Mastic and caulking compositions and composite articles

Claim 2

A coating mastic or caulking composition having a total non-volatile solids content of about 60 to about 90 weight percent, which solids content comprises at least about 15 weight percent of a water insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total non-volatile solids, wherein said polymer has a T g of about -50° C. to about -10° C., and comprises at least one functional monomer of the formula: ##STR9## in which R 1 is a divalent organic radical of at least 3 atoms in length, R 5 and R 6 are independently selected from hydrogen, hydroxy, halo, thio, amino or monovalent organic radicals, and X is --CO--R 4 or --CN wherein R 4 is hydrogen or a monovalent organic radical, and said polymer is selected from the group consisting of (a) conjugated diolefin polymers comprising at least about 30 weight percent of one or more conjugated diene monomers having 4 to about 8 carbon atoms and 0 to about 70 weight percent of one or more alkenyl substituted monoaromatic monomers; (b) olefin-ester interpolymers comprising at least about 1 weight percent of a monoolefin monomer having up to about 4 carbon atoms and at least about 40 weight percent of an alkenyl or alkenol ester of a saturated carboxylic acid; (c) olefinically unsaturated carboxylic acid ester polymers comprising at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers; (d) alkenyl ether polymers comprising at least about 30 weight percent alkenyl ether monomer units; and (e) combinations thereof.

Claim 3

The composition defined in claim 1, wherein said non-volatile solids constitute about 70 to about 90 weight percent of said composition, and said polymer has a T g of about -50° C. to about -20° C.

Claim 4

The composition defined in claim 1 comprising an amount of a thickener sufficient to increase the viscosity of said composition, and said undissolved solids other than said polymer comprises at least about 5 weight percent of an opaque, reflective pigment.

Claim 5

The composition defined in claim 1 wherein said composition is a water-base emulsion, said polymer has a T g of about -50° C. to about -20° C., and said undissolved solids other than said polymer comprises a pigment selected from the group consisting of titanium dioxide, zinc oxide, and combinations thereof.

Claim 6

The composition defined in claim 1 which comprises a dispersion of said total solids in water, and said composition comprises at least about 10 weight percent water.

Claim 7

The composition defined in claim 1 wherein said solids other than said polymer comprises a pigment.

Claim 8

The composition defined in claim 1 wherein said polymer comprises about 0.1 to about 40 weight percent of said functional monomer.

Claim 9

The composition defined in claim 1 wherein said polymer comprises a member selected from the group consisting of acrylic acid, itaconic acid, and combinations thereof.

Claim 10

The composition defined in claim 1 wherein said polymer comprises about 0.1 to about 10 weight percent of said function monomer.

Claim 11

The composition defined in claim 1 wherein said polymer comprises about 0.1 to about 5 weight percent of said functional monomer.

Claim 12

The composition defined in claim 1 which comprises a water-base mastic emulsion of said total solids dispersed in water, and said mastic is characterized by a dry adhesion to closed-foam polyurethane of at least about 1 pound per inch.

Claim 13

The composition defined in claim 1 wherein said polymer is substantially free of polymer crosslinking polyvalent metals, compounds and complexes.

Claim 14

The composition defined in claim 1 wherein said polymer is substantially free of cross-linking agents.

Claim 15

The composition defined in claim 1 wherein R 1 is a divalent organic radical 3 to about 40 atoms in length, and X is --CO--R 4 .

Claim 16

The composition defined in claim 1 wherein said polymer comprises at least about 0.1 weight percent of at least one functional monomer having the formula: ##STR10## wherein R 4 , R 5 , and R 6 are as defined in claim 1, R 3 is a divalent organic radical, Y and Z are independently selected from the group consisting of O, S, and NR 7 , and R 7 is H or monovalent organic radical.

Claim 17

The composition defined in claim 15 wherein R 4 is hydrogen or alkyl having up to about 8 carbon atoms, and R 3 is a divalent organic radical at least 2 atoms in length.

Claim 18

The composition defined in claim 16 wherein each of Y and Z is O.

Claim 19

The composition defined in claim 1 wherein said polymer comprises about 0.1 to about 10 weight percent of a member selected from the group consisting of acetoacetoxyethylmethacrylate, acetoacetoxyethylacrylate, and combinations thereof.

Claim 20

The composition defined in claim 1 wherein said polymer comprises less than about 1 weight percent of an N-methylolamide.

Claim 21

The composition defined in claim 1 wherein said polymer is substantially free of N-methylolamides.

Claim 22

The composition defined in claim 1 wherein said polymer comprises a carboxylic acid monomer.

