DESC:FIELD
The present disclosure relates to a paint composition and a process for its preparation. Particularly, the present disclosure relates to a paint composition with water-resistant properties.
DEFINITION
As used in the present disclosure, the following term is generally intended to have the meaning as set forth below, except to the extent that the context in which it is used indicate otherwise.
Pigment volume concentration (PVC) refers to the ratio of the amount of pigment to the total amount of solid components in a paint composition. The proportion of PVC is critical as it directly impacts the opacity, color strength, hiding power, and overall film integrity of the paint composition.
BACKGROUND
The background information hereinbelow relates to the present disclosure but is not necessarily prior art.
Rising dampness is a prevalent problem found within the interior walls of a house, characterized by the upward movement of groundwater through pores in the brickwork by capillary action. The ground water also carries salts that accumulate and get deposited beneath the putty once water evaporates. This process leads to the formation of damp patches on the wall and continues until the paint film peels off the wall. In the absence of timely intervention, rising dampness can result in structural issues, including the softening or crumbling of plaster, erosion of paint, and the generation of unpleasant odours. The increase in dampness or efflorescence contributes to an unhealthy surrounding environment and can potentially cause respiratory related health problems.
Conventional water-based interior paints have low PVC (pigment volume concentration) or high PVC and lack water resistance properties. Such conventional paints are prone to rising dampness or efflorescence, leading to issues such as peeling off or the formation of damp patches on the painted surfaces. These issues lead to additional problems such as cracking, mould growth, and difficulty in maintaining the painted surfaces.
There is, therefore, felt a need to provide a paint composition that mitigates the drawbacks mentioned hereinabove and provides at least an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide a paint composition.
Yet another object of the present disclosure is to provide a paint composition with water-resistant properties.
Still another object of the present disclosure is to provide a paint composition that prevents dampness and efflorescence.
Another object of the present disclosure is to provide a paint composition that is economical and environment friendly.
Still another object of the present disclosure is to provide a simple process for the preparation of a paint composition.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

SUMMARY
The present disclosure relates to a paint composition and a process for its preparation.

A paint composition comprising an emulsion polymer in an amount in the range of 5 mass % to 60 mass%, additives in an amount in the range of 35 mass% to 65 mass% and q.s water.
The additives comprise at least one pigment in an amount in the range of 0.5 mass % to 20 mass %, at least one filler in an amount in the range of 1 mass % to 35 mass%, at least one coalescing agent in an amount in the range of 0.2 mass% to 3 mass%, at least one wetting agent in an amount in the range of 0.2 mass% to 2 mass%, at least one humectant in an amount in the range of 0.2 mass% to 2 mass%, at least one thickener in an amount in the range of 1 mass% to 3 mass%, at least one pore-blocking agent in an amount in the range of 0.5 mass% to 2 mass%, at least one adhesion promoter in an amount in the range of 0.2 mass% to 1 mass%, at least one first defoamer in an amount in the range of 0.04 mass% to 1 mass%, at least one anti-microbial agent in an amount in the range of 0.2 mass% to 2 mass%, at least one first surfactant in an amount in the range of 0.2 mass% to 0.8 mass%, at least one sequestering agent in an amount in the range of 0.02 mass% to 0.08 mass%, at least one first pH stabilizer in an amount in the range of 0.05 mass% to 0.5 mass%, at least one first preservative in an amount in the range of 0.1 mass% to 0.5 mass%, extenders in an amount in the range of 1 mass% to 25 mass%, at least one scuffing additive in an amount in the range of 0.2 mass% to 1 mass% and at least one binder in an amount in the range of 0 mass% to 1 mass%, an anti-settling agent in an amount in the range of 0 mass% to 0.2 mass%, an opaque polymer in an amount in the range of 0 mass% to 15 mass%, wherein mass% of each ingredient is with respect to the total amount of the paint composition.
The emulsion polymer comprises a reaction product of 40 mass% to 60 mass% of a plurality of monomers, 0.5 mass% to 2 mass% of at least one polymerizable surfactant, 0.1 mass% to 1 mass% of at least one initiator, 0.01 mass% to 0.5 mass% of at least one coupling agent, 0.05 mass% to 0.3 mass% of a plurality of reducing agents, 0.1 mass% to 2 mass% of at least one second pH stabilizer and 0.05 mass% to 0.2 mass% of at least one buffer, 0.5 mass% to 2 mass% of a plurality of adjuvants and q.s. water; wherein the mass% of each ingredient is with respect to the total mass of the emulsion polymer composition.
The plurality of monomers are selected from the group consisting of styrene, butyl acrylate, methacrylic acid, n-butyl methacrylate, diacetone acrylamide (DAAM), ethylene glycol dimethylacrylate (EGDMA), 2-ethylhexyl acrylate and vinyl trimethoxy silane.
The polymerizable surfactant is selected from the group consisting of alcohols, C10-14-branched, C11-rich, reaction products with ethylene oxide, [(2-propenyloxy)methyl]oxirane and sulfamic acid, alkyl diphenyl oxide disulfonate, phosphate ester based polymerizable surfactants and reactive anionic emulsifier.
The initiator is selected from the group consisting of potassium persulphate, sodium persulphate and ammonium persulphate.
The coupling agent is selected from the group consisting of adipic acid dihydrazide (ADH), ethylene glycol dimethylacrylate (EGDMA) and succinic acid dihydrazide.
The plurality of reducing agents are selected from a combination of tert-butyl hydroperoxide and sodium formaldehydesulfoxylate, tert-butyl hydroperoxide and sodium acetone bisulphite, tert-butyl hydroperoxide and L-ascorbic acid, tert-butyl hydroperoxide and sodium meta bisulphate.
The second pH stabilizer is at least one selected from the group consisting of 95% of 2-amino-2-methyl-1-propanol, 2-amino ethanol, alkanolamine and potassium methylsiliconate.
The buffer is selected from the group consisting of sodium bicarbonate, sodium acetate, sodium carbonate and ethylene diaminetetraacetic acid (EDTA).
The adjuvants comprise a plurality of second preservatives, at least one non-polymerizable surfactant and at least one second defoamer.
The plurality of second preservatives are in an amount in the range of 0.1 mass% to 0.5 mass%, the non-polymerizable surfactant is in an amount in the range of 0.1 mass% to 1 mass% and the second defoamer is in an amount in the range of 0.002 mass% to 0.01 mass%; wherein the mass% of each ingredient is with respect to the total mass of the emulsion polymer composition.
The plurality of second preservatives are selected from a mixture of 5-chloro-2-methylisothiazol-3(2H)-one and 2-methylisothiazol-3(2H)-one (CIT/CMIT) and benzisothiazolinone (BIT).
The non-polymerizable surfactant is at least one selected from the group consisting of non-ionic fatty alcohol ethoxylates, sodium dodecylbenzenesulfonate, alkyl polyethylene glycol ether and secondary alcohol ethoxylate.
The second defoamer is selected from the group consisting of fumed silica, polyether siloxane emulsion and mineral oil based defoamers.
The mass ratio of the plurality of monomers to the polymerizable surfactant is in the range of 35:1 to 45:1.

The pigment is at least one selected from the group consisting of titanium dioxide and calcium carbonate.

The filler is selected from the group consisting of calcium carbonate, talc, dolomite, submicron dolomite and clay.

The coalescing agent is selected from the group consisting of 2, 2, 4-trimethyl-1, 3-pentanediol monoisobutyrate (TMPD-MIB), tripropylene glycol n-butyl ether (TBPE), dipropylene glycol dimethyl ether (Proglyde DMM), dipropylene glycol n-Butyl ether (DPnB) and 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate.

The wetting agent is selected from the group consisting of sodium salt of maleic anhydride copolymer, sodium salt of sodium acetate, sodium salt of methanoic acid or butanoic acid and sodium salt of poly carboxylic acid.

The humectant is selected from the group consisting of triethylene glycol, propylene glycol and octyl phenyl ethoxylate.

The thickener is selected from the group consisting of polyurethane thickener such as modified ethylene oxide urethane and cellulosic thickener such as hydroxy ethyl cellulose.

The pore-blocking agent is selected from the group consisting of rosin ester derivative and modified natural rosin.

The adhesion promoter is selected from the group consisting of epoxy functional silane, 3-glycidyl-oxypropyl-trimethoxy-silane, beta-(3, 4-epoxycyclohexyl) ethyltrimethoxysilane, and gamma-glycidoxypropyltrimethoxysilane.

The first defoamer is selected from the group consisting of oil-based defoamer, water-based defoamer, and silicon-based defoamer.

The oil based defoamer is selected from the group consisting of mineral oil, vegetable oil, and white oil, which are optionally enriched with wax or hydrophobic silica.

The water based defoamer is selected from the group consisting of mineral oil, a vegetable oil, and waxes such as long chain fatty alcohol, fatty acid soaps and fatty acid esters.

The silicon-based defoamer is selected from the group consisting of silicone backbones such as hydrophobic silica dispersed in silicone oil, petroleum distillates, hydrotreated heavy paraffinic in silicone oil.

The anti-microbial agent is selected from the group consisting of 2-octyl-4-isothiazolin-3-one, active silver-based preservative, zinc pyrithione, 2,4,5,6-tetrachloroisophthalonitrile, 3- (3,4-dichlorophenyl)-1,1-dimethylurea, zinc omadine, carbendazim, 2-N-octyl-4-isothiazolin-3-one and zinc oxide.

The first surfactant is selected from the group consisting of alcohol (C9-11)-branched ethoxylated surfactant, octaethylene glycol monododecyl ether and pentaethylene glycol monododecyl ether and fatty alcohol ethoxylate.

The sequestering agent is selected from the group consisting of sodium hexametaphosphate, borax, calcium hydroxide and trisodium phosphate.

The first pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol and 2-methyl-1-propanol and potassium methylsiliconate.

The first preservative is selected from the group consisting of active silver-based preservatives and zinc-based preservatives, 4,4-dimethyloxazolidine, citrus extract and a mixture of formaldehyde, chloromethyl and methylisothiazolinone.

The anti-settling agent is selected from the group consisting of magnesium aluminium phyllosilicate and attapulgite clay.

The opaque polymer is styrene acrylic latex.

The extenders are selected from the group consisting of calcium magnesium carbonate, hydrous magnesium silicate, and calcined clay.

The scuffing additive is selected from the group consisting of mixture of polyoxyethylene trimethyldecyl alcohol, deca-methylcyclopentasiloxane, octa-methylcyclotetrasiloxane, dodeca-methylcyclohexasiloxane and 1,2-benzisothiazolin-3-one.

