DESC:FIELD
The present disclosure relates to a coating composition and a process for its preparation.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise.
Spreadability: The term “spreadability” also known as “spreading capacity” or “covering capacity” refers to the area that can be covered by a specific volume or weight of coating composition. It is a measure of how far a coating composition can spread over a surface.
Hiding Power: The term “hiding power” also known as “hiding capacity” or “opacity” refers to the ability of the coating composition or coating material to obscure/hide the surface on which it is applied.
Contrast Ratio: The term “contrast ratio” refers to a ratio of the reflectance of the coating composition when applied on a black substrate to the reflectance of the same coating composition when applied on a white substrate.
Sheen: The term “sheen” refers to a visual property of the substance/material that shines with the reflected light.
Tappi Brightness: The term “tappi brightness” refers to the brightness of the film obtained by applying a coating composition/paint. Higher values indicate good brightness.
Yellowness index: The term “yellowness index” refers to a number which is calculated from spectrophotometric data. The Yellowness index defines the change in color of a test sample from clear or white to yellow. Lower value is better indicating lower yellowness in film, better whiteness and shade acceptance.
Grinding resin: The term “grinding resin” also known as “grind resin” refers to a reaction product of a dibasic acid, optionally a polybasic acid, a diol, optionally a polyol, and a fatty compound. The grinding resin has dual functionality which can be used as a binder and as a pigment dispersing agent.
Dry film fungicide: The term “dry film fungicide” refers to an additive that inhibits the growth of fungi on the surface of the dried coating. It helps to prevent fungal growth that can lead to discoloration or degradation of the coating.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
There are many coating compositions such as solvent based coating composition and water based coating composition, available for coating on an interior and exterior part of the infrastructure. However, in the market, the conventional solvent based coating compositions are associated with certain drawbacks such as the solvent used in the solvent based coating composition are expensive, volatile, flammable and toxic thereby making it uneconomic and hazardous.
Further, the conventional water based coating composition has comparatively less covering capacity. So high amount of the water based coating composition is required to coat a specific area (120 sq.ft/liter/2 coat to 140 sq.ft/liter/2 coat). As the amount of coating composition required is high, it generates plastic waste in terms of the plastic containers. The disposal of these tremendous waste plastic containers becomes a concern for the environmentalist.
Therefore, there is felt a need to provide a coating composition that mitigates the drawbacks mentioned hereinabove or at least provides 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 coating composition.
Still another object of the present disclosure is to provide a water-based coating composition that can be in highly concentrated form.
Yet another object of the present disclosure is to provide a coating composition that has good hiding power.
Still another object of the present disclosure is to provide a coating composition that has good covering capacity/spreadability.
Yet another object of the present disclosure is to provide an economic and environment friendly coating composition.
Still another object of the present disclosure is to provide a process for the preparation of a coating composition.
Yet another object of the present disclosure is to provide a simple, economical and environment friendly process for the preparation of a coating 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 coating composition and a process for its preparation.
In an aspect the present disclosure provides a coating composition. The coating composition comprises:
• a predetermined amount of at least one binder;
• a predetermined amount of at least one grinding resin;
• a predetermined amount of at least one filler;
• a predetermined amount of at least one thickener;
• a predetermined amount of at least one pigment;
• a predetermined amount of at least one antimicrobial agent;
• a predetermined amount of at least one preservative;
• a predetermined amount of at least one additive; and
• q.s water.
In an embodiment of the present disclosure, the predetermined amount of the binder is in the range of 5 mass% to 10 mass%, the predetermined amount of the grinding resin is in the range of 5 mass% to 20 mass%, the predetermined amount of the filler is in the range of 50 mass% to 65 mass%, the predetermined amount of the thickener is in the range of 1 mass% to 2 mass%, the predetermined amount of the pigment is in the range of 3 mass% to 5 mass%, the predetermined amount of the antimicrobial agent is in the range of 0.3 mass% to 1.4 mass%, the predetermined amount of the preservative is in the range of 0.1 mass% to 1.5 mass%, the predetermined amount of the additive is in the range of 3 mass% to 8.5 mass%, and q.s water i wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the binder is styrene acrylic emulsion, the grinding resin is alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene, the filler comprises a first filler and a second filler, the thickener comprises a first thickener and a second thickener, the pigment is titanium dioxide (TiO2), the antimicrobial agent is a dry film fungicide, the preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinones and non-chlorinated isothiazolinone, the additive is at least one selected from the group consisting of a dispersing agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a humectant, and a softening agent.
In an embodiment of the present disclosure, the first filler and the second filler is independently selected from the group consisting of anhydrous aluminum silicate, calcined clay, and carbonate minerals.
In an embodiment of the present disclosure, the first thickener and the second thickener is independently selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers, and the dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-n-octyl-4-isothiazolin-3-one.
In an embodiment of the present disclosure, the isothiazolinone is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolineone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT).
In an embodiment of the present disclosure, carbonate mineral are selected from calcium carbonate (lime stone) and dolomite, and the cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC).
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers.
In an embodiment of the present disclosure, the surfactant is a non-ionic surfactant selected from the group consisting of poly(oxy-1,2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy)-, branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt.
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate.
In an embodiment of the present disclosure, the defoaming agent is defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-propanetricarboxylic acid, 2-hydroxy-, tributyl ester, and 4-tert-butylcatechol (TBC).
In an embodiment of the present disclosure, the humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol).
In an embodiment of the present disclosure, the softening agent is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP).
In an embodiment of the present disclosure, the composition is characterized by having a spreadability/coverage capacity in the range of 80 % to 85 %.
In another aspect the present disclosure provides a process for the preparation of the coating composition. The process comprises the steps of:
i) charging a predetermined amount of water in a mixer and adding predetermined amounts of at least one additive and at least one grinding resin followed by mixing under stirring at a speed in the range of 350 rpm to 650 rpm for a time period in the range of 5 minutes to 10 minutes to obtain a mixture having a pH in the range of 7 to 8;
ii) adding a predetermined amount of at least one preservative in the mixture followed by stirring for a time period in the range of 2 minutes to 10 minutes to obtain a first slurry;
iii) adding a predetermined amount of at least one pigment in the first slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a second slurry;
iv) adding a predetermined amount of at least one first filler in the second slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a third slurry;
v) adding a predetermined amount of at least one second filler in the third slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a fourth slurry;
vi) dispersing the fourth slurry under stirring for a time period in the range of 50 minutes to 60 minutes to obtain a homogenous slurry;
vii) adding a predetermined amount of at least one anti-microbial agent in the homogeneous slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain an intermediate slurry;
viii) adding a predetermined amount of at least one first thickener to the intermediate slurry followed by mixing under constant stirring for a time period in the range of 5 minutes to 15 minutes to obtain a resultant slurry;
ix) adding a predetermined amount of at least one binder in the resultant slurry followed by mixing under constant stirring for a time period in the range of 10 minutes to 30 minutes to obtain an emulsified slurry; and
x) adding a predetermined amount of at least one second thickener in the emulsified slurry followed by mixing under constant stirring for a time period in the range of 20 minutes to 50 minutes to obtain the coating composition.
