Professional Documents
Culture Documents
CM
<
«
(0
0)
w
00
o
0.
UJ
This invention relates to a translucent, stain absorbent film which
is applied as a c o a t i n g of a f i l l e d acrylic latex to a substrate such as
a metal or a plastic. More p a r t i c u l a r l y , the invention relates to an
aqueous, film-forming composition comprising an a c r y l i c latex and a s o f t ,
water-insoluble extender pigment. Still more p a r t i c u l a r l y , it relates to
metal articles having an i n t e g r a l , three-dimensional, simulated wood g r a i n
in its surface and a s t a i n - a b s o r b e n t coating on i t s surface.
The t r a n s l u c e n t film of this invention is distinguished from a t r a n s -
parent one in that it is slightly opaque, permitting the imperfect trans-
mission of light relected from the substrate. The f i l m is capable of
absorbing an a p p l i e d stain while still exposing the color and markings of
the substrate.
Various techniques have been used over the years to simulate a wood
grain on metal p a n e l s . Among t h e s e is the lamination on such a panel of a
vinyl film having a wood g r a i n pattern printed thereon. The f i l m is sub-
ject to delamination and permanent disfigurement by t e a r i n g or s c u f f i n g
actions. Another technique is the printing of the wood g r a i n pattern
directly on the metal. The p r i n t e d pattern is very susceptible to
scratching and s c u f f i n g . Restoration to the original statee is exceed-
ingly difficult. A technique requiring artistic ability is the manual
staining of a metal panel to give a streaked appearance resembling a
wood g r a i n .
Furthermore, as the patentees in U.S. Patent No. 3 , 8 1 1 , 9 1 5 observe,
such simulated wood g r a i n s have the disadvantage of looking and feeling
flat as compared to the three-dimensional look and f e e l of most natural
coats of t h i s sort are used in the inventions described in U.S. Patent Nos.
1,651,136; 2,248,254; and 3 , 8 4 7 , 6 4 6 . A method for producing a "crackled"
antique finish is described in U.S. Patent No. 3 , 6 9 2 , 5 5 7 . Said method
utilizes a composition comprising an a c r y l i c resin emulsion, finely ground
marble, polyurethane, and w a t e r . The c o m p o s i t i o n may be a p p l i e d as b o t h
the first and t h i r d coatings on a s u b s t r a t e , the second coating being a
water soluble dye, or, in the case where the substrate is non-absorbent,
the water soluble dye is applied first and the acrylic/polyurethane emul-
sion is applied over the dried dye. In e i t h e r case, the w a t e r soluble dye
is said to "bleed through" upwards into the t h i r d or uppermost coating to
form the antique looking finish having a cracked surface.
In many i n s t a n c e s , pigments which p r o v i d e color and o p a c i t y to a
groundcoat a l s o have the effect of sealing the film so t h a t a stain is not
absorbed or, at b e s t , it is absorbed unevenly.
Now, i t has been discovered that a substantially colorless, translu-
cent film capable of absorbing an a p p l i e d stain may be formed on a s u b s t r a t e
by c o a t i n g the substrate with an aqueous composition comprising an a c r y l i c
latex and a w a t e r - i n s o l u b l e extender pigment having a mean p a r t i c l e size of
from about 5 to a b o u t 7 microns, then drying said coating by a s u i t a b l e
method.
The a c r y l i c latices used in this invention are aqueous emulsions of
acrylic resins; the emulsions have a solids content of from about 30% t o
acids, styrene, and similar vinyl monomers are examples of the acrylic resins
which are useful as the film forming constituents of the composition of this
invention. The term "alkyl" is used herein to mean an alkyl group having
from 1 to 8 carbon atoms. Acrylates and m e t h a c r y l a t e s in which the alkyl
group contains from 1 to 3 carbon atoms are preferred. Copolymers of such
esters with each other and/or with one or more of the monomers specifically
mentioned above are particularly preferred. The f i l m s deposited by t h e
acrylic latices useful in this invention are generally characterized by
good r e s i s t a n c e to w a t e r , high humidity, salt spray, oil and s o l v e n t s .