Claim 23

The composition defined in claim 1 wherein said polymer comprises at least about 0.1 weight percent of a monomer selected from the group consisting of olefinically unsaturated carboxylic acids having up to about 10 carbon atoms, sulfoalkyl esters of said olefinically unsaturated acids, and combinations thereof.

Claim 24

The composition defined in claim 1 wherein said polymer comprises at least about 40 weight percent polymerized, olefinically unsaturated, carboxylic acid ester monomers.

Claim 25

The composition defined in claim 23 wherein said polymer comprises at least about 0.1 weight percent of said functional monomer and at least about 60 weight percent of polymerized olefinically unsaturated, carboxylic acid ester monomers selected from the group consisting of esters of acrylic acid and methacrylic acid having 4 to about 17 carbon atoms and combinations thereof.

Claim 26

The composition defined in claim 24 wherein said polymer further comprises a polymerized, olefinically unsaturated, carboxylic acid monomer.

Claim 27

The composition defined in claim 23 wherein said polymer comprises at least about 0.1 weight percent of a monomer selected from the group consisting of olefinically unsaturated carboxylic acids having up to about 10 carbon atoms, sulfoalkyl esters of said olefinically unsaturated acids, and combinations thereof.

Claim 28

The composition defined in claim 1 wherein said polymer comprises at least about 40 weight percent of polymerized olefinically unsaturated carboxylic acid ester monomers and has a number average molecular weight of at least about 50,000.

Claim 29

A water-base emulsion coating mastic composition having a total undissolved solids content of about 70 to about 90 weight percent, which total undissolved solids comprises at least about 15 weight percent of a water insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total undissolved solids, wherein said polymer has a T g of about -50° C. to about -10° C., is permanently flexible and non-tacky when cured, and comprises pendant functional groups of the formula: ##STR11## wherein R 1 is a divalent organic radical at least 3 atoms in length, R 4 is H or a monovalent organic radical, and said polymer is selected from the group consisting of (a) conjugated diolefin polymers comprising at least about 30 weight percent of one or more conjugated diene monomers having 4 to about 8 carbon atoms and 0 to about 70 weight percent of one or more alkenyl-substituted monoaromatic monomers; (b) olefin-ester interpolymers comprising at least about 1 weight percent of a monoolefin monomer having up to about 4 carbon atoms and at least about 40 weight percent of an alkenyl or alkenol ester of a saturated carboxylic acid; (c) olefinically unsaturated carboxylic acid ester polymers comprising at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers; (d) alkenyl ether polymers comprising at least about 30 weight percent alkenyl ether monomer units; and (e) combinations thereof.

Claim 30

A water-base emulsion coating mastic composition having a total undissolved solids content of about 70 to about 90 weight percent, which total undissolved solids comprises at least about 15 weight percent of a water insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total undissolved solids, wherein said polymer has a T g of about -50° C. to about -10° C., is permanently flexible and non-tacky when cured, and comprises pendant functional groups of the formula: ##STR11## wherein R 1 is a divalent organic radical at least 3 atoms in length, R 4 is H or a monovalent organic radical, and said polymer is selected from the group consisting of (a) conjugated diolefin polymers comprising at least about 30 weight percent of one or more conjugated diene monomers having 4 to about 8 carbon atoms and 0 to about 70 weight percent of one or more alkenyl-substituted monoaromatic monomers; (b) olefin-ester interpolymers comprising at least about 1 weight percent of a monoolefin monomer having up to about 4 carbon atoms and at least about 40 weight percent of an alkenyl or alkenol ester of a saturated carboxylic acid; (c) olefinically unsaturated carboxylic acid ester polymers comprising at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers; (d) alkenyl ether polymers comprising at least about 30 weight percent alkenyl ether monomer units; and (e) combinations thereof.

Claim 31

The composition defined in claim 28 wherein R 1 is of the formula: ##STR12## wherein Y and Z are independently selected from the group consisting of oxygen, sulfur, and NR 7 , R 3 is a divalent organic radical at least about 2 atoms in in length, and R 7 is H or hydrocarbyl.

Claim 32

The composition defined in claim 29 wherein R 3 is selected from the group consisting of substituted and unsubstituted alkylene, alkyleneoxy, alkyleneimine and alkylene-thio radicals.

Claim 33

The composition defined in claim 28 wherein R 1 is an ethylene radical, R 4 is a methyl radical, and said polymer comprises about 0.1 to about 10 percent of said functional monomer.