The binder is selected from the group consisting of anionic aliphatic polyester polyurethane emulsion, anionic polyacrylate dispersion, polyurethane dispersion and acrylic -polyurethane hybrid dispersion.
Further, the present disclosure relates to a process of preparation of the paint composition.
The process for the preparation of paint composition comprises mixing predetermined amounts of water, a sequestering agent, a first surfactant a wetting agent, a first portion of first defoamer, a humectant, a first pH stabilizer sequentially under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture. Predetermined amounts of a first preservative, a pigment, an extender, a pore blocking agent and an anti-settling agent are added sequentially to the first mixture for a second predetermined time period each under stirring at a second predetermined stirring speed to obtain a second mixture. The predetermined amounts of a thickener and a coalescing agent are sequentially added to the second mixture under stirring at a third predetermined stirring speed for a third predetermined time period to obtain a third mixture. Predetermined amounts of water and an anti-microbial agent are added to the third mixture sequentially under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a fourth mixture. Predetermined amounts of an emulsion, an opaque polymer, a binder, a second portion of first defoamer and an adhesion promoter are sequentially added to the fourth mixture under stirring at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a fifth mixture. Predetermined amounts of a scuffing additive and water are sequentially added to the fifth mixture under stirring at a sixth predetermined stirring speed for a sixth predetermined time period to obtain the paint composition.
The steps for the preparation of paint composition are carried out at a temperature in the range of 25 °C to 40 °C.
The predetermined amount of the sequestering agent is in the range of 0.02 mass% to 0.08 mass% with respect to the total mass of the paint composition.
The predetermined amount of the first surfactant is in the range of 0.2 mass% to 0.8 mass% with respect to the total mass of the paint composition.
The predetermined amount of wetting agent is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition.
The predetermined amount of the first portion of the first defoamer is in the range of 0.02 mass% to 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the second portion of the first defoamer is in the range of 0.02 mass% to 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the humectant is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition.
The predetermined amount of the first pH stabilizer is in the range of 0.05 mass% to 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the first preservative is in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the pigment is in the range of 0.5 mass% to 20 mass% with respect to the total mass of the paint composition.
The predetermined amount of the extender is in the range of 10 mass% to 40 mass% with respect to the total mass of the paint composition.
The predetermined amount of the pore blocking agent is in the range of 0.5 mass% to 2 mass% with respect to the total mass of the paint composition.
The predetermined amount of the thickener is in the range of 0.1 mass% to 5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the coalescing agent is in the range of 0.2 mass% to 3 mass% with respect to the total mass of the paint composition.
The predetermined amount of the anti-microbial agent is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition.
The predetermined amount of the emulsion is in the range of 5 mass% to 60 mass% with respect to the total mass of the paint composition.
The predetermined amount of the adhesion promoter is in the range of 0.2 mass% to 1 mass% with respect to the total mass of the paint composition.
The predetermined amount of the scuffing additive is in the range of 0.2 mass% to 1 mass% with respect to the total mass of the paint composition.
The predetermined amount of water in step (i) is in the range of 65 mass% to 95 mass% with respect to the total mass of the first mixture, the predetermined amount of water in step (iv) is in the range of 55 mass% to 85 mass% with respect to the total mass of the fourth mixture and the predetermined amount of water in step (vi) is in the range of 70 mass% to 95 mass% with respect to the total mass of the fourth mixture.
The predetermined amount of the binder is in the range of 0 mass% to 1 mass% with respect to the total mass of the paint composition.
The predetermined amount of the anti-settling agent is in the range of 0 mass% to 0.2 mass% with respect to the total mass of the paint composition.
The predetermined amount of the opaque polymer is in an amount in the range of 0 mass% to 15 mass% with respect to the total mass of the paint composition.
The first predetermined stirring speed, the second predetermined stirring speed and the third predetermined stirring speed are independently in the range of 1000 rpm to 1500 rpm and the fourth predetermined stirring speed, the fifth predetermined stirring speed and the sixth predetermined stirring speed are independently in the range of 50 rpm to 150 rpm.
The first predetermined time period is in the range of 5 minutes to 20 minutes, the second predetermined time period is in the range of 2 minutes to 15 minutes, the third predetermined time period is in the range of 50 minutes to 70 minutes, the fourth predetermined time period is in the range of 5 minutes to 20 minutes, the fifth predetermined time period is in the range of 10 minutes to 30 minutes and the sixth predetermined time period is in the range of 2 minutes to 20 minutes.
DETAILED DESCRIPTION
The present disclosure relates to a paint composition and a process for its preparation. Particularly, the present disclosure relates to paint composition with water-resistant properties.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Rising dampness is a prevalent problem found within the interior walls of a house, characterized by the upward movement of groundwater through pores in the brickwork by capillary action. The ground water also carries salts that accumulate and get deposited beneath the putty once water evaporates. This process leads to the formation of damp patches on the wall and continues until the paint film peels off the wall. In the absence of timely intervention, rising dampness can result in structural issues, including the softening or crumbling of plaster, erosion of paint, and the generation of unpleasant odours. The increase in dampness or efflorescence contributes to an unhealthy surrounding environment and can potentially cause respiratory related health problems.
Conventional water-based interior paints have low PVC (pigment volume concentration) or high PVC and lack water resistance properties. Such conventional paints are prone to rising dampness or efflorescence, leading to issues such as peeling off or the formation of damp patches on the painted surfaces. These issues lead to additional problems such as cracking, mould growth, and difficulty in maintaining the painted surfaces.
The present disclosure provides a paint composition and a process of preparation of paint composition. The paint composition of the present disclosure has water-resistant properties and prevents rising dampness and efflorescence.
In an aspect of the present disclosure, there is provided a paint composition.
The paint composition comprises an emulsion polymer in an amount in the range of 5 mass % to 60 mass%, additives in an amount in the range of 35 mass% to 65 mass% and q.s water, wherein mass% of each ingredient is with respect to the total amount of paint composition. In an exemplary embodiment, the paint composition comprises an emulsion polymer in an amount of 50 mass%, additives in an amount of 40.17 mass% and q.s water, wherein mass% of each ingredient is with respect to the total amount of the paint composition. In another exemplary embodiment, the paint composition comprises an emulsion polymer in an amount of 20 mass%, additives in an amount of 60.05 mass% and q.s water, wherein mass% of each ingredient is with respect to the total amount of the paint composition. In yet another exemplary embodiment, the paint composition comprises an emulsion polymer in an amount of 10 mass%, additives in an amount of 56.52 mass% and q.s water, wherein mass% of each ingredient is with respect to the total amount of the paint composition.
The additives comprise at least one pigment in an amount in the range of 0.5 mass % to 20 mass %, at least one filler in an amount in the range of 1 mass % to 35 mass %, at least one coalescing agent in an amount in the range of 0.2 mass% to 3 mass%, at least one wetting agent in an amount in the range of 0.2 mass% to 2 mass%, at least one humectant in an amount in the range of 0.2 mass% to 2 mass%, at least one thickener in an amount in the range of 1 mass% to 3 mass%, at least one pore-blocking agent in an amount in the range of 0.5 mass% to 2 mass%, at least one adhesion promoter in an amount in the range of 0.2 mass% to 1 mass%, at least one first defoamer in an amount in the range of 0.04 mass% to 1 mass%, at least one anti-microbial agent in an amount in the range of 0.2 mass% to 2 mass%, at least one first surfactant in an amount in the range of 0.2 mass% to 0.8 mass%, at least one sequestering agent in an amount in the range of 0.02 mass% to 0.08 mass%, at least one first pH stabilizer in an amount in the range of 0.05 mass% to 0.5 mass%, at least one first preservative in an amount in the range of 0.1 mass% to 0.5 mass%, extenders in an amount in the range of 1 mass% to 25 mass%, at least one scuffing additive in an amount in the range of 0.2 mass% to 1 mass%, and at least one binder in an amount in the range of 0 mass% to 1 mass%, at least one anti-settling agent in an amount in the range of 0 mass% to 0.2 mass%, an opaque polymer in an amount in the range of 0 mass% to 15 mass%, wherein mass% of each ingredient is with respect to the total amount of paint composition.
In an exemplary embodiment, the additives comprise pigment in an amount of 16 mass %, filler in an amount of 3 mass %, coalescing agent in an amount of 2.5 mass%, wetting agent in an amount of 1 mass%, humectant in an amount of 1 mass%, thickener in an amount of 2.3 mass%, pore-blocking agent in an amount of 1 mass%, adhesion promoter in an amount of 0.5 mass%, a first defoamer in an amount of 0.4 mass%, an anti-microbial agent in an amount of 1.1 mass%, a first surfactant in an amount of 0.5 mass%, a sequestering agent in an amount of 0.05 mass%, a first pH stabilizer in an amount of 0.15 mass%, an anti-settling agent in an amount of 0.10 mass%, a first preservative in an amount of 0.37 mass%, an opaque polymer in an amount of 6 mass%, extenders in an amount of 3 mass%, a scuffing additive in an amount of 0.7 mass%, and a binder in an amount of 0.5 mass%, wherein mass% of each ingredient is with respect to the total amount of paint composition. In another exemplary embodiment, the additives comprise pigment in an amount of 6.88 mass %, filler in an amount of 11 mass %, coalescing agent in an amount of 2.5 mass%, wetting agent in an amount of 1 mass%, humectant in an amount of 1.65 mass%, thickener in an amount of 0.20 mass%, pore-blocking agent in an amount of 1 mass%, adhesion promoter in an amount of 0.5 mass%, a first defoamer in an amount of 0.25 mass%, an anti-microbial agent in an amount of 0.6 mass%, a first surfactant in an amount of 0.45 mass%, a sequestering agent in an amount of 0.05 mass%, a first pH stabilizer in an amount of 0.25 mass%, a first preservative in an amount of 0.38 mass%, an opaque polymer in an amount of 12 mass%, extenders in an amount of 21 mass%, a scuffing additive in an amount of 0.7 mass%, and a binder in an amount of 0.5 mass%, wherein mass% of each ingredient is with respect to the total amount of paint composition. In yet another exemplary embodiment, the additives comprise pigment in an amount of 1 mass %, filler in an amount of 30 mass %, coalescing agent in an amount of 0.5 mass%, wetting agent in an amount of 0.5 mass%, humectant in an amount of 0.5 mass%, thickener in an amount of 0.20 mass%, pore-blocking agent in an amount of 1 mass%, adhesion promoter in an amount of 0.5 mass%, a first defoamer in an amount of 0.1 mass%, an anti-microbial agent in an amount of 0.4 mass%, a first surfactant in an amount of 0.3 mass%, a sequestering agent in an amount of 0.05 mass%, a first pH stabilizer in an amount of 0.30 mass%, a first preservative in an amount of 0.37 mass%, extenders in an amount of 18 mass%, a scuffing additive in an amount of 0.5 mass%, and a binder in an amount of 0.5 mass%, wherein mass% of each ingredient is with respect to the total amount of paint composition.
In accordance with the present disclosure, the amount of polymer emulsion is adjusted to obtain a paint composition that effectively prevents rising dampness and increases efflorescence resistance.
The emulsion polymer comprises a reaction product of 40 mass% to 60 mass% of a plurality of monomers, 0.5 mass% to 2 mass% of at least one polymerizable surfactant, 0.1 mass% to 1 mass% of at least one initiator, 0.01 mass% to 0.5 mass% of at least one coupling agent, 0.05 mass% to 0.3 mass% of a plurality of reducing agents, 0.1 mass% to 2 mass% of at least one second pH stabilizer and 0.05 mass% to 0.2 mass% of at least one buffer, 0.5 mass% to 2 mass% of a plurality of adjuvants and q.s. water; wherein the mass% of each ingredient is with respect to the total mass of the emulsion polymer composition.
The plurality of monomers is selected from the group consisting of styrene, butyl acrylate, methacrylic acid, n-butyl methacrylate (n-BMA), diacetone acrylamide (DAAM), ethylene glycol dimethylacrylate (EGDMA), 2-ethylhexyl acrylate (2-EHA) and vinyl trimethoxy silane (Silquest A171).
The polymerizable surfactant is selected from the group consisting of alcohols, C10-14-branched, C11-rich, reaction products with ethylene oxide, [(2-propenyloxy)methyl]oxirane and sulfamic acid, alkyl diphenyl oxide disulfonate, phosphate ester based polymerizable surfactants and reactive anionic emulsifier.
The initiator is selected from the group consisting of potassium persulphate, sodium persulphate and ammonium persulphate.
The coupling agent is selected from the group consisting of adipic acid dihydrazide (ADH), ethylene glycol dimethylacrylate (EGDMA) and succinic acid dihydrazide.
In an embodiment of the present disclosure, ethylene glycol dimethylacrylate (EGDMA) acts as a monomer as well as a coupling agent.
The plurality of reducing agents are selected from a combination of tert-butyl hydroperoxide and sodium formaldehydesulfoxylate, tert-butyl hydroperoxide and sodium acetone bisulphite, tert-butyl hydroperoxide and L-ascorbic acid and tert-butyl hydroperoxide and sodium meta bisulphate.
The second pH stabilizer is at least one selected from the group consisting of 95% 2-amino-2-methyl-1-propanol solution (AMP 95), 2-amino ethanol (phlex 110), alkanolamine and potassium methylsiliconate (Silres BS 168).
The silicone-based pH stabilizer (Silres BS 168) not only helps in maintaining the pH of emulsions but also enhances water resistance. By forming three-dimensional hydrophobic networks, the silicone -based neutralizer effectively self-crosslinks, resulting in improved water resistance of water-borne coatings, thus preventing water from infiltrating the coating. Further, a mixture of organic amines and inorganic silicone-based pH stabilizer is used to neutralize the emulsion of the present disclosure in order to obtain the desired water resistance properties.
The buffer is selected from the group consisting of sodium bicarbonate, sodium acetate, sodium carbonate and ethylene diaminetetraacetic acid (EDTA).
The adjuvants comprise a plurality of preservatives, at least one non-polymerizable surfactant and at least one second defoamer.
The adjuvants comprises the plurality of preservatives in an amount in the range of 0.1 mass% to 0.5 mass%, the non-polymerizable surfactant is in an amount in the range of 0.1 mass% to 1 mass% and the second defoamer in an amount in the range of 0.002 mass% to 0.01 mass%, wherein mass% of each ingredient is with respect to the total mass of the emulsion polymer composition.
The plurality of preservatives are selected from the group consisting of a mixture of 5-chloro-2-methylisothiazol-3(2H)-one and 2-methylisothiazol-3(2H)-one (MIT/CMIT), (Sanitized Cl15) and benzisothiazolinone (BIT) (Sanitized BT 10A).
The non-polymerizable surfactant is at least one selected from the group consisting of non-ionic fatty alcohol ethoxylates (Teric 463), sodium dodecylbenzenesulfonate, alkyl polyethylene glycol ether (Emulsogen LCN 407) and secondary alcohol ethoxylate (Tergitol 15S40).
The second defoamer is selected from the group consisting of fumed silica, polyether siloxane emulsion and mineral oil based defoamers.
The mass ratio of the plurality of monomers to the polymerizable surfactant is in the range of 35:1 to 45:1.
In accordance with the embodiment of the present disclosure, the composition of the monomer is adjusted to obtain a hard and strong film. The strength of the film is improved by keto-imine crosslinking.
The keto–imine crosslinking is introduced in the polymer by using diacetone acrylamide (DAAM) as a polymerizable monomer and adipic acid dihydrazide (ADH) as crosslinking or coupling agent. The crosslinking monomer DAAM has two carbonyl groups which can undergo reaction with NH2 groups from ADH.
A schematic representation for the crosslinking reaction of the diacetone acrylamide and adipic acid dihydrazide is given as scheme A:

SCHEME A
The polymer backbone is represented by the solid black sections, with diacetone acrylamide (DAAM) attached to it. During the crosslinking process, water molecules (H2O) are released. Release of high amount of water slows down crosslinking, but it progresses favourably when water evaporation occurs. The remaining carbonyl groups from the monomer enhance adhesion and the pull-off strength of both the emulsion and the paint film. Further, the coupling agents (cross-linkers) containing two allylic groups or double bonds (bi-functional monomers) increase the molecular weight of the emulsion polymer and enhance the tensile strength of the final emulsion polymer. The hardness can be adjusted by varying the monomer combination and the resulting minimum film-forming temperature (MFFT) of the polymer, potentially influencing the tackiness of the film obtained by applying the emulsion polymer composition of the present disclosure.
In accordance with an embodiment of the present disclosure, the polymerizable surfactants augment the waterproofing performance.
In accordance with an embodiment of the present disclosure, the polymerizable surfactants of the present disclosure bind to the polymer backbone, thus avoid leaching out for a prolonged period of time.
The polymerizable surfactants have a relatively high molecular weight which has an allylic group located between the hydrophobic part and hydrophilic part, enabling easy accessibility for acrylic or styrene monomers to react. Thus, the surfactants will have a bigger hydrophobic part and the allylic group participates in the additional polymerization reaction. The polymer film formed by using the emulsion polymer composition of the present disclosure will have excellent water resistance and film clarity.
The use of polymerizable surfactant in combination with the coupling agent (crosslinking agent), enhances the water resistance of the emulsion polymer (backbone) and the paint prepared by using the emulsion polymer composition.
In accordance with the present disclosure, the emulsion polymer formulated provides high-strength films, uses APEO-free surfactants, and employs formaldehyde free biocides.
In accordance with an embodiment of the present disclosure, the emulsion polymer of the present disclosure is well-suited for creating high-quality interior paint that offers prolonged durability.
In an embodiment of the present disclosure, the pigment is at least one selected from the group consisting of titanium dioxide, and calcium carbonate. In an exemplary embodiment, the pigment is titanium dioxide. In another exemplary embodiment, the pigment is a mixture of titanium oxide and calcium carbonate (Lithomer LC80).
In an embodiment of the present disclosure, the filler is selected from the group consisting of calcium carbonate, talc, dolomite, submicron dolomite, clay. In an exemplary embodiment, the filler is calcium carbonate.

In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2, 2, 4-trimethyl-1, 3-pentanediol monoisobutyrate (TMPiB), tripropylene glycol n-butyl ether (TPnB), dipropylene glycol dimethyl ether (DMM), 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, and dipropylene glycol n-Butyl ether (DPnB). In an exemplary embodiment, the coalescing agent is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate.
In an embodiment of the present disclosure, the wetting agent is selected from the group consisting of sodium salt of maleic anhydride copolymer, sodium salt of sodium acetate, sodium salt of methanoic acid or butanoic acid and sodium salt of poly carboxylic acid (Indofil 731). In an exemplary embodiment, the wetting agent is sodium salt of poly carboxylic acid (Indofil 731).
In an embodiment of the present disclosure, the humectant is selected from the group consisting of triethylene glycol, propylene glycol and octyl phenyl ethoxylate (polysorbate 80). In an exemplary embodiment, the humectant is triethylene glycol.
In an embodiment of the present disclosure, the thickener is selected from the group consisting of polyurethane thickener such as modified ethylene oxide urethane and cellulosic thickener such as hydroxy ethyl cellulose. In an exemplary embodiment, the thickener is modified ethylene oxide urethane. In another exemplary embodiment, the thickener is hydroxy ethyl cellulose.
The thickeners are responsible for providing the paint composition with essential rheological characteristics, such as viscosity, which effectively prevents the settling of heavy pigment particles during storage. Also, the thickeners play a crucial role in maintaining flow and levelling of the paint composition.
Cellulosic thickeners function by entangling polymer chains and creating hydrogen bonds with water molecules. On the other hand, polyurethane thickeners, which are partially soluble in water, work by interacting with other paint components such as binders/emulsions. The addition of polyurethane thickeners enhances levelling, reduces roller spatter, and improves gloss levels of the paint composition.
In an embodiment of the present disclosure, the pore-blocking agent is selected from the group consisting of rosin ester derivative, and modified natural rosin. In an exemplary embodiment, the pore-blocking agent is modified natural rosin (Elotex Era 200).
In an embodiment of the present disclosure, the rosin ester derivative predominantly comprises abietic acid. The rosin ester derivative in the paint composition enters the pores of the concrete structure and reacts with the calcium hydroxide (a by-product of the cement hydration) in the presence of moisture to form an insoluble inert mass that blocks the capillaries or pores, thereby preventing the capillary action of water and prevents its contact with the paint.
In an embodiment of the present disclosure, the pore-blocking agents enhance the performance of the paint composition of the present disclosure by effectively blocking the capillaries or pores within the concrete structure.
In an embodiment of the present disclosure, the adhesion promoter is selected from the group consisting of epoxy functional silane, 3-glycidyl-oxypropyl-trimethoxy-silane, beta-(3, 4-epoxycyclohexyl) ethyltrimethoxysilane, and gamma-glycidoxypropyltrimethoxysilane. In an exemplary embodiment, the adhesion promoter is gamma-glycidoxypropyltrimethoxysilane.
In an embodiment of the present disclosure, the first defoamer is selected from the group consisting of oil-based defoamer, water-based defoamer, and silicon-based defoamer.