The aqueous composition of this invention comprises from about 10% t o
about 15% of, the acrylic resin by w e i g h t . Water constitutes from about 10%.
to about 40% of the weight of the composition; this includes water in the
width. The depth of the grooves is also not uniform. Although the tics are
for the most p a r t parallel, they and the plateaus appear to converge and d i -
verge because of the varying lengths and w i d t h s of the grooves. Before being
coated, the minimum depth of the grooves is about 2.2 times the thickness of
the dry film which is to be d e p o s i t e d from the coating composition. A par-
Example 1
A mixture of w a t e r (66 p a r t s ) , an a n t i - f o a m i n g agent comprising a non-
ionic surfactant and a s i l i c o n e sold under the trademark NOPCO NXZ(0.2 p a r t ) ,
ethylene glycol (8 p a r t s ) , the quaternary ammonium s a l t of 2-dimethylamino
methyl propanol and d i ( d i o c t y l p y r o p h o s p h a t o ) ethylene titanate (1.2 p a r t s ) ,
zinc phosphate having an average particle size of 6 microns and sold under
the product designation J0852 by Mineral Pigments Corporation (175 p a r t s )
is dispersed at high speed in a Cowles mixer for 10 m i n u t e s . Then 120 p a r t s
of an a c r y l i c latex having a solids content of about 43% by weight, a pH o f
9.4 to 10, a viscosity at 25°C. of from 500 to 2000 cps. and wherein the
particle size of the all-acrylic resin is less than 0.1 micron is added a l o n g
with 15 p a r t s of isopropanol and 2 p a r t s of a c r o s s l i n k e d , acidic acrylic
emulsion copolymer as a t h i c k e n i n g agent- Ammonium h y d r o x i d e (3 p a r t s ) is
added to activate the thickening agent. The m i x t u r e is thoroughly blended
at room t e m p e r a t u r e . The a c r y l i c latex is sold under the trademark Rhoplex
MV-23 by Rohm & H a a s .
A stainable f i l m having a porous surface resulted when the composition
thus prepared was a p p l i e d to a s u b s t r a t e and d r i e d .
Example 2
The g e n e r a l procedure of Example 1 is repeated except that the acrylic
latex used is an aqueous emulsion of an a c r y l i c / s t y r e n e copolymer sold by
Polyvinyl Chemical Industries under the trademark Neocryl A-623 and 10 p a r t s
of b u t y l cellosolve are used in a d d i t i o n to the ethylene glycol. The a c r y l i c
latex has a solids c o n t e n t of 35% by w e i g h t , a pH of 7.5, and a B r o o k f i e l d
viscosity at 25°C. of 320 c p s .
This composition also provided a stainable, porous film when a p p l i e d
to a s u b s t r a t e and d r i e d .
In c o n t r a s t to the results of Examples 1 and 2, compositions prepared
terra alba (finely divided gypsum), or a finely divided clay for the zinc
phosphate give films having a sealted surface that do not accept a de-
corative stain.
Example 3
Example 4
The g e n e r a l procedure of Example 3 is repeated except that zinc
phosphate having an a v e r a g e particle size of 6 microns is used in p l a c e of
the calcium carbonate.
The f i l m deposited on metal panels by the acqueous composition thus
Example 5
Sheet steel is embossed to achieve a pattern of g e n e r a l l y parallel
lines or tics of random l e n g t h to s i m u l a t e the pattern of a wood g r a i n . The
wood g r a i n effect is obtained by an a r r a n g e m e n t of individual tics spaced
the stain.
In c o n t r a s t to the results in Example 5, the presence of a pigment a t
a low l e v e l of concentration in an aqueous coating composition otherwise
microns.
2. The c o m p o s i t i o n of claim 1 wherein the weight percent of s a i d
acrylic resin is from about 10% to about 15% of the total weight.
4. The c o m p o s i t i o n of c l a i m 1 wherein the weight ratio of said
agent.
6. The c o m p o s i t i o n of claim 5 wherein the amount of coupling agent is
from about 0.25% to about 0.75% of the weight of the extender pigment.
7. The c o m p o s i t i o n of claim 1 wherein the mean p a r t i c l e size is from
simulated wood g r a i n .
filled acrylic resin wherein the filler/resin ratio is from about 1.5:1 to
about 3.6:1 by w e i g h t .
21. The metal article of claim 19 w h e r e i n the filler is zinc phos-
p h a t e .
22. The metal article of claim 19 w h e r e i n the filler is calcium
carbonate. -
23. The metal article of claim 20 w h e r e i n the acrylic resin is a
styrene/acrylic copolymer.
24. The metal article of claim 17 h a v i n g a pigmented primer coat
under said translucent coating.
25.. A steel architectural door characterized by at least one face