CN-122029050-A - Coating for passive water management and multilayer structure using the same

Abstract

Provided herein is a structure for construction applications and a method of making the same. The structure may include a substrate layer having a first surface and an opposing second surface, and a crosslinked coating deposited on at least a portion of the first surface of the substrate layer. The crosslinked coating may comprise a mixture of polyvinyl alcohol and polycarboxylic acid. The multilayer structure may be configured to facilitate the evacuation of water vapor from the crosslinked coating toward the substrate layer in a first direction when the relative humidity of the crosslinked coating side is higher than the substrate layer side, and may be configured to inhibit the intrusion of water vapor from the substrate layer toward the crosslinked coating in a second direction when the relative humidity of the substrate layer side is higher than the crosslinked coating side.

Inventors

• D. M. Stan
• RASKIN ILYA
• Leick J.
• D. Karachozov

Assignees

• 艾德普特材料公司

Dates

Publication Date

20260512

Application Date

20240823

Priority Date

20230823

Claims (20)

1. 1. A multilayer structure, the multilayer structure comprising: A substrate layer having a first surface and an opposing second surface, and A crosslinked coating deposited on at least a portion of the first surface of the substrate layer, the crosslinked coating comprising a mixture of polyvinyl alcohol and polycarboxylic acid, wherein the crosslinked coating has a first dry coating weight, and wherein after the first crosslinked coating is exposed to water, the crosslinked coating has a second dry coating weight that is greater than 90% of the first dry coating weight; Wherein the multilayer structure is configured to promote the venting of water vapor from the crosslinked coating to the substrate layer in a first direction when the relative humidity of the crosslinked coating side is higher than the substrate layer side; Wherein the multilayer structure is configured to inhibit intrusion of water vapor from the substrate layer into the crosslinked coating layer in a second direction when the relative humidity of the substrate layer side is higher than that of the crosslinked coating layer side, and Wherein the multi-layer structure has a first wet-cup process permeability in the first direction and a second wet-cup process permeability in the second direction, the first wet-cup process permeability being greater than the second wet-cup process permeability.
2. 2. The multilayer structure of claim 1 wherein the polyvinyl alcohol comprises a polyvinyl alcohol copolymer.
3. 3. The multilayer structure of claim 1 or claim 2, wherein the polycarboxylic acid comprises one or more polycarboxylic acid copolymers.
4. 4. The multilayer structure according to any one of the preceding claims, wherein the polycarboxylic acid comprises polyacrylic acid.
5. 5. The multilayer structure of claim 4 wherein the polyacrylic acid comprises one or more polyacrylic acid copolymers.
6. 6. The multilayer structure according to any one of the preceding claims, wherein the polycarboxylic acid comprises polymaleic acid.
7. 7. The multilayer structure of claim 6 wherein the polymaleic acid comprises one or more polymaleic acid copolymers.
8. 8. The multilayer structure of any one of the preceding claims, wherein the first dry coating weight is from about 3 gsm to about 50 gsm.
9. 9. The multilayer structure of claim 8, wherein the first dry coat weight is 10 gsm.
10. 10. The multilayer structure according to any one of the preceding claims, wherein the first wet-cup process permeability is at least 30 US perms.
11. 11. The multilayer structure according to any one of the preceding claims, wherein the second wet-cup process permeability is at most 30 US perms.
12. 12. The multilayer structure of any one of the preceding claims, wherein the ratio of the first wet-cup permeability to the second wet-cup permeability is about 3:2.
13. 13. The multilayer structure of any one of claims 1 to 11 wherein the ratio of the first wet-cup process permeability to the second wet-cup process permeability is about 2:1.
14. 14. The multilayer structure of any one of the preceding claims, wherein the multilayer structure has a dry cup permeability of about 0.1 US perms to 10 US perms.
15. 15. The multilayer structure of any one of the preceding claims, wherein the multilayer structure has a dry cup permeability of about 1 US perms to 10 US perms.
16. 16. The multilayer structure of any one of the preceding claims, wherein the crosslinked coating further comprises at least one of one or more fillers, one or more pigments, or one or more pigment extenders.
17. 17. The multilayer structure of any one of the preceding claims, wherein the crosslinked coating further comprises one or more crosslinking agents, one or more crosslinking catalysts, or both.
18. 18. The multilayer structure of any one of the preceding claims, wherein the crosslinked coating further comprises one or more plasticizers.
19. 19. The multilayer structure according to any one of the preceding claims, wherein the substrate layer comprises a desiccant material.
20. 20. The multilayer structure of any one of claims 1-18 wherein the base layer does not comprise a desiccant material.