In an embodiment of the present disclosure, the oil based defoamer is selected from the group consisting of mineral oil, vegetable oil, and white oil, which are optionally enriched with wax or hydrophobic silica.
In an embodiment of the present disclosure, the wax is selected from the group consisting of ethylene bis(stearamide), paraffin waxes, ester waxes, and fatty alcohol waxes.
In an embodiment of the present disclosure, the water based defoamer is selected from the group consisting of mineral oil, a vegetable oil, and waxes such as long chain fatty alcohol, fatty acid soaps, and fatty acid esters.
In an embodiment of the present disclosure, the silicon-based defoamer is selected from the group consisting of silicone backbones such as hydrophobic silica dispersed in silicone oil. In an exemplary embodiment, the defoamer is petroleum distillates, hydrotreated heavy paraffinic in silicone oil (DAPRO 7010).
In an embodiment of the present disclosure, the anti-microbial agent is selected from the group consisting of 2-octyl-4-isothiazolin-3-one, active silver-based preservative, zinc pyrithione, 2,4,5,6-tetrachloroisophthalonitrile, 3-(3, 4-dichlorophenyl)-1,1-dimethylurea, zinc omadine, carbendazim, 2-N-octyl-4-isothiazolin-3-one and zinc oxide. In an exemplary embodiment, the anti-microbial agent is a mixture of zinc omadine, 2-octyl-4-isothiazolin-3-one, zinc pyrithione and carbendazim.
In an embodiment of the present disclosure, the first surfactant is selected from the group consisting of alcohol (C9-C11)-branched ethoxylated surfactant, octaethylene glycol monododecyl ether and pentaethylene glycol monododecyl ether, fatty alcohol ethoxylate. In an exemplary embodiment, the first surfactant is fatty alcohol ethoxylate (EMULSOGEN LCN 118).

In an embodiment of the present disclosure, the sequestering agent is selected from the group consisting of sodium hexametaphosphate, borax, calcium hydroxide and trisodium phosphate. In an exemplary embodiment, the sequestering agent is sodium hexametaphosphate.
In an embodiment of the present disclosure, the first pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol and 2-methyl-1-propanol and potassium methylsiliconate. In an exemplary embodiment, the first pH stabilizer is 2-amino-2-methyl-1-propanol (felamine plus).
In an embodiment of the present disclosure, the first preservative is selected from the group consisting of active silver-based preservatives and zinc-based preservatives, 4,4-dimethyloxazolidine, citrus extract and a mixture of formaldehyde, chloromethyl and methylisothiazolinone. In an exemplary embodiment, the first preservative is 4, 4-dimethyloxazolidine. In yet another exemplary embodiment, the first preservative is citrus extract (mixture of ICL RASEPHYTE and ICH RASEPHYTE).
In an embodiment of the present disclosure, the anti-settling agent is selected from the group consisting of magnesium aluminium phyllosilicate and attapulgite clay. In an exemplary embodiment, the anti-settling agent is magnesium aluminium phyllosilicate.
In an embodiment of the present disclosure, the opaque polymer is styrene acrylic latex.
In an embodiment of the present disclosure, the opaque polymer and anti-settling agent are added or removed in the paint composition based on pigment volume concentration (PVC) of the paint composition.
In an embodiment of the present disclosure, the extender is selected from the group consisting of calcium magnesium carbonate, hydrous magnesium silicate, and calcined clay. In an exemplary embodiment, the extender is calcium magnesium carbonate. In another exemplary embodiment, the extender is hydrous magnesium silicate. In still another exemplary embodiment, the extender is calcined clay.
In an embodiment of the present disclosure, the scuffing additive is selected from the group consisting of mixture of polyoxyethylene trimethyldecyl alcohol, deca-methylcyclopentasiloxane, octa-methylcyclotetrasiloxane, dodeca-methylcyclohexasiloxane and 1,2-benzisothiazolin-3-one. In an exemplary embodiment, the scuffing additive is mixture of polyoxyethylene trimethyldecyl alcohol, decamethylcyclopentasiloxane, octamethylcyclotetrasiloxane and dodecamethylcyclohexasiloxane and 1,2-benzisothiazolin-3-one (Coatosil SE610).
In an embodiment of the present disclosure, the binder is selected from the group consisting of anionic aliphatic polyester polyurethane emulsion, anionic polyacrylate dispersion, polyurethane dispersion and acrylic -polyurethane hybrid dispersion. In an exemplary embodiment, the binder is aliphatic polyester polyurethane emulsion.
In another aspect of the present disclosure, there is provided a process for the preparation of the paint composition.
The process for the preparation of paint composition comprises the following steps:
i. mixing predetermined amounts of water, a sequestering agent, a first surfactant a wetting agent, a first portion of first defoamer, a humectant, a first pH stabilizer sequentially under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;
ii. adding predetermined amounts of a first preservative, a pigment, an extender, a pore blocking agent and an anti-settling agent sequentially to the first mixture for a second predetermined time period each under stirring at a second predetermined stirring speed to obtain a second mixture;
iii. adding predetermined amounts of a thickener and a coalescing agent sequentially to the second mixture under stirring at a third predetermined stirring speed for a third predetermined time period to obtain a third mixture;
iv. adding predetermined amounts of water and an anti-microbial agent to the third mixture sequentially under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a fourth mixture;
v. adding predetermined amounts of an emulsion, an opaque polymer, a binder, a second portion of first defoamer and an adhesion promoter sequentially to the fourth mixture under stirring at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a fifth mixture; and
vi. adding predetermined amounts of a scuffing additive and water sequentially to the fifth mixture under stirring at a sixth predetermined stirring speed for a sixth predetermined time period to obtain the paint composition.