In an embodiment of the present disclosure, the stirring speed in the steps (iii) to (x) is in the range of 900 rpm to 1400 rpm.
In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a dispersing agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a humectant, and a softening agent; and the grinding resin is alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 20 mass% to 30 mass%, the predetermined amount of the additive is in the range of 3 mass% to 8.5 mass%; and the predetermined amount of the grinding resin is in the range of 5 mass% to 20 mass%; wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers.
In an embodiment of the present disclosure, the surfactant is a non-ionic surfactant selected from the group consisting of poly(oxy-1,2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy)-, branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt.
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate.
In an embodiment of the present disclosure, the defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-propanetricarboxylic acid, 2-hydroxy-, tributyl ester, and 4-tert-butylcatechol (TBC).
In an embodiment of the present disclosure, the humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol).
In an embodiment of the present disclosure, the softening agent is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP).
In an embodiment of the present disclosure, the predetermined amount of the preservative is in the range of 0.1 mass% to 1.5 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinones and non-chlorinated isothiazolinone, wherein the isothiazolinone is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolineone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT).
In an embodiment of the present disclosure, the stirring speed in the steps (iii) to (x) is in the range of 900 rpm to 1400 rpm.
In an embodiment of the present disclosure, the predetermined amount of the pigment is in the range of 3 mass% to 5 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the pigment is titanium dioxide (TiO2).
In an embodiment of the present disclosure, the predetermined amount of the first filler is in the range of 15 mass% to 20 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first filler is selected from the group consisting of anhydrous aluminum silicate, carbonate minerals and calcined clay.
In an embodiment of the present disclosure, the predetermined amount of the second filler is in the range of 35 mass% to 45 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second filler is selected from the group consisting of carbonate minerals, anhydrous aluminum silicate and calcined clay.
In an embodiment of the present disclosure, the carbonate minerals are selected from calcium carbonate (lime stone) and dolomite.
In an embodiment of the present disclosure, the predetermined amount of the antimicrobial agent is in the range of 0.6 mass% to 1.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the antimicrobial agent is a dry film fungicide.
In an embodiment of the present disclosure, the dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-noctyl-4-isothiazolin-3-one.
In an embodiment of the present disclosure, the predetermined amount of the first thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers.
In an embodiment of the present disclosure, the binder is styrene acrylic emulsion.
In an embodiment of the present disclosure, the predetermined amount of the binder is in the range of 5 mass% to 10 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers.
In an embodiment of the present disclosure, the cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC).
DETAILED DESCRIPTION
The present disclosure relates to a coating composition and a process for its preparation.
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.
There are many coating compositions such as solvent based coating composition and water based coating composition, available for coating on an interior and exterior part of the infrastructure. However, in the market, the conventional solvent based coating compositions are associated with certain drawbacks such as the solvent used in the solvent based coating composition are expensive, volatile, flammable and toxic thereby making it uneconomic and hazardous.
Further, the conventional water based coating composition has comparatively less covering capacity. So high amount of the water based coating composition is required to coat a specific area (120 sq.ft/liter/2 coat to 140 sq.ft/liter/2 coat). As the amount of coating composition required is high, it generates plastic waste in terms of the plastic containers. The disposal of these tremendous waste plastic containers becomes a concern for the environmentalist.
The present disclosure provides a coating composition and a process for its preparation.
In an aspect, the present disclosure provides a coating composition.
The coating composition comprises:
• a predetermined amount of at least one binder;
• a predetermined amount of at least one grinding resin;
• a predetermined amount of at least one filler;
• a predetermined amount of at least one thickener;
• a predetermined amount of at least one pigment;
• a predetermined amount of at least one antimicrobial agent;
• a predetermined amount of at least one preservative;
• a predetermined amount of at least one additive; and
• q.s water.
In an embodiment of the present disclosure, the binder is styrene acrylic emulsion.
In an embodiment of the present disclosure, the predetermined amount of the binder can be in the range of 5 mass% to 10 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the binder is 7 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the grinding resin is selected from the group consisting of alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene.
In accordance with the present disclosure, the grinding resin is in the form of water based emulsion. Grinding resins are essential components that contribute to the overall performance, durability, and application characteristics of the coating composition. They ensure proper dispersion of pigments, stability of the coating composition, and formation of a durable, protective film on surfaces.
The grinding resin helps in pigment dispersion. Further, it acts as a binder which helps to load more pigment in the coating composition to achieve desired coverage. Further, it helps to incorporate excessive loading of pigments and extenders, to provide better flow and levelling and rheology to keep pigment and extenders in suspended form.
In an embodiment of the present disclosure, the predetermined amount of the grinding resin is in the range of 5 mass% to 20 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the grinding resin is 6 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the filler is selected from the group consisting of a first filler and a second filler. In an exemplary embodiment of the present disclosure, the filler consists a mixture of the first filler and the second filler.
In an embodiment of the present disclosure, the predetermined amount of the filler is in the range of 50 mass% to 65 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the filler is 52 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first filler and the second filler independently selected from the group consisting of anhydrous aluminum silicate, carbonate minerals and calcined clay. In an embodiment of the present disclosure, the first filler is anhydrous aluminum silicate. In an exemplary embodiment of the present disclosure, the second filler is a carbonate mineral.
In an embodiment of the present disclosure, the carbonate mineral are selected from calcium carbonate (lime stone) and dolomite. In an exemplary embodiment of the present disclosure, the carbonate mineral is calcium carbonate.
In an embodiment of the present disclosure, the predetermined amount of the first filler is in the range of 15 mass% to 20 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the first filler is 16 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the predetermined amount of the second filler is in the range of 35 mass% to 45 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the second filler is 36 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the thickener comprises a first thickener and a second thickener.
In an embodiment of the present disclosure, the predetermined amount of the thickener is in the range of 1 mass% to 2 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the thickener is 1.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first thickener and the second thickener are independently selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers. In an exemplary embodiment of the present disclosure, the first thickener is a polyurethane thickener. In an exemplary embodiment of the present disclosure, the second thickener is a cellulosic thickener.
In an embodiment of the present disclosure, the cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC). In an exemplary embodiment of the present disclosure, the cellulosic thickener is 2-hydroxyethyl cellulose.
In an embodiment of the present disclosure, the polyurethane thickener is selected from the group consisting of nonionic polyurethane associative thickeners.
In an embodiment of the present disclosure, the predetermined amount of the first thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the first thickener is 0.7 mass% with respect to the total mass of the coating composition.
The polyurethane thickeners impart good flow and leveling properties to the coating composition.
In an embodiment of the present disclosure, the predetermined amount of the second thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the second thickener is 0.6 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the pigment is titanium dioxide (TiO2).
In an embodiment of the present disclosure, the titanium dioxide pigment is selected from the group consisting of rutile and anatase.