Claim 34

The mastic composition defined in claim 29 wherein said polymer comprises at least about 0.1 weight percent of a monomer selected from the group consisting of olefinically unsaturated carboxylic acids having up to about 10 carbon atoms, sulfoalkyl esters of said olefinically unsaturated acids, and combinations thereof.

Claim 35

A water base roofing mastic composition having a total undissolved solids content of about 60 to about 90 weight percent in which said total undissolved solids comprises at least about 15 weight percent of a water insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total non-volatile solids, wherein said polymer has a T g of about -50° C. to about -10° C., and comprises at least about 0.1 weight percent pendant functional groups of the formula: ##STR13## wherein R 3 is a divalent organic radical at least 2 atoms in length, R 4 is hydrogen or an organic radical, said polymer is selected from the group consisting of (a) olefin-ester interpolymers comprising at least about 1 weight percent of a monoolefin monomer having up to about 4 carbon atoms and at least about 40 weight percent of an alkenyl or alkenol ester of a saturated carboxylic acid; (b) olefinically unsaturated carboxylic acid ester polymers comprising at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers; (c) alkenyl ether polymers comprising at least about 30 weight percent alkenyl ether monomer units; and (d) combinations thereof, said polymer comprises at least about 0.1 weight percent of a monomer selected from the group consisting of olefinically unsaturated carboxylic acids having up to about 10 carbon atoms, sulfoalkyl esters of said olefinically unsaturated acids, and combinations thereof, and said mastic composition, when cured, has a dry adhesion to closed foam polyurethane of at least about 1 pound per inch.

Claim 36

A water base roofing mastic composition having a total undissolved solids content of about 60 to about 90 weight percent in which said total undissolved solids comprises at least about 15 weight percent of a water insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total non-volatile solids, wherein said polymer has a T g of about -50° C. to about -10° C., and comprises at least about 0.1 weight percent pendant functional groups of the formula: ##STR13## wherein R 3 is a divalent organic radical at least 2 atoms in length, R 4 is hydrogen or an organic radical, said polymer is selected from the group consisting of (a) olefin-ester interpolymers comprising at least about 1 weight percent of a monoolefin monomer having up to about 4 carbon atoms and at least about 40 weight percent of an alkenyl or alkenol ester of a saturated carboxylic acid; (b) olefinically unsaturated carboxylic acid ester polymers comprising at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers; (c) alkenyl ether polymers comprising at least about 30 weight percent alkenyl ether monomer units; and (d) combinations thereof, said polymer comprises at least about 0.1 weight percent of a monomer selected from the group consisting of olefinically unsaturated carboxylic acids having up to about 10 carbon atoms, sulfoalkyl esters of said olefinically unsaturated acids, and combinations thereof, and said mastic composition, when cured, has a dry adhesion to closed foam polyurethane of at least about 1 pound per inch.

Claim 37

A roofing mastic composition comprising a water base latex containing about 60 to about 90 weight percent total dissolved solids, which total undissolved solids comprise at least about 15 weight percent of a water-insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total non-volatile solids, wherein said dissolved solids other than said polymer comprise at least about 5 weight percent of an opaque, reflective pigment, and said polymer has a T g of about -5020 C. to about -10° C., is permanently flexible and non-tacky when cured, and comprises at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers and pendant functional groups attached to the polymer backbone having the formula: ##STR14## in which R 1 is a divalent organic radical at least 3 atoms in length, X is --CO--R 4 or --CN, and R 4 is hydrogen or a monovalent organic radical.

Claim 38

A roofing mastic composition comprising a water base latex containing about 60 to about 90 weight percent total dissolved solids, which total undissolved solids comprise at least about 15 weight percent of a water-insoluble polymer and undissolved solids other than said polymer, said undissolved solids other than said polymer constitute about 30 to about 60 weight percent of said composition and are selected from the group consisting of pigments, fillers, extenders and combinations thereof, and said fillers and extenders, other than pigment, constitute about 10 to about 70 weight percent of said total non-volatile solids, wherein said dissolved solids other than said polymer comprise at least about 5 weight percent of an opaque, reflective pigment, and said polymer has a T g of about -5020 C. to about -10° C., is permanently flexible and non-tacky when cured, and comprises at least about 40 weight percent polymerized olefinically unsaturated carboxylic acid ester monomers and pendant functional groups attached to the polymer backbone having the formula: ##STR14## in which R 1 is a divalent organic radical at least 3 atoms in length, X is --CO--R 4 or --CN, and R 4 is hydrogen or a monovalent organic radical.