The process for the preparation of paint composition is detailed below:
In a first step, predetermined amounts of water, a sequestering agent, a first surfactant a wetting agent, a first portion of first defoamer, a humectant, a first pH stabilizer are mixed sequentially under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture.
In an embodiment of the present disclosure, the sequestering agent is selected from the group consisting of sodium hexametaphosphate, borax, calcium hydroxide and trisodium phosphate. In an exemplary embodiment, the sequestering agent is sodium hexa meta phosphate.
In an embodiment of the present disclosure, the predetermined amount of sequestering agent is in the range of 0.02 mass% to 0.08 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of sequestering agent is 0.05 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the first surfactant is selected from the group consisting of alcohol (C9-C11)-branched ethoxylated surfactant, octaethylene glycol monododecyl ether (C12E8), pentaethylene glycol monododecyl ether (C12E5), fatty alcohol ethoxylate (Emulsogen LCN 118). In an exemplary embodiment, the first surfactant is fatty alcohol ethoxylate (Emulsogen LCN 118).
In an embodiment of the present disclosure, the predetermined amount of the first surfactant is in the range of 0.2 mass% to 0.8 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of the first surfactant is 0.5 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of the first surfactant is 0.45 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of first surfactant is 0.3 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the wetting agent is selected from the group consisting of sodium salt of poly carboxylic acid (INDOFIL 731), alkylol ammonium salt and sodium salt of acrylic acid. In an exemplary embodiment, the wetting agent is sodium salt of poly carboxylic acid (INDOFIL 731).
In an embodiment of the present disclosure, Indofil 731 acts as a dispersing as well as wetting agent.
In an embodiment of the present disclosure, the predetermined amount of wetting agent is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of wetting agent is 1 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of the wetting agent is 0.58 mass% with respect to the total mass of the paint composition. In still another exemplary embodiment, the predetermined amount of wetting agent is 0.5 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the first defoamer is selected from the group consisting of oil-based defoamer, water-based defoamer, and silicon-based defoamer. In an exemplary embodiment, the defoamer in the first portion of the first defoamer is petroleum distillates, hydrotreated heavy paraffinic in silicone oil (DAPRO DF 7010).
In an embodiment of the present disclosure, the predetermined amount of the first portion of first defoamer is in the range of 0.02 mass% to 0.5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the first portion of first defoamer is 0.2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of first portion of first defoamer is 0.1 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of first portion of first defoamer is 0.05 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the humectant is selected from the group consisting of triethylene glycol, propylene glycol and octyl phenyl ethoxylate (polysorbate 80). In an exemplary embodiment, the humectant is triethylene glycol.
In an embodiment of the present disclosure, the predetermined amount of humectant is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of humectant is 1 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of humectant is 1.65 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of humectant is 0.5 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the first pH stabilizer is selected from the group consisting of ethanolamine, and 2-amino-2-methyl-1-propanol (felamine plus), potassium methylsiliconate. In an exemplary embodiment, the first pH stabilizer is 2-amino-2-methyl-1-propanol (felamine plus).
In an embodiment of the present disclosure, the predetermined amount of first pH stabilizer is in the range of 0.05 mass% to 0.5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of pH stabilizer is 0.15 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of pH stabilizer is 0.25 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of pH stabilizer is 0.30 mass% with respect to the total mass of the paint composition.
The predetermined amount of water is in an amount in the range of 65 mass% to 95 mass% with respect to the total mass of the first mixture. In an exemplary embodiment the predetermined amount of water is 70.19 mass% with respect to the total mass of the first mixture. In another exemplary embodiment the predetermined amount of water is 80.96 mass% with respect to the total mass of the first mixture. In an exemplary embodiment the predetermined amount of water is 93.75 mass% with respect to the total mass of the first mixture.
In an embodiment of the present disclosure, the first predetermined stirring speed is in the range of 1000 rpm to 1500 rpm. In an exemplary embodiment, the first predetermined stirring speed is 1200 rpm.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 5 minutes to 20 minutes. In an exemplary embodiment, the first predetermined time period is 10 minutes.
In a second step, predetermined amounts of a first preservative, a pigment, an extender, a pore blocking agent and an anti-settling agent are sequentially added to the first mixture for a second predetermined time period each under stirring at a second predetermined stirring speed to obtain a second mixture.
In an embodiment of the present disclosure, the first preservative is selected from the group consisting of active silver-based preservatives and zinc-based preservatives, 4,4-dimethyl-oxazolidine, citrus extract (ICL RASEPHYTE and ICH RASEPHYTE) and a mixture of formaldehyde, chloromethyl and methylisothiazolinone (Nipacide CFX2). In an exemplary embodiment of the present disclosure, the first preservative is a mixture of citrus extract (ICL RASEPHYTE and ICH RASEPHYTE).
In an embodiment of the present disclosure, the predetermined amount of first preservative is in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of first preservative is 0.37 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of the first preservative is 0.38 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the pigment is at least one selected from the group consisting of titanium dioxide, and calcium carbonate. In an exemplary embodiment, the pigment is a mixture of titanium dioxide and calcium carbonate (Lithomer LC80). In another exemplary embodiment, the pigment is titanium dioxide.
In an embodiment of the present disclosure, the predetermined amount of pigment is in the range of 0.5 mass% to 20 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of pigment is 16 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of pigment is 6.88 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of pigment is 1 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the extender is selected from the group consisting of calcium magnesium carbonate, hydrous magnesium silicate, and calcined clay. In an exemplary embodiment, the extender is calcium magnesium carbonate (submicron dolomite). In another exemplary embodiment, the extender is a mixture of magnesium carbonate (submicron dolomite) and calcined clay. In yet another exemplary embodiment the extender is calcined clay.
In an embodiment of the present disclosure, the predetermined amount of extender is in the range of 10 mass% to 40 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of extender is 3 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of extender is of 21 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of extender is 18 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the pore-blocking agent is selected from the group consisting of rosin ester derivative and modified natural rosin. In an exemplary embodiment, the pore blocking agent is modified natural rosin (ELOTEX ERA 200).
In an embodiment of the present disclosure, the predetermined amount of pore blocking agent is in the range of 0.5 mass% to 2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of pore blocking agent is 1 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the anti-settling agent is selected from the group consisting of magnesium aluminium phyllosilicate, and attapulgite clay. In an exemplary embodiment, the anti-settling agent is magnesium aluminium phyllosilicate.
In an embodiment of the present disclosure, the predetermined amount of anti-settling agent is in the range of 0 mass% to 0.2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of anti-settling agent is 0.1 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the second predetermined stirring speed is in the range of 1000 rpm to 1500 rpm. In an exemplary embodiment, the second predetermined stirring speed is 1200 rpm.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 2 minutes to 15 minutes.
In an exemplary embodiment, a mixture of first preservatives were added to the first mixture and mixed for 5 minutes, followed by the addition of pigment and mixed for 10 minutes followed by the addition of extender and mixed for 10 minutes followed by addition of a pore blocking agent and mixed for 10 minutes. This is followed by the addition of an anti-settling agent and mixed for 5 minutes under stirring to obtain a second mixture.
In a third step, predetermined amounts of a thickener and a coalescing agent are sequentially added to the second mixture under stirring at a third predetermined stirring speed for a third predetermined time period to obtain a third mixture.
In an embodiment of the present disclosure, the thickener is selected from the group consisting of polyurethane thickener such as modified ethylene oxide urethane and cellulosic thickener such as hydroxy ethyl cellulose. In an exemplary embodiment, the thickener is a mixture of polyurethane resin (Acrysol RM 2020) and modified ethylene oxide urethane (RHEOLATE SCT 275). In another exemplary embodiment, the thickener is hydroxy ethyl cellulose (TYLOSE HS 100000 YP2).
In an embodiment of the present disclosure, the predetermined amount of thickener is in the range of 0.1 mass% to 5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of thickener is 2.3 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of thickener is 1.26 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of thickener is 1.5 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether and dipropylene glycol n-butyl ether. In an exemplary embodiment, the coalescing agent is 2,2,4-Trimethyl-1,3-Pentanediol monoisobutyrate (OPTIFILM ENHANCER 300).
In an embodiment of the present disclosure, the predetermined amount of coalescing agent is in the range of 0.2 mass% to 3 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of coalescing agent is 2.5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of coalescing agent is 1 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of coalescing agent is 0.5 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the third predetermined stirring speed is in the range of 1000 rpm to 1500 rpm. In an exemplary embodiment, the third predetermined stirring speed is 1200 rpm.
In an embodiment of the present disclosure, the third predetermined time period is in the range of 50 minutes to 70 minutes. In an exemplary embodiment, the third predetermined time period is 60 minutes.
In a fourth step, predetermined amounts of water and an anti-microbial agent are added to the third mixture sequentially under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a fourth mixture.
In an embodiment of the present disclosure, the anti-microbial agent is selected from the group consisting of a fungicide and antiviral agent.
In an embodiment of the present disclosure, the fungicide is selected from the group consisting of carbendazim, 2-N-octyl-4-isothiazolin-3-one and zinc oxide. In an exemplary embodiment, the fungicide is a mixture of 2-N-octyl-4-isothiazolin-3-one (Bioban O45) and Carbendazim (NIPACIDE CDI). In another exemplary embodiment, the fungicide is Carbendazim (NIPACIDE CDI).
The antiviral agent is silver nitrate (Santized Ag+).
In an embodiment of the present disclosure, the predetermined amount of the anti-microbial agent is in the range of 0.2 mass% to 2 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of anti-microbial agent is 1.1 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of anti-microbial agent is 0.6 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of anti-microbial agent is 0.9 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 55 mass% to 85 mass% with respect to the total mass of the fourth mixture. In an exemplary embodiment of the present disclosure, the predetermined amount of water is 58.82 mass% with respect to the total mass of the fourth mixture. In another exemplary embodiment of the present disclosure, the predetermined amount of water is 78.95 mass% with respect to the total mass of the fourth mixture. In another exemplary embodiment of the present disclosure, the predetermined amount of water is 80 mass% with respect to the total mass of the fourth mixture.
In an embodiment of the present disclosure, the fourth predetermined stirring speed is in the range of 50 rpm to 150 rpm. In an exemplary embodiment, the fourth predetermined stirring speed is 100 rpm.
In an embodiment of the present disclosure, the fourth predetermined time period is in the range of 5 minutes to 20 minutes. In an exemplary embodiment, the fourth predetermined time period is 10 minutes.
In a fifth step, predetermined amounts of an emulsion polymer, an opaque polymer, a binder, a second portion of first defoamer and an adhesion promoter are added sequentially to the fourth mixture under stirring at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a fifth mixture.
The emulsion polymer comprises a reaction product of 40 mass% to 60 mass% of a plurality of monomers, 0.5 mass% to 2 mass% of at least one polymerizable surfactant, 0.1 mass% to 1 mass% of at least one initiator, 0.01 mass% to 0.5 mass% of at least one coupling agent, 0.05 mass% to 0.3 mass% of a plurality of reducing agents, 0.1 mass% to 2 mass% of at least one pH stabilizer and 0.05 mass% to 0.2 mass% of at least one buffer, 0.5 mass% to 2 mass% of a plurality of adjuvants and q.s. water; wherein the mass% of each ingredient is with respect to the total mass of the emulsion polymer composition.
In an embodiment of the present disclosure, the opaque polymer is styrene acrylic latex. In an exemplary embodiment of the present disclosure, the opaque polymer is styrene acrylic latex (0844 OP U 30).
In an embodiment of the present disclosure, the binder is selected from the group consisting of anionic aliphatic polyester polyurethane emulsion, anionic polyacrylate dispersion, polyurethane dispersion, acrylic polyurethane hybrid dispersion. In an exemplary embodiment, the binder is polyurethane dispersion (Bayhydrol UH 2864).
In an embodiment of the present disclosure, the first defoamer is selected from the group consisting of oil-based defoamer, water-based defoamer, and silicon-based defoamer. In an exemplary embodiment, the first defoamer is petroleum distillates, hydrotreated heavy paraffinic in silicone oil (DAPRO 7010).
In an embodiment of the present disclosure, the adhesion promoter is selected from the group consisting of epoxy functional silane, 3-glycidyl-oxypropyl-trimethoxy-silane, beta-(3, 4-epoxycyclohexyl) ethyltrimethoxysilane, and gamma-glycidoxypropyltrimethoxysilane. In an exemplary embodiment, the adhesion promoter is vinyl trimethoxy silane (silquest A187).
In an embodiment of the present disclosure, the predetermined amount of emulsion is in the range of 5 mass% to 60 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of emulsion is 50 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of emulsion is 20 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of emulsion is 10 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the predetermined amount of the opaque polymer is in the range of 0 mass% to 15 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of the opaque polymer is 6 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of opaque polymer is 12 mass% with respect to the total mass of the paint composition.
The predetermined amount of the binder is in the range of 0 mass% to 1 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of binder is 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of the adhesion promoter is in the range of 0.2 mass% to 1 mass% with respect to the total mass of the paint composition. In an exemplary embodiment the predetermined amount of adhesion promoter is 0.5 mass% with respect to the total mass of the paint composition.
The predetermined amount of second portion of first defoamer is in the range of 0.02 mass% to 0.5 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of second portion of first defoamer is 0.2 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of second portion of first defoamer is 0.15 mass% with respect to the total mass of the paint composition. In yet another exemplary embodiment, the predetermined amount of second portion of first defoamer is 0.05 mass% with respect to the total mass of the paint composition.
The fifth predetermined stirring speed is in the range of 50 rpm to 150 rpm. In an exemplary embodiment, the fifth predetermined stirring speed is 100 rpm.
The fifth predetermined time period is in the range of 10 minutes to 30 minutes. In an exemplary embodiment, the fifth predetermined time period is 15 minutes.
In a final step, predetermined amounts of a scuffing additive and water are sequentially added to the fifth mixture under stirring at a sixth predetermined stirring speed for a sixth predetermined time period to obtain the paint composition.
In an embodiment of the present disclosure, the scuffing additive is selected from the group consisting of silicone polyether block copolymer, mixture of polyoxyethylene trimethyldecyl alcohol, decamethylcyclopentasiloxane, octamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane and 1,2-benzisothiazolin-3-one. In an exemplary embodiment, the scuffing additive is mixture of polyoxyethylene trimethyldecyl alcohol, decamethylcyclopentasiloxane, octamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane and 1,2-benzisothiazolin-3-one (COATOSIL SE 610).
The predetermined amount of scuffing additive is in the range of 0.2 mass% to 1 mass% with respect to the total mass of the paint composition. In an exemplary embodiment, the predetermined amount of scuffing additive is 0.7 mass% with respect to the total mass of the paint composition. In another exemplary embodiment, the predetermined amount of scuffing additive is 0.5 mass% with respect to the total mass of the paint composition.
In an embodiment of the present disclosure, the sixth predetermined stirring speed is independently in the range of 50 rpm to 150 rpm. In an exemplary embodiment, the sixth predetermined stirring speed is 100 rpm.
In an embodiment of the present disclosure, the sixth predetermined time period is in the range of 2 minutes to 20 minutes. In an exemplary embodiment, the sixth predetermined time period is 10 minutes.
The predetermined amount of amount of water is in the range of 70 mass% to 95 mass% with respect to the total mass of the fourth mixture. In an exemplary embodiment, the predetermined amount of amount of water is 74 mass % with respect to the total mass of the fourth mixture. In another exemplary embodiment, the predetermined amount of amount of water is 92.31 mass % with respect to the total mass of the fourth mixture.
The steps for the preparation of paint composition are carried out at a temperature in the range of 25 °C to 40 °C. In an exemplary embodiment, the steps for the preparation of paint composition are carried out at a temperature of 30 °C.
The paint composition of the present disclosure has water-resistant properties and prevents dampness and efflorescence.
The paint composition of the present disclosure is suitable for preparing different water-based low PVC (pigment volume concentration), mid PVC and high PVC paints used for interiors of the house with waterproofing properties. The paint compositions when applied on the interior walls provide resistance to rising dampness and efflorescence.
The paint composition of the present disclosure is used as a water-based primer, distemper, economy and premium interior emulsion, and luxury finish topcoat paint for application on the interior of the house.
In accordance with an embodiment of the present disclosure, the distemper, emulsions can be used as a primer as well as for topcoat for the interior concrete surfaces. The APEO (alkyl phenol ethylene oxide) free polymer dispersion of acrylic ester and styrene used in the paint composition provides enhanced scrub resistance, water resistance, and alkali resistance.
In accordance with an embodiment of the present disclosure, the resistance against the rising dampness depends on the amount of polymer emulsion used in the paint composition, wherein distempers offer less performance and low PVC emulsion offers the best performance against rising dampness.
The paint composition of the present disclosure is prepared using APEO free anionic polymer emulsion, and additives incorporated in the paint help for pore blocking in the concrete structure.
The paint composition of the present disclosure is well-suited for providing aesthetic properties such as colour, texture, finish, and the like in addition to functional properties such as water resistance, preventing rising dampness, efflorescence, and the like.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment 1: Process for preparation of the paint composition in accordance with the present disclosure
Example 1
In a twin shaft disperser (TSD) 6.83 ml of water, 0.05g of sodium hexa metaphosphate (sequestering agent), 0.5g Emulsogen LCN118 (first surfactant), 1g Indofil 731 (wetting agent), 0.2g DAPRO DF 7010 (first portion of first defoamer), 1g triethylene glycol (humectant), 0.15 g felamine plus (first pH stabilizer) were mixed sequentially under stirring at 30 °C and a stirring speed of 1200 rpm for 10 minutes to obtain a first mixture.
0.07g ICH RASEPHYTE (first preservative) and 0.3g ICL Rasephyte (first preservative) were added to the so obtained first mixture and were mixed for 5 minutes, followed by addition of 16g titanium dioxide tronox CR-828 (pigment) and were mixed for 10 minutes followed by addition of 3g submicron dolomite (extender) and were stirred for 10 minutes. If lump formation was seen then the mixture was stirred for another 10 minutes. Then 1g ELOTEX ERA 200 (pore blocking agent) was added and mixed for 10 minutes followed by addition of 0.1g ATTAGEL 50 (anti-settling agent) and mixed at 30 °C for 5 minutes under stirring at 1200rpm to obtain a second mixture.
1.8g ACRYSOL RM (thickener), 0.5g Rheolate (thickener), and 2.50g optifilm enhancer 300 (coalescing agent) were added sequentially under stirring to the second mixture at 30 °C, at a speed of 1200rpm and stirred for 60 minutes to obtain a third mixture.
1ml of water, 0.1g BIOBAN O45(fungicide), 0.2g Nipacide CDI (fungicide), 0.4g Sanitized Ag+ (Silver nitrate) (antiviral) (anti-microbial agent) were added to the third mixture sequentially under stirring at 30 °C, at a speed of 100 rpm for 10 minutes to obtain a fourth mixture.
50g of polymer emulsion, 6g 08444 OPU30 (opaque polymer), 0.5g Bayhydrol UH2864 (binder), 0.2g of DAPRO DF 7010 (second portion of first defoamer), 0.5g Silquest A187 (adhesion promoter) were added sequentially under stirring at 100 rpm and mixed for 15 minutes to obtain a fifth mixture.
0.7g COATOSIL SE (scuffing additive), and 2 ml water were added one after another to the fifth mixture under stirring at 30 °C and stirred for 10 minutes at a stirring speed of 100rpm to obtain the paint composition.
Different paint compositions were prepared by following the same procedure as in example 1 except by varying the ingredients and their amounts as tabulated in Table 1 below:

Table 1: Preparation of paint composition in accordance with the present disclosure:
Sr.No. Role of ingredient Ingredient Paint composition
LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Comparative example-1 Comparative example-2 Example 1 Comparative example-3 Comparative example-4 Example 2 Comparative example-5 Comparative example-6 Example-3
1 Polymer emulsion Polymer emulsion 0 0 50 0 0 20 0 0 10
Styrene acrylic emulsion 50 50 0 20 20 0 10 10 0
Total emulsion 50 50 50 20 20 20 10 10 10
2 Pigment TITANIUM DIOXIDE TRONOX CR-828 16 16 16 3.63 3.63 3.63 1 1 1
LITHOMER LC 80 0 0 0 1.75 1.75 1.75 0 0 0
ZEOLEX 325 (titanium dioxide) 0 0 0 1.5 1.5 1.5 0 0 0
Total pigment 16 16 16 6.88 6.88 6.88 1 1 1
3 Filler Calcium carbonate 0 0 0 11 11 11 30 30 30
Vaporlite 90T (Calcium carbonate) 3 3 3 0 0 0 0 0 0
Total filler 3 3 3 11 11 11 30 30 30
4 Coalescing agent OPTIFILM ENHANCER 300 1 1 2.50 0.65 0.65 1 0.36 0.36 0.5
5 Wetting agent Indofil 731 1 1 1 0.58 0.58 0.58 0.5 0.5 0.5
6 Humectant Triethylene glycol 1 1 1 1.65 1.65 1.65 0.5 0.5 0.5
7 Thickener ACRYSOL RM 1.8 1.8 1.8 0 0 0 0 0 0
RHEOLATE 0.5 0.5 0.5 0 0 0 0 0 0
TYLOSE HS 0 0 0 0.2 0.2 0.2 0.2 0.2 0.2
RHEOVIS HS1181 AM 0 0 0 1.06 1.06 1.06 1.30 1.30 1.30
Total 2.3 2.3 2.3 1.26 1.26 1.26 1.50
1.50
1.50

8 Pore blocking agent ELOTEX ERA 200 0 1 1 0 1 1 0 1 1
9 Additives SILQUEST A 187 (Adhesion promoter) 0 0.5 0.5 0 0.5 0.5 0 0.5 0.5
DAPRO 7010 (First Defoamer) 0.2 0.2 0.2 0.1 0.1 0.1 0.05 0.05 0.05
Dapro DF 7010
(First Defoamer) 0.2 0.2 0.2 0.15 0.15 0.15 0.05 0.05 0.05
ZINC Omadine
(Anti-microbial agent) 0 0.4 0.4 0 0.2 0.2 0 0.4 0.4
EMULSOGEN LCN 118 (First surfactant) 0.5 0.5 0.5 0.45 0.45 0.45 0.3 0.3 0.3
SODIUM HEXA META PHOSPHATE
(sequestering agent) 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
FELAMINE PLUS (pH stabilizer) 0.15 0.15 0.15 0.25 0.25 0.25 0.3 0.3 0.3
BIOBAN CS 1135 (INCAN PRESERVATIVE) 0.07 0.07 0 0.08 0.08 0 0.07 0.07 0
ICH RASEPHYTE (BIOBASED IN CAN PRESERVATIVE) 0 0 0.07 0 0 0.08 0 0 0.07
NIPACIDE CFX 2
(INCAN PRESERVATIVE) 0.3 0.3 0 0.3 0.3 0 0.3 0.3 0
ICL RASEPHYTE
(BIOBASED IN CAN PRESERVATIVE) 0 0 0.3 0 0 0.3 0 0 0.3
ATTAGEL 50 (anti-settling agent) 0.1 0.1 0.1 0 0 0 0 0 0
BIOBAN O 45
(fungicide) 0.1 0.1 0.1 0.05 0.05 0.05 0 0 0
NIPACIDE CDI
(DRY FILM FUNGICIDE) 0.3 0.3 0 0.3 0.3 0 0.3 0.3 0
SANITIZED AG+
(Antiviral) 0 0.4 0.4 0 0.2 0.2 0 0.4 0.4
0844 OP U 30 (Opaque polymer) 6 6 6 12 12 12 0 0 0
COATOSIL SE 610 (Scuffing additive) 0 0 0.7 0 0 0.7 0 0 0.5
SUBMICRON DOLOMITE CaMg(CO3)2 (Extender) 0 0 0.7 0 0 0.7 0 0 0.5
STEATITE 90 (silica AND magnesia)
(Extender) 0 0 0 0 0 0 10 10 10
CALCINED CLAY 902 (Silica and alumina) 0 0 0 10.75 10.75 10.75 8 8 8
Total additives 11.87 13.17 13.87 35.16 36.06 36.76 19.72 21.02 21.52
10 Fluid medium UV treated Water
(Step-i) 9.83 7.03 6.83 16.55 14.15 13.10 28.92 26.12 25.48
UV treated Water
(Step-iv) 2 2 1 1.50 1.50 1.50 2 2 2
UV treated Water
(Step-vi) 1 1 0.5 3.35 3.35 3.35 2 2 2
UV treated Water
(Step-vi) 1 1 0.5 0 0 0 2 2 2
UV treated Water
(Step-vi) 1
1 1 2 2 2 2 2 2
Total fluid medium 14.83 12.03 9.83 23.40 21 19.95 36.92 34.12 33.48
11 Binder BAYHYDROL UH 2864
(Binder/POLYURETHANE BINDER) 0 0.5 0.5 0 0.5 0.5 0 0.5 0.5

The emulsion polymer composition was prepared by using the process as disclosed in IN202321050948 and the same is not repeated here for the sake of brevity.
Experiment 2: Test Parameters for the paint composition prepared in accordance with the present disclosure.
Example 1: TEST METHOD: SHEEN ON GLASS PLATE
The paint compositions were applied on glass plate individually by using 4 mil paint applicator and cured for 24 hours at 25±5 °C and at a relative humidity 55±5 %RH. The gloss/sheen was checked using glossometer at different angles. The results are mentioned in Table 2 below.
Table 2: Measurement of sheen on glass plate by applying the conventional paint compositions and the paint compositions prepared in accordance with the present disclosure
Sr. No. SHEEN ON GLASS PLATE LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 2 Market sample Comparative example 1 Comparative example 2 Example 3
1 200 2.2 2.1 2.2 2.8 1.67 1.66 1.72 2.3 1 1.1 1 1.5
2 600 13.5 11.35 12.21 20.4 9.8 9.99 9.89 12.7 5 5.4 5.5 9.8
3 850 48.6 47.23 49.45 70 17.13 17.14 17.21 27.6 10 10.6 10.5 15.7