In an embodiment of the present disclosure, the predetermined amount of the pigment is in the range of 3 mass% to 5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pigment is 4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the antimicrobial agent is a dry film fungicide.
In an embodiment of the present disclosure, the dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-n-octyl-4-isothiazolin-3-one. In an exemplary embodiment of the present disclosure, the dry film fungicide is a mixture of 2-noctyl-4-isothiazolin-3-one and methyl benzimidazole-2-ylcarbamate.
In an embodiment of the present disclosure, the predetermined amount of the antimicrobial agent is in the range of 0.3 mass% to 1.4 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the antimicrobial agent is 1 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinone and non-chlorinated isothiazolinone. In an exemplary embodiment of the present disclosure the preservative is methyl benzimidazole-2-ylcarbamate.
In an embodiment of the present disclosure, the isothiazolinones is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolinone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT).
In an embodiment of the present disclosure, the predetermined amount of the preservative is in the range of 0.1 mass% to 1.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the preservative is 0.6 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a dispersing agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a humectant, and a softening agent.
In an embodiment of the present disclosure, the predetermined amount of the additive is in the range of 3 mass% to 8.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the additive is 6.2 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers. In an exemplary embodiment of the present disclosure, the dispersing agent is sodium salt of a maleic anhydride copolymer.
In an embodiment of the present disclosure, the predetermined amount of the dispersing agent is in the range of 1 mass% to 3 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the dispersing agent is 2 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the surfactant is a non-ionic surfactant selected from the group consisting of poly(oxy-1,2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy)-, branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt having CAS No. 68649-55-8. In an exemplary embodiment of the present disclosure, the surfactant is poly (oxy-1,2-ethanediyl).
In an embodiment of the present disclosure, the predetermined amount of the surfactant is in the range of 0.3 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the surfactant is 0.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate. In an exemplary embodiment of the present disclosure, the pH stabilizer is ethanolamine.
In an embodiment of the present disclosure, the predetermined amount of the pH stabilizer is in the range of 0.2 mass% to 0.4 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pH stabilizer is 0.3 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil. In an exemplary embodiment of the present disclosure, the defoaming agent is modified polysiloxane with hydrophobic particles.
In an embodiment of the present disclosure, the predetermined amount of the defoaming agent is in the range of 0.2 mass% to 0.4 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the defoaming agent is 0.3 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-propanetricarboxylic acid, 2-hydroxy tributyl ester, and 4-tert-butylcatechol (TBC). In an exemplary embodiment of the present disclosure, the coalescing agent is 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate.
In an embodiment of the present disclosure, the predetermined amount of the coalescing agent is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the coalescing agent is 0.6 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol). In an embodiment of the present disclosure, the humectant is a mixture of mono ethylene glycol and tri ethylene glycol.
In an embodiment of the present disclosure, the predetermined amount of the humectant is in the range of 1 mass% to 3 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the humectant is 2.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, a softening agent is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP). In an exemplary embodiment of the present disclosure, a softening agent is sodium hexametaphosphate (SHMP).
In an embodiment of the present disclosure, the predetermined amount of the softening agent is in the range of 0.01 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the softening agent (water softening agent) is 0.5 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, water is selected from the group consisting of UV treated water, and distilled water. In an exemplary embodiment of the present disclosure, water is UV treated water.
The additives helps to incorporate excessive loading of pigments, to provide better flow, leveling, rheology and to keep pigment in suspended form in the coating composition.
The coating composition of the present disclosure is a high concentrated water-based coating composition which is diluted up to 100% to 150% with water by volume to achieve coverage capacity in the range of 220 sq.ft/liter/2 coats to 250 sq.ft/liter/2 coats. The spreadability/coverage capacity of the coating composition of the present disclosure is 80 % to 85 % which is greater as compared to the coverage capacity of the conventional water based coating composition depending on quality of product, amount of emulsion polymer used and quality of substrate.
The coating composition of the present disclosure provides the aesthetic properties, better covering capacity along with the reduction in plastic waste.
The coating composition of the present disclosure is used to develop a primer, popular category and premium category interior emulsion and exterior emulsion.
In another aspect, the present disclosure provides a process for the preparation of a coating composition.
In an embodiment of the present disclosure, the process for the preparation of a coating composition comprises the following steps of:
i) charging a predetermined amount of water in a mixer and adding predetermined amounts of at least one additive and at least one grinding resin followed by mixing under stirring at a speed in the range of 350 rpm to 650 rpm for a time period in the range of 5 minutes to 10 minutes to obtain a mixture having a pH in the range of 7 to 8;
ii) adding a predetermined amount of at least one preservative in the mixture followed by stirring for a time period in the range of 2 minutes to 10 minutes to obtain a first slurry;
iii) adding a predetermined amount of at least one pigment in the first slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a second slurry;
iv) adding a predetermined amount of at least one first filler in the second slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a third slurry;
v) adding a predetermined amount of at least one second filler in the third slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a fourth slurry;
vi) dispersing the fourth slurry under stirring for a time period in the range of 50 minutes to 60 minutes to obtain a homogenous slurry;
vii) adding a predetermined amount of at least one anti-microbial agent in the homogeneous slurry followed by mixing under stirring f for a time period in the range of 5 minutes to 15 minutes to obtain an intermediate slurry;
viii) adding a predetermined amount of at least one first thickener to the intermediate slurry followed by mixing under constant stirring for a time period in the range of 5 minutes to 15 minutes to obtain a resultant slurry;
ix) adding a predetermined amount of at least one binder in the resultant slurry followed by mixing under constant stirring for a time period in the range of 10 minutes to 30 minutes to obtain an emulsified slurry; and
x) adding a predetermined amount of at least one second thickener in the emulsified slurry followed by mixing under constant stirring for a time period in the range of 20 minutes to 50 minutes to obtain the coating composition.
The process is described in detail.
In a first step, a predetermined amount of water is charged in a mixer and predetermined amounts of at least one additive and at least one grinding resin are added followed by mixing under stirring at a speed in the range of 350 rpm to 650 rpm for a time period in the range of 5 minutes to 10 minutes to obtain a mixture having a pH in the range of 7 to 8.
In an embodiment of the present disclosure, water is selected from the group consisting of UV treated water, and distilled water. In an exemplary embodiment of the present disclosure, water is UV treated water.
In an embodiment of the present disclosure, the predetermined amount of the water is in the range of 20 mass% to 30 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the water is 22 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the predetermined amount of additive is in the range of 3 mass% to 8.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of additive is 6.5 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of softening agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a dispersing agent, and an humectant.
In an embodiment of the present disclosure, the softening agent (water softening agent) is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP). In an embodiment of the present disclosure, the softening agent is sodium hexametaphosphate (SHMP).
In an embodiment of the present disclosure, the predetermined amount of the softening agent is in the range of 0.01 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the softening agent is 0.5 mass% with respect to the total mass of the coating composition.
The softening agent improves the dispersability of extenders in water.
