacetone (acetone free).
It is preferred that the reactants be present in the
following eercentages by weight: .1% to 50% - acrylic emulsion,
99.9~ to 45% - alcohol, and 0% to 5% - diacetone alcohol
(acetone free).
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The present invention further provides for the process
of making an hydroxilic bonding resin solution which comprises
mixing any one or a blend of two or more acrylic emulsions and
any one or a blend of two or more primary or secondary
5alcohols. The alcohol or blend thereof is specific to
dissolving the selected acrylic emulsion.
DETAILED DESCRIPTION OF THE INVENTION
The present invention eroduces an acrylic resin
solution, preferably clear, which may be used as a binder in
10alcohol-based systems and which is applicable to a wide variety
of substrates. The process of producing the solution according
to the ~resent invention, contrary to conventional systems in
which solids are dissolved into the desired resin solution or
suspension, requires the simele mixing of two or more liquids.
15Many of the previously-noted shortcomings of
conventional acrylic emulsions are eliminated with the
emulsions of the present invention. The hydroxilic bonding
resin solutions which are the product of the present invention
are unaffected by extreme temperature changes and remain clear
20and stable. They are immune to bacterial attack because of the
alcohol present in the system, thus providing for improved
shelf life.
Binder solutions may be prepared according to the
present invention which, when mixed with milled fiberglass and
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applied to a substrate with fiberglass scrim, will resist water
pressures in excess of 50 ~si. Such mixtures are earticularly
well-suited foL application as coatings to swimming pools and
basement walls, where they would be subjected to high water
eressures~
Because of the hydroxilic bonding nature of the resin
solutions produced according to the eresent invention, the
solutions can be cross-linked with silicone, either before or
after the reaction with the alcohol. The end product is one
which has an extremely high LesistanCe to salt spray, acid,
chalking and the like. Such end product is paLticularly
well-suited as a concrete coating.
The acrylic ~esin solutions according to the present
invention provide a wide variety of coatings suitable for
application to wood, concrete, brick, masonry in general,
aluminum, plaster board, stucco, asphalt and its derivatives,
canvas, fabeics (either natural or synthetic), leather of all
kinds, plastics. Their application may be carried out under
noemal or extremely adverse conditions, such as below~freezing
temperatures, high relative humidity, moist o~ even in some
cases wet substrates.
The acrylic emulsions to be used in accordance with
the present invention are any one, or a blend of two or more,
of commercially available acrylic emulsions. The acrylic
emulsion may for example be RHOPLEX E - 330 (Trade Mark~, a
:,,
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cement mortar modifier manufactured by ~ohm & Hass Co. of
Philadelphia, Penn. containing methyl and butyl acrylates~
Acrylic resin solutions in accordance with the present
invention, having very low concentrations of resin solids, can be
injected into the soil with or without the addition of an alkoxide,
to form an impervious layer. When this layer comes in contact with
water, it gels to a semi-solid mass that is waterproof.
Acrylic resin solutions in accordance with the present
invention, whe~ mixed with a small amount of alkoxide, turn into
T~/~t~6,
soft or firm gels. These gels are shear ~itY~ and can be used
in the manufacture of waterproof coatings especially suited for
porous substrates where one single coat will prevent penetration of
water without affecting the breathing ability of the substrate,
i.e. concrete blocks.
The solutions in accordance with the present invention
produce a variety of alcohol/acrylic coatings suitable for
application to wood, concrete, brick, masonry in general, aluminum,
plasterboard, stucco, asphalt and its derivatives, canvas, fabrics
either natural or synthetic, leather of all kinds, and plastics.
They may be applied under normal as well as very adverse conditions
such as below-freezing temperatures, high relative humidity, and
onto moist or even, in some cases, wet substrates.
Thus it is apparent that there have been provided in
accordance with the invention, acrylic emulsion compositions
and methods of makin~ same that fully satisfy the objects, aims
and advantages set forth above. While the invention has been
desc~ibed i.n conjunction with specific embodiments thereof, it
is evident that many alternatives, modifications and variations
will be ap~a~ent to those skilled in the art in light of the
foregoing description. ~ccordingly, it is intended to embrace
all such alte~natives, modifications and vari.ations as fall
within the spirit and broad scope of the invention.
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