From Table 2 it is observed that gloss/sheen values of Low PVC Paint (Example 1), Mid PVC Paint (Example 2) and High PVC Paint (Example 3) prepared in accordance with the present disclosure are higher than the market sample and conventional paints.
EXAMPLE 2: STAIN RESISTANCE
Paint samples were applied on laneta paper using 4 mil paint applicator and cured for 7 days at 25±5 °C and relative humidity 55±5 %RH. Then materials such as turmeric, grease, oil crayons, wax crayons, pen, marker and pencil were applied on paint film alongside each other, kept for 1-2 hours, then washed with 5% soap solution on wet abrasion table and checked visually for stains. The results are tabulated in Table 3 below:
Table 3: Measurement of stain resistance
Sr. No. STAIN RESISTANCE LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 3
1 Turmeric 4 4 3 6 2 2 2 3 1 1 1 1
2 Grease 3 3 3 5 2 2 2 3 1 1 1 2
3 Oil crayons 2 2 3 4 1 2 2 3 1 1 1 2
4 Wax crayons 3 3 3 5 2 1 2 4 1 1 1 1
5 Pen 2 3 3 4 1 2 1 3 1 1 1 1
6 Marker 4 4 4 6 2 1 1 3 1 1 1 1
7 Pencil 4 4 4 6 1 2 2 3 1 1 1 2
Total rating 22 23 23 36 11 12 12 22 7 7 7 10
*10 is excellent and 1 is bad
From Table 3 it is seen that Low PVC Paint (Example 1), Mid PVC Paint (Example 2) and High PVC Paint (Example 3) samples prepared in accordance with the present disclosure show better stain resistance compared to market sample and conventional emulsion paints.
Example 3: FILM PROPERTIES:
The paint compositions were applied on laneta substrate to obtain a film of 60 microns to 70 microns thickness and were evaluated. The results are tabulated in Table 4 below:
Table 4: Film properties of conventional paint compositions and paint compositions prepared in accordance with the present disclosure
Sr. No. FILM PROPERTIES LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 2 Market sample Comparative example 1 Comparative example 2 Example 3
1 Contrast ratio 93.69 93 93.22 95.24 83 83.12 82.15 87.12 65.12 65 65.87 66
2 Tappi brightness 88.75 88.89 89.14 89.93 80.11 80.1 80.74 82.14 63.54 63 63.6 64
3 Whiteness index 86.53 85.99 86 87.17 80 80.2 80.34 81.12 62.34 63 63.55 63.97
4 Yellowness index 0.51 0.8 0.78 0.41 0.72 0.69 0.69 0.71 1.1 1 1.12 0.95

From Table 4 it is observed that Low PVC Paint (Example 1), Mid PVC Paint (Example 2) and High PVC Paint (Example 3) prepared in accordance with the present disclosure shows better contrast ratio, tappi brightness and whiteness index compared to market samples and other conventional paints which are based on conventional emulsions.
Example 4: TEST METHOD - WET SCRUB
Paint samples were applied on laneta paper using 4 mil paint applicator and cured for 7 days at 25±5 °C and relative humidity 55±5 %RH. Then these panels were tested on wet abrasion table using brush of 250 g weight and scrub gelly. Results were recorded in number of cycles till the paint was removed. (Test method followed is ASTM D2486). The results are tabulated in Table 5 below:
Table 5: Wet scrub resistance of conventional paint compositions and paint compositions prepared in accordance with the present disclosure
Sr. No WET SCRUB LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 2 Market sample Comparative example 1 Comparative example 2 Example 3
1 560 550 571 802 289 245 293 350 70 74 72 85

From Table 5 it is observed that Low PVC Paint (Example 1), Mid PVC Paint (Example 2) and high PVC Paint (Example 3) samples prepared in accordance with the present disclosure shows better wet scrub resistance than market samples and other conventional paint samples based on conventional emulsion.
Example 5: TEST METHOD - WATERPROOFING PERFORMANCE
The paint composition was applied on porous concrete panel of a size 300 mm width x 300 mm length x 25 mm thickness. First interior water based primer was taken and diluted with water at 100%, then applied 1 coat on porous concrete panel which then was kept for 4 to 6 hours for drying followed by application of two coats of cement putty over it keeping the gap of 4 to 6 hours between two coats and dried for 24 hours. Then interior water-based primer at 100% dilution was applied over this putty and kept for 4-6 hours for drying. Then two coats of topcoat (paint sample) were applied at 40% dilution with water keeping the gap of 4-6 hours between them. The panel was dried at 25±5 °C and relative humidity 55±5 %RH for 7 days. After 7 days, this panel was kept in water tray in a way that 75% of panel was dipped in water. The panel was kept for 7 days and observed for dampness and efflorescence. The results are tabulated in Table 6 below:
Table 6: Waterproofing performance of paint compositions
Sr. No. WATERPROOFING PERFORMANCE LOW PVC PAINTS MID PVC PAINTS HIGH PVC PAINTS
Market sample Comparative example 1 Comparative example 2 Example 1 Market sample Comparative example 1 Comparative example 2 Example 2 Market sample Comparative example 1 Comparative example 2 Example 3
1 Rising Dampness Failed after 24 hours Failed after 24 hours Failed after 2 days Pass for 7 days Failed after 6 hours Failed after 6 hours Failed after 24 hours Failed after 5 days Failed after 2 hours Failed after 2 hours Failed after 4 hours Failed after 2 days
2 Efflorescence Failed after 24 hours Failed after 24 hours Failed after 2 days Pass for 7 days Failed after 6 hours Failed after 6 hours Failed after 24 hours Failed after 5 days Failed after 2 hours Failed after 2 hours Failed after 4 hours Failed after 2 days

From Table 6 it is observed that Low PVC Paint (Example 1), Mid PVC Paint (Example 2) and High PVC Paint (Example 3) prepared in accordance with the present disclosure show better waterproofing performance in terms of dampness and efflorescence compared to market samples and other paints samples based on conventional emulsion.
TECHNICAL ADVANCES AND ECONOMIC SIGNIFICANCE
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a paint composition that:
• provides resistance to dampness and efflorescence;
• improves the waterproofing performance for interior applications;
• has enhanced scrub resistance and alkali resistance;
• contains additives capable of blocking the capillaries of the concrete structure to boost performance;
• provides anti-bacterial, anti-viral, and anti-fungal performance;
• protects against water damage and enhances the longevity of the paint; and
• is economical and environment friendly;
a process for preparing the paint composition that:
• is simple, environment-friendly, and cost-efficient.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A paint composition comprising:
a. an emulsion polymer in an amount in the range of 5 mass % to 60 mass%;
b. additives in an amount in the range of 35 mass% to 65 mass%; and
c. q.s water;

wherein said mass% of each ingredient is with respect to the total mass of the paint composition.

2. The paint composition as claimed in claim 1, wherein said additives comprise
a. at least one pigment in an amount in the range of 0.5 mass % to 20 mass %;
b. at least one filler in an amount in the range of 1 mass % to 35 mass %;
c. at least one coalescing agent in an amount in the range of 0.2 mass% to 3 mass%;
d. at least one wetting agent in an amount in the range of 0.2 mass% to 2 mass%;
e. at least one humectant in an amount in the range of 0.2 mass% to 2 mass%;
f. at least one thickener in an amount in the range of 1 mass% to 3 mass%;
g. at least one pore-blocking agent in an amount in the range of 0.5 mass% to 2 mass%;
h. at least one adhesion promoter in an amount in the range of 0.2 mass% to 1 mass%;
i. at least one first defoamer in an amount in the range of 0.04 mass% to 1 mass%;
j. at least one anti-microbial agent in an amount in the range of 0.2 mass% to 2 mass%;
k. at least one first surfactant in an amount in the range of 0.2 mass% to 0.8 mass%;
l. at least one sequestering agent in an amount in the range of 0.02 mass% to 0.08 mass%;
m. at least one first pH stabilizer in an amount in the range of 0.05 mass% to 0.5 mass% with respect to the total mass of the composition;
n. at least one first preservative in an amount in the range of 0.1 mass% to 0.5 mass%;
o. extenders in an amount in the range of 1 mass% to 25 mass%;
p. at least one scuffing additive in an amount in the range of 0.2 mass% to 1 mass%;
q. at least one binder in an amount in the range of 0 mass% to 1 mass%;
r. an anti-settling agent in an amount in the range of 0 mass% to 0.2 mass%; and
s. an opaque polymer in an amount in the range of 0 mass% to 15 mass%;
wherein said mass% of each ingredient is with respect to the total mass of the paint composition.

3. The paint composition as claimed in claim 1, wherein said emulsion polymer comprises:
A. a reaction product of
i. 40 mass% to 60 mass% of a plurality of monomers;
ii. 0.5 mass% to 2 mass% of at least one polymerizable surfactant;
iii. 0.1 mass% to 1 mass% of at least one initiator;
iv. 0.01 mass% to 0.5 mass% of at least one coupling agent;
v. 0.05 mass% to 0.3 mass% of a plurality of reducing agents;
vi. 0.1 mass% to 2 mass% of at least one second pH stabilizer; and
vii. 0.05 mass% to 0.2 mass% of at least one buffer;
B. 0.5 mass% to 2 mass% of a plurality of adjuvants; and
C. q.s. water
wherein said mass% of each ingredient is with respect to the total mass of said emulsion polymer composition.

4. The paint composition as claimed in claim 3, wherein said plurality of monomers are selected from the group consisting of styrene, butyl acrylate, methacrylic acid, n-butyl methacrylate, diacetone acrylamide (DAAM), ethylene glycol dimethylacrylate (EGDMA), 2-ethylhexyl acrylate and vinyl trimethoxy silane.

5. The paint composition as claimed in claim 3, wherein said polymerizable surfactant is selected from the group consisting of alcohols, C10-14-branched, C11-rich, reaction products with ethylene oxide, [(2-propenyloxy)methyl]oxirane and sulfamic acid, alkyl diphenyl oxide disulfonate, phosphate ester based polymerizable surfactants and reactive anionic emulsifier.

6. The paint composition as claimed in claim 3, wherein said initiator is selected from the group consisting of potassium persulphate, sodium persulphate and ammonium persulphate.

7. The paint composition as claimed in claim 3, wherein said coupling agent is selected from the group consisting of adipic acid dihydrazide (ADH), ethylene glycol dimethylacrylate (EGDMA) and succinic acid dihydrazide.