In an embodiment of the present disclosure, the surfactant is a nonionic surfactant selected from the group consisting of poly (oxy-1, 2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy)-, branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt having CAS No. 68649-55-8). In an exemplary embodiment of the present disclosure, the non-ionic surfactant is poly (oxy-1, 2-ethanediyl).
In an embodiment of the present disclosure, the predetermined amount of the surfactant is in the range of 0.3 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the surfactant is 0.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the hydrophile-lipophile balance value (HLB value) of the surfactants is in the range of 8 to 16.
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate. In an exemplary embodiment of the present disclosure, the pH stabilizer is ethanolamine.
In an embodiment of the present disclosure, the predetermined amount of the pH stabilizer is in the range of 0.2 mass% to 0.4 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pH stabilizer is 0.3 mass% with respect to the total mass of the coating composition.
The pH stabilizer helps to achieve a coating composition with a pH in the range of 8 to 9.5. At pH in the range of 8 to 9.5, the coating composition of the present disclosure achieves optimum thickening efficiency. Further, the coating composition is able to maintain a stable viscosity which helps to keep the pigment and filler particles in suspended form throughout the shelf life (2 years) of the coating composition. If the pH is less than 8 .i.e. in the range of 5 to 7 it helps in the proliferation of micro-organisms. If the pH is more than 9.5 it affects the functionality of the antimicrobial agents.
The antimicrobial agent helps to prevent the fungal attack on the coating composition when applied on a substrate.
In an embodiment of the present disclosure, the defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil. In an exemplary embodiment of the present disclosure, the defoaming agent is polysiloxane with hydrophobic particles.
In an embodiment of the present disclosure, the predetermined amount of the defoaming agent is in the range of 0.2 mass% to 0.4 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the defoaming agent is 0.3 mass% with respect to the total mass of the coating composition.
The defoaming agents help to eliminate the foam which may form during the process of preparing the coating composition or while applying the coating composition on the substrate.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-Propanetricarboxylic acid, 2-hydroxy tributyl ester, and 4-tert-butylcatechol (TBC). In an exemplary embodiment of the present disclosure, the coalescing agent is 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate.
In an embodiment of the present disclosure, the predetermined amount of the coalescing agent is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the coalescing agent is 0.6 mass% with respect to the total mass of the coating composition.
The coalescing agents help to form uniform film.
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers. In an embodiment of the present disclosure, the dispersing agent is sodium salt of a maleic anhydride copolymer.
In an embodiment of the present disclosure, the predetermined amount of the dispersing agent is in the range of 1 mass% to 3 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the dispersing agent is 2 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol). In an embodiment of the present disclosure, the humectant is a mixture of tri ethylene glycol and mono ethylene glycol.
In an embodiment of the present disclosure, the predetermined amount of the humectant is in the range of 1 mass% to 3 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the humectant is 2.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the grinding resin is selected from the group consisting of alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene. In an exemplary embodiment of the present disclosure, the grinding resin is alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene.
In accordance with the present disclosure, the grinding resin is in the form of water based emulsion.
In an embodiment of the present disclosure, the predetermined amount of the grinding resin is in the range of 5 mass% to 20 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the grinding resin is 6 mass% with respect to the total mass of the coating composition.
The APEO free anionic polymer dispersion of acrylic ester and styrene helps in pigment dispersion. It helps in maintaining the paint stability. It also acts as a binder which helps in higher pigment loading to achieve desired coverage. Further, the coating composition comprising APEO free anionic polymer dispersion of acrylic ester and styrene have good washability and moderate stain resistance.
In an exemplary embodiment of the present disclosure, a predetermined amount of water is charged in a mixer and predetermined amounts of at least one additive and at least one grinding resin is added followed by mixing under stirring at a speed of 400 rpm for a time period of 7 minutes to obtain a mixture having a pH of 7.5.
In a second step, a predetermined amount of at least one preservative is added in the mixture followed by stirring for a time period in the range of 2 minutes to 10 minutes to obtain a first slurry.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one preservative is added in the mixture followed by stirring for 5 minutes to obtain first slurry.
In an embodiment of the present disclosure, the predetermined amount of the preservative is in the range of 0.1 mass% to 1.5 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the preservative is 0.6 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinones and non-chlorinated isothiazolinones. In an embodiment, the isothiazolinones is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolineone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT). In an embodiment of the present disclosure, the isothiazolinones is methyl benzimidazole-2-ylcarbamate.
The preservatives of the present disclosure prevent the fungal/microbial attack on the coating composition during storage and transportation.
In a third step, a predetermined amount of at least one pigment is added in the first slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a second slurry.
In an embodiment of the present disclosure, the pigment is titanium dioxide (TiO2).
In an embodiment of the present disclosure, the titanium dioxide (TiO2) is selected from the group consisting of rutile and anatase.
In an embodiment of the present disclosure, the predetermined amount of the pigment is in the range of 3 mass% to 5 mass% with respect to the total mass of the coating composition. In an embodiment of the present disclosure, the predetermined amount of the pigment is 4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the purity of titanium dioxide is at least 93%.
In an embodiment of the present disclosure, the particle size of the titanium dioxide is in the range of 200 nm to 300 nm.
The titanium dioxide imparts opacity to the coating composition.
In an embodiment of the present disclosure, when titanium dioxide is used as a pigment in the coating composition a contrast ratio is in the range of 93 % to 95%; whereas conventionally when anhydrous aluminium silicate is used as a pigment in the coating composition the contrast ratio is in the range of 85% to 90%, and when calcium carbonate is used as a pigment in the coating composition the contrast ratio is in the range of 15% to 20%.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one pigment is added in the first slurry followed by mixing under stirring at a speed of 1200 rpm for a time period of 10 minutes to obtain second slurry.
In a fourth step, a predetermined amount of at least one first filler is added in the second slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a third slurry.
In an embodiment of the present disclosure, the first filler is selected from the group consisting of anhydrous aluminum silicate, carbonate minerals and calcined clay. In an exemplary embodiment of the present disclosure, the first filler is anhydrous aluminum silicate.
In an embodiment of the present disclosure, the predetermined amount of the first filler is in the range of 15 mass% to 20 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the first filler is 16 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one first filler is added in the second slurry followed by mixing under stirring at a speed of 1200 rpm for a time period of 10 minutes to obtain a third slurry.
In a fifth step, a predetermined amount of at least one second filler is added in the third slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a fourth slurry
In an embodiment of the present disclosure, the second filler is a carbonate minerals selected from calcium carbonate (lime stone) (dolomite), anhydrous aluminium silicate and calcined clay. In an embodiment of the present disclosure, the second filler is calcium carbonate.
In an embodiment of the present disclosure, the predetermined amount of the second filler is in the range of 35 mass% to 45 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the second filler is 36 mass% with respect to the total mass of the coating composition.
The fillers also act as an extender for imparting opacity to the coating composition.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one second filler is added in the third slurry followed by mixing under stirring at a speed of 1200 rpm for a time period of 10 minutes to obtain a fourth slurry.
In a sixth step, the fourth slurry is dispersed under stirring for a time period in the range of 50 minutes to 60 minutes to obtain a homogenous slurry.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm.
In an exemplary embodiment of the present disclosure, the fourth slurry is dispersed under stirring at a speed of 1200 rpm for a time period of 55 minutes to obtain homogenous slurry.
In accordance with the present disclosure, the steps of dispersing helps to remove the lumps and to obtain lumps free and smooth homogeneous slurry.
In a seventh step, a predetermined amount of at least one anti-microbial agent is added in the homogeneous slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain an intermediate slurry.
In an embodiment of the present disclosure, the antimicrobial agent is a dry film fungicide.
In an embodiment of the present disclosure, the dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-n-octyl-4-isothiazolin-3-one. In an exemplary embodiment of the present disclosure, the dry film fungicide is a mixture of 2-noctyl-4-isothiazolin-3-one and methyl benzimidazole-2-ylcarbamate.
In an embodiment of the present disclosure, the predetermined amount of the antimicrobial agent is in the range of 0.3 mass% to 1.4 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the antimicrobial agent is 0.8 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one anti-microbial agent is added in the homogeneous slurry followed by mixing under stirring for a speed of 1200 rpm for a time period of 10 minutes to obtain intermediate slurry.
In the eighth step, a predetermined amount of at least one first thickener is added to the intermediate slurry followed by mixing under constant stirring for a time period in the range of 5 minutes to 15 minutes to obtain a resultant slurry.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one first thickener is added to the intermediate slurry followed by mixing under constant stirring for a time period of 10 minutes to obtain resultant slurry.
In an exemplary embodiment of the present disclosure, the first thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers. In an exemplary embodiment of the present disclosure, the first thickener is a polyurethane thickener.
The polyurethane thickener is selected from the group consisting of nonionic polyurethane associative thickeners.
In an embodiment of the present disclosure, the predetermined amount of the first thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the first thickener is 0.7 mass% with respect to the total mass of the coating composition.
The polyurethane thickener helps in maintaining the flow and leveling properties of the coating composition.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm. In an exemplary embodiment of the present disclosure the stirring speed is 1200 rpm.
In the ninth step, a predetermined amount of at least one binder is added in the resultant slurry followed by mixing under constant stirring for a time period in the range of 10 minutes to 30 minutes to obtain an emulsified slurry.
In an embodiment of the present disclosure, the binder is styrene acrylic emulsion.
In an embodiment of the present disclosure, the predetermined amount of the binder is in the range of 5 mass% to 10 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the binder is 7 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the glass transition temperature (Tg) of styrene acrylic emulsion is in the range of 4 °C to 5 °C.
In an embodiment of the present disclosure, the minimum film forming temperature of styrene acrylic emulsion is in the range of 16 °C to 17 °C.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one binder is added in the resultant slurry followed by mixing under constant stirring for a time period of 20 minutes to obtain emulsified slurry.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm. In an exemplary embodiment of the present disclosure the stirring speed is 1200 rpm.
In a final step, a predetermined amount of at least one second thickener is added in the emulsified slurry followed by mixing under constant stirring for a time period in the range of 20 minutes to 50 minutes to obtain the coating composition.
In an embodiment of the present disclosure, the second thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers. In an exemplary embodiment of the present disclosure, the second thickener is cellulosic thickener (in fluidized suspension form).
In an embodiment of the present disclosure, the cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC). In an exemplary embodiment of the present disclosure, the cellulosic thickener is 2-hydroxyethyl cellulose.
In an embodiment of the present disclosure, the predetermined amount of the second thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the second thickener is 0.7 mass% with respect to the total mass of the coating composition.
The cellulosic thickener imparts consistency to the coating composition.
In an embodiment of the present disclosure the stirring speed is in the range of 900 rpm to 1400 rpm. In an exemplary embodiment of the present disclosure the stirring speed is 1200 rpm.
In an exemplary embodiment of the present disclosure, a predetermined amount of at least one second thickener is added in the emulsified slurry followed by mixing under constant stirring for a time period of 20 minutes to obtain the coating composition.
To get homogeneous, lumps free, smooth, and properly dispersed coating composition, adherence to recommended time is important. If less mixing is given than recommended time, then risk of not getting above properties of the coating composition is very high. If more time is given than recommended time, then the coating composition will lose its whiteness and greyish tone will develop.
The coating composition of the present disclosure has comparable whiteness, hiding power and better spreadability.
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
Example No 1: Process for preparation of the coating composition in accordance with the present disclosure.
22 g of UV treated water was charged in a reactor mixer and 0.05 g of sodium hexametaphosphate (SHMP) (softening agent), 0.4 g of poly(oxy-1,2-ethanediyl) (non-ionic surfactant), 0.3 g of ethanolamine (pH stabilizer), 2 g of sodium salt of a maleic anhydride copolymer (dispersing agent), 0.3 g of modified polysiloxane with hydrophobic particles (defoaming agent), 0.6 g of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate (coalescing agent), and 1.2 g of tri ethylene glycol (humectant) and 7 g of APEO free anionic polymer dispersion of acrylic ester and styrene (grinding resin) were added followed by mixing under stirring at 400 rpm for 7 minutes to obtain a mixture having a pH of 7.5.
0.6 g of methyl benzimidazole-2-ylcarbamate (preservative) was added in the mixture followed by stirring for 5 minutes to obtain a first slurry.
In the so obtained first slurry 4 g of titanium dioxide (pigment) was added followed by mixing under stirring at 1200 rpm for 10 minutes to obtain a second slurry.
16 g of anhydrous aluminum silicate (first filler) was added in the second slurry followed by mixing under stirring at 1200 rpm for 10 minutes to obtain a third slurry.
36 g of calcium carbonate (second filler) was added in the third slurry followed by mixing under stirring at 1200 rpm for 10 minutes to obtain a fourth slurry.
The fourth slurry was dispersed under stirring at 1200 rpm for 55 minutes to obtain a homogenous slurry.
In the homogeneous slurry, 0.4 g of 2-noctyl-4-isothiazolin-3-one and 0.4 g of methyl benzimidazole-2-ylcarbamate (carbendazim and formaldehyde based CIT MIT) (anti-microbial agent) was added followed by mixing under stirring at 1200 rpm for 10 minutes to obtain an intermediate slurry.
0.7 g of polyurethane thickener (first thickener) was added to the intermediate slurry followed by mixing under constant stirring at 1200 rpm for 10 minutes to obtain a resultant slurry.
In the resultant slurry, 7 g of styrene acrylic emulsion (binder) was added followed by mixing under constant stirring for 20 minutes to obtain an emulsified slurry.
0.7 g of 2-hydroxyethyl cellulose (cellulosic thickener) (second thickener) was added in the emulsified slurry followed by mixing under constant stirring for 30 minutes to obtain the coating composition.
Table 1 illustrates the ingredients and the amounts of the coating composition in accordance with the present disclosure and the comparative example. Table 2 illustrates the properties of water used in the coating composition of the present disclosure.
Table1: Coating composition prepared in accordance with the present disclosure and the comparative example.
Sr.No Ingredients Function Example 1
(of the present disclosure)
(g) Comparative
Example 1
(g)
1 Water 22 41.5
2 Sodium hexa-metaphosphate (SHMP) Dispersing agent
0.5 0.07
poly(oxy-1,2-ethanediyl) Surfactant
0.4 0.3
Ethanolamine pH stabilizer 0.3 --
Ammonia pH stabilizer -- 0.45
Sodium salt of a maleic anhydride copolymer Dispersing agent
2 0.7
modified polysiloxane with hydrophobic particles Defoaming agent
0.3 0.16
2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate Coalescing agent
0.6 0.4
Mono Ethylene Glycol Humectant
1.2 0.8
Tri Ethylene Glycol 1.2 --
3 APEO free anionic polymer dispersion of acrylic ester and styrene Grinding resin
6 --
4 Methyl benzimidazole-2-ylcarbamate Preservative
(Dry film fungicide )
0.6 0.15
5 Chlorinated and non-chlorinated isothiazolinones 0.4 0.07
6 TiO2 Pigment Pigment
4 0.5
7 Anhydrous Aluminum Silicate First Filler
16 --
Calcium Carbonate Second Filler
36 9
Calcium magnesium carbonate -- 19
Magnesium Aluminum Silicate -- 0
8 Aluminum Oxide Filler -- 9
Talc -- 8
9 2-n-Octyl-4-isothiazolin-3-one and methyl benzimidazole-2-ylcarbamate Antimicrobial agent
0.8 0.4
10 Polyurethane Thickener First Thickener 0.7 --
11 Styrene Acrylic Emulsion Binder
7 8
12 Cellulosic Thickener Second Thickener
0.6 0.3
Rheology modifier -- 1.2
Total 100 100
Table 2: Characteristics of water used in the coating composition of the present disclosure.
Characteristics of UV treated Water
1 Appearance Clear colorless liquid, free from suspended particles
2 pH 6.5 - 8
3 Colour <= 10.00 APHA
4 SP. Conductivity
(specific conductivity) <= 900.00 ?S/CM
5 Hardness as CaCO3 <= 200.00 PPM
6 Total Dissolved solids <= 550.00 PPM
7 Microbial Load Total Bacterial Count /ml should be < 100
Total Pseudomonas count / ml should be < 100
Characteristics of the coating composition prepared in accordance with the present disclosure.
The coating composition obtained in example 1 of the present disclosure was subjected for evaluation of the properties.
• Physical properties of the coating composition of the present disclosure:
The coating composition obtained in example 1 of the present disclosure was subjected for the evaluation of physical properties.
The viscosity of the coating composition obtained in example 1 of the present disclosure was evaluated by using a Stormer viscometer. The results are summarized in table 3.
Table 3: Table 3 demonstrates the weight/10 liters in kgs, viscosity and solid content of the coating composition prepared in accordance with the present disclosure and the comparative example.
Sr. No Properties Example 1 of the present disclosure Comparative example 1
1 Wt/10 Lit in Kgs 14.2 14.08
2 Viscosity on Stormer Viscometer
(KU) 132 113
3 Solids @150°C for 30 minutes 55.44% 44.63%
From table 3 it was observed that the coating composition prepared in accordance with example 1 of the present disclosure have higher Wt/10 liter (in Kgs), higher viscosity and higher solid (@150°C for 30 minutes) as compared to the comparative example. If wt/liter of the coating composition is not within the specific value, then there can be some error in charging the batch. The wt/liter of the coating composition acts as a check on the solids of coating composition, to fill the final coating composition in container. If viscosity is high, then more water can be added to dilute the coating composition. Solids indicate the weight of solids in the coating composition. Higher solids mean higher coverage.
• Aesthetic properties of the coating composition of the present disclosure:
The coating composition obtained in example 1 of the present disclosure was subjected for the evaluation of color properties.
The coating composition was applied on paper panel at 100 Mic WFT followed by cure for 24 hours and coloristic values were measured on a spectrophotometer.
The Yellowness of the coating composition was measured by ASTM E313.
For measuring the color properties, the coating composition was applied on a glass plate using 4 mill applicator such that the dry film thickness of the coating composition will be close to 50 microns to obtain a film. The film was dried at 27 °C and 60 RH for 1 day to obtain a dried film. The results are summarized in table 4.
Table 4: Color properties of the coating composition.
Sr. No Properties Example 1 of the present disclosure Comparative example 1
1. Opacity Wet-visual R=9 R=7
Dry visual R=9 R=7
2. Contrast ratio 98.4 93.92
3. Tappi Brightness 92.55 87.89
4. Whiteness index 88.69 87.07
5. Yellowness 1.83 1.47
Visual ratings on R1-R10 scale, where 1 is worst and 10 is Best.
From Table 4 it was observed that the opacity of the coating composition prepared in accordance with the example 1of the present disclosure is higher than the opacity of the comparative example.
Further, it was observed that the contrast ratio of the coating composition prepared in accordance with the example 1 of the present disclosure is high as compared to the comparative example which indicated that the film obtained by applying the coating composition of the present disclosure was bright. Furthermore, it was observed that the Tappi Brightness of the coating composition of example 1 prepared in accordance with the present disclosure was higher than the coating composition of the comparative example which indicated that the film obtained by applying the coating composition of the present disclosure was bright compared to the film obtained by applying the comparative coating composition. Even further, the higher whiteness index of the coating composition prepared in accordance with the present disclosure indicated that the film obtained by using the coating composition of the present disclosure was brighter as compared to the coating composition of the comparative example.
• Stability test of the coating composition prepared in accordance with the present disclosure.
To evaluate the stability, the coating composition obtained in example 1 of the present disclosure was placed in an incubator at a temperature of 60 °C for 10 days and assessed for any phase separation or particle formation. Further, to evaluate the settling, water is added to the coating composition obtained in example 1 of the present disclosure as per recommendation (one liter coating composition is diluted by adding 1.25 liter to 1.5 liter water) and kept overnight to check for separation or hard settling. The results are summarized in table 5.
Table 5: Stability properties of coating composition prepared in accordance with the present disclosure.
Sr. No Properties Example 1 of the present disclosure Comparative example 1
1. Dilution viscosity on B4 ford Cup in seconds 20 59
2. Separation No separation after 24 hours No separation after 24 hours
3. Settling (ASTM D869) No
settling after 24 hours No
settling
after 24 hours
From table 5 it was evident that the dilution viscosity of the coating composition prepared in accordance with the present disclosure is 20 seconds which is less than the coating composition of the comparative example. The dilution viscosity affects the application consistency, film thickness, coverage, curing and drying time. The low dilution viscosity indicates that the coating composition of the present disclosure have more coverage capacity as compared to the comparative coating composition.
• Washability resistance:
The coating composition obtained in example 1 of the present disclosure was evaluated for washability resistance by ASTM D3450. The results are summarized in table 6.
Table 6: Washability resistance of the coating composition prepared in accordance with the present disclosure.
Sr. No Properties Example 1 of the present disclosure Comparative example 1
1. Washability resistance after 7 days (ASTM D3450) 380 cycles 10 cycles
From Table 6 it was observed that the coating composition obtained in example 1 of the present disclosure had washability resistance up to 380 cycles which indicated that the coating can withstand 380 cycles when wiped with wet sponge.
• Application on wall
The properties of the coating composition obtained in example 1 of the present disclosure were evaluated for applying on a wall. The results are demonstrated in table 7.
Table 7: Application on wall properties of the coating composition prepared in accordance with the present disclosure.
Sr. No Properties Example 1 of the present disclosure Comparative example 1
1. % Thinning 120 50
2. Brushability Comparable
3. Whiteness index after drying R = 9 R = 8
4. Opacity
(dry visual values) R = 9 R = 8
5. Flow & Leveling Comparable
6. Smoothness Comparable
From Table 7 it was observed that the higher thinning percentage of the coating composition obtained in example 1 of the present disclosure indicated that the coating composition of the present disclosure can be diluted from 100 % to 150%.
• Coverage capacity
The coverage of the coating composition obtained in example 1 of the present disclosure was evaluated by using different application tools. The results are summarized in table 8 and table 9.
Table 8: Coverage of the coating composition prepared in accordance with the present disclosure (by using Felt Roller as application tool).
Sr. No Properties Coating composition of example 1 Comparative example 1
Coverage - Application Tool - Felt Roller
1. Wt/10 Lit in KGS. 14.2 14.08
2. Thinning Ratio of the Paint 120 50
3. Length of Patch Applied in Ft 6 6
4. Breadth of Patch Applied in Ft 2.5 2.5
5. Area Painted in Sq.Ft. is 15 15
6. Quantity of Paint Applied in GMS for 1st coat 99.5 146
7. Quantity of Paint Applied in GMS for 2nd coat 102.8 140.2
8. Coverage of 1st coat 260.68 128.67
9. Coverage 2nd coat 252.32 134.73
10. Coverage in sq.ft/lit/coat 256.5 131.7
11. Coverage in sq.ft/lit/2 coat 128.25 65.85
12. Coverage in sq mt/lit/2 coat 11.91 6.12
From Table 8 it was observed that the coverage capacity of the coating composition obtained in example 1 of the present disclosure by using Felt Roller was higher as compared to the coverage capacity of the coating composition of the comparative example.
Table 9: Coverage of the coating composition prepared in accordance with the present disclosure (by using Brush followed by sponge roller).
Sr. No Properties Coating composition of example 1 Comparative example 1
Coverage - Application Tool - Brush followed by sponge roller
1. Wt/10 Lit in KGS. 14.2 14.08
2. Thinning Ratio of the Paint 120 50
3. Length of Patch Applied in Ft 6 6
4. Breadth of Patch Applied in Ft 2.5 2.5
5. Area Painted in Sq.Ft. is 15 15
6. Quantity of Paint Applied in GMS for 1st coat 53.1 175.5
7. Quantity of Paint Applied in GMS for 2nd coat 52.4 165.4
8. Coverage of 1st coat 488.5 107.63
9. Coverage 2nd coat 495 114.2
10. Coverage in sq.ft/lit/coat 491.75 110.91
11. Coverage in sq.ft/lit/2 coat 245.88 55.46
12. Coverage in sq mt/lit/2 coat 22.84 5.15
From Table 9 it was observed that the coverage capacity of the coating composition obtained in example 1 of the present disclosure by using Brush followed by a sponge roller was higher as compared to the coverage capacity of the coating composition of the comparative example.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of:
? a coating composition that:
• has good spreadability/coverage capacity;
• is highly concentrated, therefore requires less plastic containers for packaging and hence reduces the plastic waste generation;
• is economic; and
• is environment friendly.
and
? a process for the preparation of a coating composition that;
• is simple and economical.
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 invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment 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 coating composition comprising:
• a predetermined amount of at least one binder;
• a predetermined amount of at least one grinding resin;
• a predetermined amount of at least one filler;
• a predetermined amount of at least one thickener;
• a predetermined amount of at least one pigment;
• a predetermined amount of at least one antimicrobial agent;
• a predetermined amount of at least one preservative;
• a predetermined amount of at least one additive; and
• q.s water.
2. The composition as claimed in claim 1, wherein
• said predetermined amount of said binder is in the range of 5 mass% to 10 mass%;
• said predetermined amount of said grinding resin is in the range of 5 mass% to 20 mass%;
• said predetermined amount of said filler is in the range of 50 mass% to 65 mass%;
• said predetermined amount of said thickener is in the range of 1 mass% to 2 mass%;
• said predetermined amount of said pigment is in the range of 3 mass% to 5 mass%;
• said predetermined amount of said antimicrobial agent is in the range of 0.3 mass% to 1.4 mass%;
• said predetermined amount of said preservative is in the range of 0.1 mass% to 1.5 mass%; and
• said predetermined amount of said additive is in the range of 3 mass% to 8.5 mass%;
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.

3. The composition as claimed in claim 1, wherein
• said binder is styrene acrylic emulsion;
• said grinding resin is alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene;
• said filler comprises a first filler and a second filler;
• said thickener comprises a first thickener and a second thickener;
• said pigment is titanium dioxide (TiO2);
• said antimicrobial agent is a dry film fungicide;
• said preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinone and non-chlorinated isothiazolinone; and
• said additive is at least one selected from the group consisting of a dispersing agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a humectant, and a softening agent.
4. The composition as claimed in claim 3, wherein
• said first filler and said second filler are independently selected from the group consisting of anhydrous aluminum silicate, carbonate minerals and calcined clay;
• said first thickener and said second thickener are independently selected from the group consisting of polyurethane thickener, cellulosic thickener (in fluidized suspension form), acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers;
• said dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-n-octyl-4-isothiazolin-3-one; and
• said isothiazolinone is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolineone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT).
5. The composition as claimed in claim 4, wherein
• said carbonate mineral is selected from calcium carbonate (lime stone) and dolomite; and
• said cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC).
6. The composition as claimed in claim 3, wherein
• said dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers;
• said surfactant is a non-ionic surfactant selected from the group consisting of poly(oxy-1,2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy), branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt;
• said pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate;
• said defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil;
• said coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-propanetricarboxylic acid, 2-hydroxy tributyl ester, and 4-tert-butylcatechol (TBC);
• said humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol); and
• said softening agent is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP).
7. The composition as claimed in claim 1, wherein said composition is characterized by a spreadability in the range of 80 % to 85 %.
8. A process for the preparation of a coating composition, said process comprising the following steps:
i) charging a predetermined amount of water in a mixer and adding predetermined amounts of at least one additive and at least one grinding resin followed by mixing under stirring at a speed in the range of 350 rpm to 650 rpm for a time period in the range of 5 minutes to 10 minutes to obtain a mixture having a pH in the range of 7 to 8;
ii) adding a predetermined amount of at least one preservative in said mixture followed by stirring for a time period in the range of 2 minutes to 10 minutes to obtain a first slurry;
iii) adding a predetermined amount of at least one pigment in said first slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a second slurry;
iv) adding a predetermined amount of at least one first filler in said second slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a third slurry;
v) adding a predetermined amount of at least one second filler in said third slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a fourth slurry;
vi) dispersing said fourth slurry under stirring for a time period in the range of 50 minutes to 60 minutes to obtain a homogenous slurry;
vii) adding a predetermined amount of at least one anti-microbial agent in said homogeneous slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain an intermediate slurry;
viii) adding a predetermined amount of at least one first thickener to said intermediate slurry followed by mixing under stirring for a time period in the range of 5 minutes to 15 minutes to obtain a resultant slurry;
ix) adding a predetermined amount of at least one binder in said resultant slurry followed by mixing under stirring for a time period in the range of 10 minutes to 30 minutes to obtain an emulsified slurry; and
x) adding a predetermined amount of at least one second thickener in said emulsified slurry followed by mixing under stirring for a time period in the range of 20 minutes to 50 minutes to obtain said coating composition.
9. The process as claimed in claim 8, wherein
• said additive is at least one selected from the group consisting of a dispersing agent, a surfactant, a pH stabilizer, a defoaming agent, a coalescing agent, a humectant, and a softening agent; and
• said grinding resin is alkylphenol ethoxylates (APEO) free anionic polymer dispersion of acrylic ester and styrene.
10. The process as claimed in claim 8, wherein
• said predetermined amount of water is in the range of 20 mass% to 30 mass%;
• said predetermined amount of said additive is in the range of 3 mass% to 8.5 mass%; and
• said predetermined amount of said grinding resin is in the range of 5 mass% to 20 mass%;
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.
11. The process as claimed in claim 9, wherein
• said dispersing agent is selected from the group consisting of sodium salt of a maleic anhydride copolymer, sodium salts of polyacrylic acid, ammonium salts of polyacrylic acid, styrene-acrylic and vinyl acetate homo and copolymers, modified acrylic, styrene, ethylene, propylene copolymers;
• said surfactant is a non-ionic surfactant selected from the group consisting of poly(oxy-1,2-ethanediyl), alpha-sulfo-omega-(nonylphenoxy), branched, ammonium salt (polyethylene glycol branched nonylphenyl ether sulfate ammonium salt;
• said pH stabilizer is selected from the group consisting of ethanolamine, 2-amino-2-methyl-1-propanol, ammonia, and potassium silicate;
• said defoaming agent is selected from the group consisting of modified polysiloxane with hydrophobic particles, polyether modified polysiloxane, polysiloxanes and hydrophobic solids in polyglycol, dispersions of metallic salt of fatty acid and ultra-fine dispersion of wax in mineral oil;
• said coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentane diol mono-isobutyrate, propylene glycol mono esters of C6/C10-aliphatic acids, propylene glycol butyl ether, dipropylene glycol butyl ether, 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate), 1,2,3-propanetricarboxylic acid, 2-hydroxytributyl ester, and 4-tert-butylcatechol (TBC);
• said humectant is selected from the group consisting of tri ethylene glycol, 2,2,4 trimethyl 1,3 pentanediol monoisobutyrate, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, mono ethylene glycol, propane-1,2-diol, 2,2-oxydiethanol, and diglycol (diethylene glycol); and
• said softening agent is selected from the group consisting of sodium hexametaphosphate (SHMP), ammonia, borax, calcium hydroxide (slaked lime), trisodium phosphate, tetra potassium pyrophosphate (TPPP), and potassium tri poly phosphate (KTPP).

12. The process as claimed in claim 8, wherein said predetermined amount of said preservative is in the range of 0.1 mass% to 1.5 mass% with respect to the total mass of said coating composition.
13. The process as claimed in claim 8, wherein said preservative is at least one preservative selected from methyl benzimidazole-2-ylcarbamate, chlorinated isothiazolinone and non-chlorinated isothiazolinone, wherein said isothiazolinone is selected from the group consisting of 2-noctyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolineone and 2-methyl-4- isothiazlinone (formaldehyde based CIT/MIT).
14. The process as claimed in claim 8, wherein said stirring speed in said steps (ii) to (x) is in the range of 900 rpm to 1400 rpm and said steps (i) to (x) are carried at a temperature in the range of 20 ºC to 40 ºC.
15. The process as claimed in claim 8, wherein said predetermined amount of said pigment is in the range of 3 mass% to 5 mass% with respect to the total mass of said coating composition and wherein said pigment is titanium dioxide (TiO2).
16. The process as claimed in claim 8, wherein said predetermined amount of said first filler is in the range of 15 mass% to 20 mass% with respect to the total mass of the coating composition and wherein said first filler is selected from the group consisting of anhydrous aluminum silicate, carbonate minerals and calcined clay and
17. wherein said predetermined amount of said second filler is in the range of 35 mass% to 45 mass% with respect to the total mass of the coating composition and wherein said second filler is selected from the group consisting of carbonate minerals, anhydrous aluminum silicate and calcined clay.
18. The process as claimed in claims 16 and 17, wherein said carbonate minerals are selected from calcium carbonate (lime stone) and dolomite.
19. The process as claimed in claim 8, wherein said predetermined amount of said antimicrobial agent is in the range of 0.3 mass% to 1.4 mass% with respect to the total mass of said coating composition and wherein said antimicrobial agent is a dry film fungicide.
20. The process as claimed in claim 19, wherein said dry film fungicide is selected from the group consisting of methyl benzimidazole-2-ylcarbamate (carbendazim), chlorothalonil (CTL), iodopropynylbutylcarbamate (IPBC), octylisothiazolinone (OIT), dichlorooctylisothiazolinone (DCOIT), n-butyl-benzisothiazolinone (BBIT), zinc pyrithione (ZnPT), and 2-noctyl-4-isothiazolin-3-one.
21. The process as claimed in claim 8, wherein said predetermined amount of said first thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of said coating composition and wherein said first thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener, acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers.
22. The process as claimed in claim 8, wherein said binder is styrene acrylic emulsion and wherein said predetermined amount of said binder is in the range of 5 mass% to 10 mass% with respect to the total mass of said coating composition.
23. The process as claimed in claim 8, wherein said second thickener is in the range of 0.5 mass% to 1 mass% with respect to the total mass of the coating composition and wherein said second thickener is selected from the group consisting of polyurethane thickener, cellulosic thickener, acrylic acid, methyl ester of acrylic acid, ethyl ester of acrylic acid, polymerized acrylic acid, methyl ester of polymerized acrylic acid, ethyl ester of polymerized acrylic acid, alkali swellable emulsions, hydrophobically modified alkali swellable emulsions, hydrophobically modified ethoxylate urethanes, and clay based rheology modifiers.
24. The process as claimed in claims 21 and 23, wherein said cellulosic thickener is selected from 2-hydroxyethyl cellulose, and hydrophobically modified hydroxyethyl cellulose (HMHEC).
Dated this 03rd 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, MUMBAI