Description

Coating for passive water management and multilayer structure using the same Cross Reference to Related Applications The present application claims priority from U.S. provisional patent application No. 63/534,235, entitled "MULTILAYER STRUCTURES AND COATINGS FOR BUILDING APPLICATIONS," filed 8/23, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field The subject matter described herein relates to coatings and multilayer structures for passive water management, such as in architectural applications. Background The purpose of the wall assembly is to provide a comfortable and safe environment inside the building for the occupants. There has been great effort to develop building materials and components that effectively regulate the temperature and relative humidity of the interior environment under varying external environmental conditions and internal usage scenarios. One desirable goal is to maintain the internal temperature and relative humidity within established ranges for human comfort and health with minimal energy input from the HVAC system. One trend in the construction industry is to increase the thermal efficiency of buildings with building materials and their components that more effectively entrap air and heat. However, materials that effectively trap air and heat tend to also trap moisture within them, and in many cases, building materials and components can create a risk of fungal growth and other forms of moisture damage due to excessive moisture and water vapor entrapment within the wall components. Accordingly, there remains a need for improved materials to regulate the transmission of water (e.g., water vapor) into and out of wall assemblies, thereby maintaining comfortable conditions inside a building and reducing the risk of the building being subject to moisture damage. Disclosure of Invention In certain embodiments of the present subject matter, challenges associated with the regulation of moisture in a building may be addressed by incorporating one or more features described herein or comparable/equivalent methods as will be appreciated by those of ordinary skill in the art. Embodiments of the present subject matter relate to coatings and multilayer structures that provide water conditioning capabilities, such as in architectural applications. In some embodiments, one or more of the following features may optionally be incorporated in any feasible combination. In one embodiment, a multi-layer structure for passive water management is provided. The multilayer structure includes a substrate layer having a first surface and an opposing second surface, and a crosslinked coating (cross-linked coat layer) deposited on at least a portion of the first surface of the substrate layer, the crosslinked coating may comprise a mixture of polyvinyl alcohol and polycarboxylic acid, wherein the crosslinked coating has a first dry coating weight, and wherein the crosslinked coating has a second dry coating weight that is greater than 90% of the first dry coating weight after the first crosslinked coating is exposed to water. The multilayer structure is arranged to promote the evacuation (egress) of water vapor from the crosslinked coating to the substrate layer in a first direction when the relative humidity of the crosslinked coating side (adjacent) is higher than the substrate layer side. The multilayer structure is further arranged to inhibit intrusion of water vapor from the substrate layer into the crosslinked coating layer in the second direction when the relative humidity of the substrate layer side is higher than the crosslinked coating layer side. The multi-layer structure has a first wet-cup process permeability (wet-cup permeance) in a first direction and a second wet-cup process permeability in a second direction, the first wet-cup process permeability being greater than the second wet-cup process permeability. In some embodiments, the polyvinyl alcohol may include a polyvinyl alcohol copolymer. In some embodiments, the polycarboxylic acid may comprise one or more polycarboxylic acid copolymers. In some embodiments, the polycarboxylic acid may comprise polyacrylic acid. In some embodiments, the polyacrylic acid may include one or more polyacrylic acid copolymers. In some embodiments, the polycarboxylic acid may comprise polymaleic acid. In some embodiments, the polymaleic acid may comprise one or more polymaleic acid copolymers. In some embodiments, the first dry coating weight may be from about 3 gsm to about 50 gsm. In some embodiments, the first dry coating weight may be 10 gsm. In some embodiments, the first wet-cup process permeability may be at least 30 US perms. In some embodiments, the second wet-cup permeability may be up to 30 US perms. In some embodiments, the ratio of the first wet-cup permeability to the second wet-cup permeability may be about 3:2. In some embodiments, the ratio of the first wet-cup permeability to the second wet-cup