8. The paint composition as claimed in claim 3, wherein said plurality of reducing agents are selected from a combination of
• tert-butyl hydroperoxide and sodium formaldehydesulfoxylate;
• tert-butyl hydroperoxide and sodium acetone bisulphite;
• tert-butyl hydroperoxide and L-ascorbic acid; and
• tert-butyl hydroperoxide and sodium meta bisulphate.

9. The paint composition as claimed in claim 3, wherein said second pH stabilizer is at least one selected from the group consisting of 95% 2-amino-2-methyl-1-propanol, 2-amino ethanol, alkanolamine and potassium methylsiliconate.

10. The paint composition as claimed in claim 3, wherein said buffer is selected from the group consisting of sodium bicarbonate, sodium acetate, sodium carbonate and ethylene diaminetetraacetic acid (EDTA).

11. The paint composition as claimed in claim 3, wherein said adjuvants comprise a plurality of second preservatives, at least one non-polymerizable surfactant and at least one second defoamer.

12. The paint composition as claimed in claim 11, wherein
• said plurality of second preservatives are in an amount in the range of 0.1 mass% to 0.5 mass%;
• said non-polymerizable surfactant is in an amount in the range of 0.1 mass% to 1 mass%; and
• said second defoamer is in an amount in the range of 0.002 mass% to 0.01 mass%;
wherein said mass% of each ingredient is with respect to the total mass of said emulsion polymer composition.

13. The paint composition as claimed in claim 11, wherein said plurality of second preservatives are selected from a mixture of 5-chloro-2-methylisothiazol-3(2H)-one and 2-methylisothiazol-3(2H)-one (MIT/CMIT) and benzisothiazolinone (BIT).

14. The paint composition as claimed in claim 11, wherein said non-polymerizable surfactant is at least one selected from the group consisting of non-ionic fatty alcohol ethoxylates, sodium dodecylbenzenesulfonate, alkyl polyethylene glycol ether and secondary alcohol ethoxylate.

15. The paint composition as claimed in claim 11, wherein said second defoamer is selected from the group consisting of fumed silica, polyether siloxane emulsion and mineral oil based defoamers.

16. The paint composition as claimed in claim 3, wherein a mass ratio of said plurality of monomers to said polymerizable surfactant is in the range of 35:1 to 45:1.

17. The paint composition as claimed in claim 2, wherein said pigment is at least one selected from titanium dioxide, and calcium carbonate.

18. The paint composition as claimed in claim 2, wherein said filler is selected from the group consisting of calcium carbonate, talc, dolomite, submicron dolomite and clay.

19. The paint composition as claimed in claim 2, wherein said coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether, dipropylene glycol n-butyl ether and 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate.

20. The paint composition as claimed in claim 2, wherein said wetting agent is selected from the group consisting of sodium salt of maleic anhydride copolymer, sodium salt of sodium acetate, sodium salt of methanoic acid or butanoic acid and sodium salt of poly carboxylic acid.

21. The paint composition as claimed in claim 2, wherein said humectant is selected from the group consisting of triethylene glycol, propylene glycol and octyl phenyl ethoxylate.

22. The paint composition as claimed in claim 2, wherein said thickener is selected from the group consisting of polyurethane thickener such as modified ethylene oxide urethane and cellulosic thickener such as hydroxy ethyl cellulose.

23. The paint composition as claimed in claim 2, wherein said pore-blocking agent is selected from the group consisting of rosin ester derivative and modified natural rosin.

24. The paint composition as claimed in claim 2, wherein
• said adhesion promoter is selected from the group consisting of epoxy functional silane, 3-glycidyl-oxypropyl-trimethoxy-silane, beta-(3, 4-epoxycyclohexyl) ethyltrimethoxysilane, and gamma-glycidoxypropyltrimethoxysilane;
• said first defoamer is selected from the group consisting of oil-based defoamer, water-based defoamer, and silicon-based defoamer;
• said anti-microbial agent is selected from the group consisting of 2-octyl-4-isothiazolin-3-one, active silver-based preservative, zinc pyrithione, 2,4,5,6-tetrachloroisophthalonitrile, 3-(3,4-dichlorophenyl)-1,1-dimethylurea, zinc omadine, carbendazim, 2-N-octyl-4-isothiazolin-3-one and zinc oxide.
• said first surfactant is selected from the group consisting of alcohol (C9-11)-branched ethoxylated surfactant, octaethylene glycol monododecyl ether and pentaethylene glycol monododecyl ether and fatty alcohol ethoxylate;
• said sequestering agent is selected from the group consisting of sodium hexametaphosphate, borax, calcium hydroxide and trisodium phosphate;
• said first pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol and 2-methyl-1-propanol and potassium methylsiliconate.
• said first preservative is selected from the group consisting of active silver-based preservatives and zinc-based preservatives, 4,4-dimethyl-oxazolidine, citrus extract and a mixture of formaldehyde, chloromethyl and methylisothiazolinone;
• said anti-settling agent is selected from the group consisting of magnesium aluminium phyllosilicate and attapulgite clay.
• said opaque polymer is styrene acrylic latex;
• said extenders are selected from the group consisting of calcium magnesium carbonate, hydrous magnesium silicate, and calcined clay; and
• said scuffing additive is selected from the group consisting of mixture of polyoxyethylene trimethyldecyl alcohol, decamethylcyclopentasiloxane, octamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane and 1,2-benzisothiazolin-3-one.

25. The composition as claimed in claim 2, wherein said binder is selected from the group consisting of anionic aliphatic polyester polyurethane emulsion, anionic polyacrylate dispersion, polyurethane dispersion and acrylic-polyurethane hybrid dispersion.

26. The composition as claimed in claim 24, wherein
• said oil based defoamer is selected from the group consisting of mineral oil, vegetable oil, and white oil, optionally enriched with wax or hydrophobic silica;
• said water based defoamer is selected from the group consisting of mineral oil, a vegetable oil, and waxes such as long chain fatty alcohol, fatty acid soaps and fatty acid esters; and
• said silicon-based defoamer is selected from the group consisting of silicone backbones such as hydrophobic silica dispersed in silicone oil, petroleum distillates, hydrotreated heavy paraffinic in silicone oil.

27. A process for the preparation of a paint composition as claimed in claims 1 and 2, said process comprising the following steps:
i. mixing predetermined amounts of water, a sequestering agent, a first surfactant, a wetting agent, a first portion of first defoamer, a humectant, a first pH stabilizer sequentially under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;
ii. adding predetermined amounts of a first preservative, a pigment, an extender, a pore blocking agent and an anti-settling agent sequentially to said first mixture for a second predetermined time period each under stirring at a second predetermined stirring speed to obtain a second mixture;
iii. adding predetermined amounts of a thickener and a coalescing agent sequentially to said second mixture under stirring at a third predetermined stirring speed for a third predetermined time period to obtain a third mixture;
iv. adding predetermined amounts of water and an anti-microbial agent to said third mixture sequentially under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a fourth mixture;
v. adding predetermined amounts of an emulsion polymer, an opaque polymer, a binder, a second portion of first defoamer and an adhesion promoter sequentially to said fourth mixture under stirring at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a fifth mixture; and
vi. adding predetermined amounts of a scuffing additive and water sequentially to said fifth mixture under stirring at a sixth predetermined stirring speed for a sixth predetermined time period to obtain said paint composition.

28. The process as claimed in claim 27, wherein said steps (i) to (vi) are carried out at a temperature in the range of 25 °C to 40 °C.

29. The process as claimed in claim 27, wherein
• said predetermined amount of said sequestering agent is in the range of 0.02 mass% to 0.08 mass%;
• said predetermined amount of said first surfactant is in the range of 0.2 mass% to 0.8 mass%;
• said predetermined amount of said wetting agent is in the range of 0.2 mass% to 2 mass%;
• said predetermined amount of said first portion of said first defoamer is in the range of 0.02 mass% to 0.5 mass%;
• said predetermined amount of said second portion of said first defoamer is in the range of 0.02 mass% to 0.5 mass%;
• said predetermined amount of said humectant is in the range of 0.2 mass% to 2 mass%;
• said predetermined amount of said first pH stabilizer is in the range of 0.05 mass% to 0.5 mass%;
• said predetermined amount of said first preservative is in the range of 0.1 mass% to 0.5 mass%;
• said predetermined amount of said pigment is in the range of 0.5 mass% to 20 mass%;
• said predetermined amount of said extender is in the range of 10 mass% to 40 mass%;
• said predetermined amount of said pore blocking agent is in the range of 0.5 mass% to 2 mass%;
• said predetermined amount of said thickener is in the range of 0.1 mass% to 5 mass%;
• said predetermined amount of said coalescing agent is in the range of 0.2 mass% to 3 mass%;
• said predetermined amount of said anti-microbial agent is in the range of 0.2 mass% to 2 mass%;
• said predetermined amount of said emulsion is in the range of 5 mass% to 60 mass%;
• said predetermined amount of said adhesion promoter is in the range of 0.2 mass% to 1 mass%;
• said predetermined amount of said scuffing additive is in the range of 0.2 mass% to 1 mass%;
• said predetermined amount of water in step (i) is in the range of 65 mass% to 95 mass% with respect to the total mass of the first mixture; said predetermined amount of water in step (iv) is in the range of 55 mass% to 85 mass% with respect to the total mass of the fourth mixture; and said predetermined amount of water in step (vi) is in the range of 70 mass% to 95 mass% with respect to the total mass of the fourth mixture;
• said predetermined amount of said binder is in the range of 0 mass% to 1 mass%;
• said predetermined amount of said anti-settling agent is in the range of 0 mass% to 0.2 mass%; and
• said predetermined amount of said opaque polymer is in the range of 0 mass% to 15 mass%;
wherein said mass% of each ingredient is with respect to the total mass of said paint composition.

30. The process as claimed in claim 27, wherein
• said first predetermined stirring speed, said second predetermined stirring speed and said third predetermined stirring speed are independently in the range of 1000 rpm to 1500 rpm; and
• said fourth predetermined stirring speed, said fifth predetermined stirring speed and said sixth predetermined stirring speed are independently in the range of 50 rpm to 150 rpm.

31. The process as claimed in claim 27, wherein
• said first predetermined time period is in the range of 5 minutes to 20 minutes;
• said second predetermined time period is in the range of 2 minutes to 15 minutes;
• said third predetermined time period is in the range of 50 minutes to 70 minutes;
• said fourth predetermined time period is in the range of 5 minutes to 20 minutes;
• said fifth predetermined time period is in the range of 10 minutes to 30 minutes; and
• said sixth predetermined time period is in the range of 2 minutes to 20 minutes.

Dated this 20th day of July, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI