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.
Hydrophobic: The term “Hydrophobic” refers to a property of a compound that repels water.
Damp surface: The term “Damp surface” refers to a surface wherein moisture is permeated into a surface but has not collected to the point that it is visible to the naked eye.
Anti-efflorescence: The term “Anti-efflorescence” refers to a property which avoids the deposit of crusty white mineral salts that appear on a masonry surface/substrate (concrete, render, brick or mortar) that have leached out from within the substrate when moisture migrates through it.
Pigment Volume Concentration (PVC): The term “Pigment volume concentration (PVC)” refers to a percentage volume of pigment in the total volume solids content of the dry paint film.
Glass transition temperature (Tg): The term “Glass transition temperature refers” to a temperature at which resin changes from a rigid glassy material to a soft material.
Negative-side water resistance: Negative-side waterproofing resistance is the resistance of the waterproofing substances to the negative side, or dry side, that is the interior side of building's foundation or wall.
BACKGROUND
The background information hereinbelow relates to the present disclosure but is not necessarily prior art.
Water penetration or seepage into the building or concrete structures (masonry surfaces) is a very common phenomenon. Conventionally, several coatings and polymeric formulations are used to make masonry surfaces impervious to water. However, these coatings and the polymeric formulations are associated with certain drawbacks such as when these coatings or polymeric formulations are applied on the masonry surfaces, they either give temporary protection (waterproofing) or only provide durability and no waterproofing or they require multiple coats.
Conventional primers for interior waterproofing application are commonly based on latex emulsion including butyl acrylate, styrene and acrylonitrile or chlorinated polyolefin emulsion which can be used on all types of concrete and masonry surfaces. They are useful for facilitating bonding of a barrier coating which is applied subsequently. However, they do not work well on damp or moist surfaces where surface moisture is up to 40%.
Therefore, there is felt a need to provide a coating composition that mitigates the drawbacks mentioned hereinabove and provides at least an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide a coating composition.
Yet another object of the present disclosure is to provide a coating composition for water proofing application
Still another object of the present disclosure is to provide a water proof coating primer composition.
Yet another object of the present disclosure is to provide a water proof coating composition for the treatment of damp surfaces.
Still another object of the present disclosure is to provide a water proof coating composition for the treatment of damp surfaces where the surface moisture is upto 40%.
Yet another object of the present disclosure is to provide a simple 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
A coating composition comprises:
i. 25 mass % to 40 mass % of an acrylic emulsion;
ii. 0.5 mass % to 4 mass % of a functional polysiloxane;
iii. 0.5 mass % to 4 mass % of a first additive;
iv. 25 mass % to 40 mass % of at least one second additive; and
v. 25 mass % to 40 mass % of water;
wherein mass% of each ingredient is w.r.t the total mass of the coating composition.
The acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion.
The functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane, amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin.
The first additive is a hydrophobic anti-efflorescence additive selected from the group consisting of zinc stearate, calcium stearate, modified rosin with fatty acid derivative, tall oil fatty acid, stearic acid salt, elotex era and a wax emulsion.
The second additive is at least one selected from the group consisting of biocide, pigment, extender, defoaming agent, thickening agent, wetting agent, dispersing agent, surfactant, coalescing agent and pH regulator.
The biocide is at least one selected from 3-iodo-2-propynyl-butyl carbamate and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one.
The pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate.
The extender is at least one selected from calcium carbonate and marble powder.
The defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent such as carboxylic acid based defoaming agent.
The thickening agent is a cellulosic thickener such as hydroxyethyl cellulose.
The dispersing agent is selected from ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid.
The surfactants are selected from polyoxyethylene C12-C15 alcohol.
The coalescing agent is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate.
The pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol and alkanolamines.
The biocide is present in an amount in the range of 0.1 mass % to 0.6 mass %.
The pigment is present in an amount in the range of 2 mass % to 15 mass %.
The extender is present in an amount in the range of 15 mass % to 25 mass %.
The defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass %.
The thickening agent is present in an amount in the range of 0.1 mass % to 0.8 mass %.
The dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass %.
The surfactant is present in an amount in the range of 0.1 mass % to 1 mass %.
The coalescing agent is present in an amount in the range of 0.1 mass % to 0.8 mass %.
The pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass %,
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
The coating composition is characterized by at least one of the following:
• pigment volume concentration (PVC) in the range of 30 to 38;
• water vapor transmission rate in the range of 0.3 g/m2 /day to 0.5 g/m2 /day; and
• withstands at a negative water pressure in the range of 2 bar to 2.5 bar.
Further, the present disclosure relates to a process for the preparation of a coating composition.
The process comprises the following steps:
i. mixing water, a defoaming agent, a dispersing agent and a biocide at a first predetermined temperature, at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;
ii. adding a thickening agent to the first mixture at the first predetermined stirring speed and maintaining for a second predetermined time period to obtain a second mixture;
iii. adding a pH regulator to the second mixture at the first predetermined temperature at the first predetermined stirring speed for a third predetermined time period followed by maintaining for a fourth predetermined time period to obtain a third mixture having a pH in the range of 9 to 11 to obtain a third mixture;
iv. increasing stirring speed from a first predetermined stirring speed to a second predetermined stirring speed followed by adding at least one surfactant, at least one pigment, at least one extender, water, a coalescing agent and optionally a pH regulator sequentially to the third mixture under stirring at the first predetermined temperature, at said second predetermined stirring speed for a fifth predetermined time period to obtain a fourth mixture by maintaining a second predetermined temperature and a pH in the range of 9 to 10.5;
v. decreasing stirring speed from said second predetermined stirring speed to said first predetermined stirring speed followed by adding an acrylic emulsion and functional polysiloxane to the fourth mixture at the second predetermined temperature to obtain a fifth mixture;
vi. adding an aqueous first additive to the fifth mixture under stirring and continuing stirring at the second predetermined temperature for a sixth predetermined time period at the first predetermined stirring speed to obtain a sixth mixture;
vii. adding water to the sixth mixture under stirring and continuing stirring at the second predetermined temperature for a seventh predetermined time period at the first predetermined stirring speed to obtain the coating composition.
The defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent, carboxylic acid based defoaming agent.
The dispersing agent is selected from the group consisting of ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid.
The biocide is at least one selected from the group consisting of 3-iodo-2-propynyl-butyl carbamate and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one.
The thickening agent is a cellulosic thickener such as hydroxyethyl cellulose.
The pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol and alkanolamines or a combination thereof.
The pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate.
The extender is at least one selected from calcium carbonate and marble powder.
The coalescing agent is 2,2,4-trimethyl-1,3- pentanediol monoisobutyrate.
The acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion.
The functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane, amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin.
The aqueous first additive is a hydrophobic anti-efflorescence additive selected from the group consisting of aqueous zinc stearate, aqueous calcium stearate, aqueous modified rosin with fatty acid derivative, aqueous tall oil fatty acid, aqueous stearic acid salt, aqueous elotex era and an aqueous wax emulsion.
The defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of said coating composition.
The dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass % with respect to the total mass of said coating composition.
The biocide is present in an amount in the range of 0.1 mass % to 0.6 mass % with respect to the total mass of said coating composition.
The thickening agent is present in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of said coating composition.
The pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass % with respect to the total mass of said coating composition.
The pigment is present in an amount in the range of 2 mass % to 15 mass % with respect to the total mass of said coating composition.
The extender is present in an amount in the range of 15 mass % to 25 mass % with respect to the total mass of said coating composition.
The coalescing agent is present in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of said coating composition.
The acrylic emulsion is present in an amount in the range of 20 mass % to 45 mass% with respect to the total mass of said coating composition.
The functional polysiloxane is present in an amount in the range of 0.5 mass % to 4 mass % with respect to the total mass of said coating composition.
The first additive is present in an amount in the range of 0.5 mass % to 4 mass % with respect to the total mass of said coating composition.
The first predetermined temperature is in the range of 25 oC to 40 oC.
The second predetermined temperature is in the range of 45 oC to 55 oC.
The first predetermined stirring speed is in the range of 8 m/s to 14 m/s.
The second predetermined stirring speed is in the range of 18 m/s to 25 m/s.
The first predetermined time period is in the range of 5 minutes to 20 minutes.
The second predetermined time period is in the range of 2 minutes to 15 minutes.
The third predetermined time period is in the range of 5 minutes to 15 minutes.
The fourth predetermined time period is in the range of 5 minutes to 15 minutes.
The fifth predetermined time period is in the range of 20 minutes to 60 minutes.
The sixth predetermined time period is in the range of 25 minutes to 45 minutes.
The seventh predetermined time period is in the range of 10 minutes to 30 minutes.
BRIEF DESCRIPTION OF THE DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates the panels coated with the coating composition in accordance with the present disclosure which are exposed to sponge soaked in tap water;
Figure 2 illustrates the intermittent exposure of panels coated with the coating composition in accordance with the present disclosure to water in the form of mist/shower (rain simulation); and
Figure 3 illustrates i) uncoated wall, ii) a wall coated with primer putty and iii) a wall coated with the coating composition of the present disclosure sprayed with water in the form of mist/shower.
DETAILED DESCRIPTION
The present disclosure relates to a coating composition and a process for its preparation. Particularly the present disclosure relates to water proofing primer composition and a process for its preparation.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
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.
Conventionally, several coatings and polymeric formulations are used to make masonry surfaces impervious to water. However, these coatings and polymeric formulations are associated with certain drawbacks such as when these coatings or polymeric formulations are applied on the masonry surfaces, they either give temporary protection (waterproofing) or only provide durability and no waterproofing, or they require multiple coats.
Conventional primers for interior waterproofing application are commonly based on latex emulsion including butyl acrylate, styrene and acrylonitrile or chlorinated polyolefin emulsion which can be used on all types of concrete and masonry surfaces. They are useful for facilitating bonding of a barrier coating which is applied subsequently. However, they do not work well on damp or moist surfaces where surface moisture is up to 40%.
The present disclosure provides a coating composition and a process of preparation of coating composition.
The coating composition of the present disclosure provides waterproofing property even when applied on surfaces having moisture upto 40%, effective on damp surfaces and is economical.
In an aspect of the present disclosure, there is provided a coating composition.
The coating composition comprises 25 mass % to 40 mass % of an acrylic emulsion, 0.5 mass % to 4 mass % of a functional polysiloxane, 0.5 mass % to 4 mass % of a first additive, 25 mass % to 40 mass % of at least one second additive and 25 mass % to 40 mass % of water wherein mass% of each ingredient is w.r.t the total mass of the coating composition.
In an exemplary embodiment, the coating composition comprises 30 mass % of a styrene acrylic emulsion, 1 mass % of a functional polysiloxane, 1 mass % of a first additive, 32.35 mass % of at least one second additive and 36.65 mass% of water wherein mass% of each ingredient is w.r.t the total mass of the coating composition. In another exemplary embodiment, 30 mass % of a styrene acrylic emulsion, 2 mass % of a functional polysiloxane, 1% of a first additive, 30.7 mass % of at least one second additive and 37.3 mass% of water wherein mass% of each ingredient is w.r.t the total mass of the coating composition. In still another exemplary embodiment, 35 mass % of a styrene acrylic emulsion, 1 mass % of a functional polysiloxane, 2 mass % of a first additive, 30.7 mass % of at least one second additive and 33.3 mass% of water wherein mass% of each ingredient is w.r.t the total mass of the coating composition.
In an embodiment of the present disclosure, the acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion. In an exemplary embodiment, the acrylic emulsion is styrene acrylic emulsion.
In an embodiment of the present disclosure, the glass transition temperature (Tg) of the acrylic emulsion is in the range of 10 °C to 30 °C.
In an embodiment of the present disclosure, the functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane (polydimethylsiloxanes such as Super 9, Silres BS 1052, Silres BS 1042, Silres BS 1346) amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin (Silres BS 1306, Silres BS 1310). In an exemplary embodiment, the functional polysiloxane is polydimethyl siloxane (Super 9).
In an embodiment of the present disclosure, the functional polysiloxane is modified with functional silicone resin.
In an embodiment of the present disclosure, the functional polysiloxane modified with functional silicone resin provides water repellant property to the coating composition.
The functional polysiloxanes in the coating composition of the present disclosure strongly bind to the polymeric backbone of the styrene acrylic emulsion and do not migrate within the primer film, thereby providing enhanced waterproofing properties.
In an embodiment of the present disclosure, the first additive is an aqueous hydrophobic anti-efflorescence additive selected from the group consisting of aqueous zinc stearate, aqueous calcium stearate, aqueous modified rosin with fatty acid derivative, aqueous tall oil fatty acid, aqueous stearic acid salt, aqueous elotex era and an aqueous wax emulsion. In an exemplary embodiment, the first additive is modified rosin with fatty acid derivative (tall oil fatty acid).
In an embodiment of the present disclosure, the second additive is at least one selected from the group consisting of biocide, pigment, extender, defoaming agent, thickening agent, dispersing agent, surfactant, coalescing agent and pH regulator.
In an embodiment of the present disclosure, the biocide is at least one selected from 3-iodo-2-propynyl-butyl carbamate (Troy PI 30) and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150). In an exemplary embodiment, the biocide is a combination of 3-lodo-2-propynyl-butyl carbamate (Troy PI 30) and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150).
In an embodiment of the present disclosure, the pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate. In an exemplary embodiment, the pigment is a mixture of titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate.
In an embodiment of the present disclosure, the extender is at least one selected from calcium carbonate and marble powder. In an exemplary embodiment, the extender is a combination of calcium carbonate and marble powder.
In an embodiment of the present disclosure, the defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent such as carboxylic acid based (AM 1512 A). In an exemplary embodiment, the defoaming agent is carboxylic acid based defoaming agent (AM 1512 A).
In an embodiment of the present disclosure, the thickening agent is a cellulosic thickener which is hydroxyethyl cellulose (Natrosol MHR). In an embodiment of the present disclosure, the dispersing agent is selected from ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid (Indofil 731). In an exemplary embodiment, the dispersing agent is sodium salt of polycarboxylic acid (Indofil 731).
In an embodiment of the present disclosure, the surfactant is polyoxyethylene C12-C15 alcohol.
In an embodiment of the present disclosure, the coalescing agent is 2,2,4 - trimethyl -1,3- pentanediol monoisobutyrate (MONOISOBUTYRATE C12).
In an embodiment of the present disclosure, the pH regulator is an amine based pH regulator is selected from 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines (Loramine 101). In an exemplary embodiment, the pH regulator is a mixture of 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines, (Loramine 101).
In an embodiment of the present disclosure, the biocide is present in an amount in the range of 0.1 mass % to 0.6 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of biocide is 0.5 mass % with respect to the total mass of the coating composition, wherein the amount of 3-lodo-2-propynyl-butyl carbamate (Troy PI 30) is present in an amount of 0.2 mass% and the amount of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) is present in an amount of 0.3 mass%. In another exemplary embodiment, the amount of biocide is 0.35 mass % with respect to the total mass of the coating composition., wherein the amount of 3-lodo-2-propynyl-butyl carbamate (Troy PI 30) is present in an amount of 0.1 mass% and the amount of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) is present in an amount of 0.25 mass%. In yet another exemplary embodiment, the amount of biocide is 0.45 mass % with respect to the total mass of the coating composition., wherein the amount of 3-lodo-2-propynyl-butyl carbamate (Troy PI 30) is present in an amount of 0.15 mass% and the amount of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) is present in an amount of 0.3 mass%.
In an embodiment of the present disclosure, the pigment is present in an amount in the range of 2 mass % to 15 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of pigment is 7 mass% with respect to the total mass of the coating composition, wherein the amount of titanium dioxide is present in an amount of 5 mass% and the amount of precipitated synthetic sodium magnesium aluminosilicate is present in an amount of 2 mass %. In another exemplary embodiment, the amount of pigment is 6% with respect to the total mass of the coating composition wherein the amount of titanium dioxide is present in an amount of 4 mass% and the amount of precipitated synthetic sodium magnesium aluminosilicate is present in an amount of 2 mass %. In still another exemplary embodiment, the pigment is 5 mass % with respect to the total mass of the coating composition wherein the amount of titanium dioxide is present in an amount of 4 mass% and the amount of precipitated synthetic sodium magnesium aluminosilicate is present in an amount of 1 mass %.
In an embodiment of the present disclosure, the extender is present in an amount in the range of 15 mass % to 25 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of the extender is 22% mass % with respect to the total mass of the coating composition. In another exemplary embodiment, the amount of the extender is 21.25% mass % with respect to the total mass of the coating composition. In yet another exemplary embodiment, the amount of the extender is 21 mass % with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the defoaming agent is 0.4 mass % with respect to the total mass of the coating composition
In an embodiment of the present disclosure, the thickening agent is in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of the thickening agent is 0.5 mass % with respect to the total mass of the coating composition. In another exemplary embodiment, the amount of the thickening agent is 0.65 mass % with respect to the total mass of the coating composition
In an embodiment of the present disclosure, the dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of the dispersing agent is 0.5 mass % with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the surfactant is present in an amount in the range of 0.1 mass % to 1 mass %. In an exemplary embodiment, the amount of the surfactant is 0.3 mass%.
In an embodiment of the present disclosure, the coalescing agent is present in an amount in the range of 0.1 mass % to 0.8 mass %. In an exemplary embodiment, the amount of the coalescing agent is 0.3 mass%. In another exemplary embodiment, the amount of the coalescing agent is 0.4 mass%. In still another exemplary embodiment, the amount of the coalescing agent is 0.5 mass%.
In an embodiment of the present disclosure, the pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the amount of the pH regulator is 0.25 mass % with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the coating composition is characterized by at least one of pigment volume concentration (PVC) in the range of 30 to 38, water vapor transmission rate in the range of 0.3 g/m2 /day to 0.5 g/m2 /day, and withstands at a negative water pressure in the range of 2 bar to 2.5 bar. In an exemplary embodiment, the coating composition exhibits pigment volume concentration of 36 to 38, water vapor transmission rate of 0.3 g/m2/day; and withstands a negative water pressure of 2.5 bar. In another exemplary embodiment, the coating composition exhibits pigment volume concentration of 32 to 36, water vapor transmission rate of 0.5 g/m2/day; and withstands a negative water pressure of 2.5 bar.
The water based waterproofing coating composition of the present disclosure provides coatings with excellent anti-efflorescence performance comprising a synergistic effect of blend of highly hydrophobic styrene acrylic emulsion, functional polysiloxane emulsion, first additive and second additives.
The coating composition of the present disclosure is a highly flexible anti-efflorescence waterproofing paint/coating single component, cement free formulation that also possesses crack bridging ability.
In accordance with the present disclosure, the coating composition is applied on smooth cement putty surface aiding in effective absorption of the coating composition than if applied on cement plaster.
In another aspect of the present disclosure, there is provided a process for the preparation of a coating composition.
The process comprises the following steps:
i. mixing water, a defoaming agent, a dispersing agent and a biocide at a first predetermined temperature, at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;
ii. adding a thickening agent to the first mixture at the first predetermined stirring speed and maintaining for a second predetermined time period to obtain a second mixture;
iii. adding a pH regulator to the second mixture at the first predetermined temperature, at the first predetermined stirring speed for a third predetermined time period followed by maintaining for a fourth predetermined time period to obtain a third mixture having a pH in the range of 9 to 11 to obtain a third mixture;
iv. increasing stirring speed from a first predetermined stirring speed to a second predetermined stirring speed followed by adding at least one pigment, at least one extender, water, a coalescing agent and optionally a pH regulator sequentially to the third mixture under stirring at the first predetermined temperature, at said second predetermined stirring speed for a fifth predetermined time period to obtain a fourth mixture by maintaining second predetermined temperature and a pH in the range of 9 to 10.5;
v. decreasing stirring speed from the second predetermined stirring speed to the first predetermined stirring speed followed by adding acrylic emulsion and functional polysiloxane to the fourth mixture at the second predetermined temperature at the first predetermined stirring speed to obtain a fifth mixture;
vi. adding an aqueous first additive to the fifth mixture under stirring and continuing stirring at the second predetermined temperature for a sixth predetermined time period at the first predetermined stirring speed to obtain a sixth mixture;
vii. adding a fluid medium to the sixth mixture under stirring and continuing stirring at the second predetermined temperature for a seventh predetermined time period at the first predetermined stirring speed to obtain the coating composition.
The process is described in detail below.
In first step, water, a defoaming agent, a dispersing agent and a biocide are mixed at a first predetermined temperature at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture.
In an embodiment of the present disclosure, the defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent such as carboxylic acid based defoaming agent (AM 1512 A). In an exemplary embodiment, the defoaming agent is carboxylic acid based defoaming agent (AM 1512 A).
In an embodiment of the present disclosure, the defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass % of the total mass of the coating composition. In an exemplary embodiment, the amount of the defoaming agent is 0.4 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 ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid (Indofil 731). In an exemplary embodiment, the dispersing agent is sodium salt of polycarboxylic acid (Indofil 731).
In an embodiment of the present disclosure, the dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass % of the total mass of the coating composition. In an exemplary embodiment, the dispersing agent is 0.5 mass % of the total mass of the coating composition.
In an embodiment of the present disclosure, the biocide is selected from the group consisting of 3-iodo-2-propynyl-butyl carbamate (Troy PI 30) and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150). In an exemplary embodiment, the biocide is a combination of 3-iodo-2-propynyl-butyl carbamate (Troy PI 30) and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150).
In an embodiment of the present disclosure, the biocide is in an amount in the range of 0.1 mass % to 0.6 mass % of the total mass of the coating composition. In an exemplary embodiment, the biocide is 0.1 mass % of the total mass of the coating composition.
In an embodiment of the present disclosure, the first predetermined temperature is in the range of 25 oC to 40 oC. In an exemplary embodiment, the first predetermined temperature is 30 oC.
In an embodiment of the present disclosure, the first predetermined stirring speed is in the range of 8 m/s to 14 m/s. In an exemplary embodiment, the first predetermined stirring speed is 10 m/s.
In an embodiment of the present disclosure, the first predetermined time period is in the range of in the range of 5 minutes to 20 minutes. In an exemplary embodiment, the first predetermined time period is 10 minutes.
In a second step, a thickening agent is added to the first mixture at the first predetermined stirring speed and maintained for a second predetermined time period to obtain a second mixture.
In an embodiment of the present disclosure, the thickening agent is a cellulosic thickener which is hydroxyethyl cellulose (Natrosol MHR).
In an embodiment of the present disclosure, the thickening agent is present in an amount in the range of 0.1 mass % to 0.8 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the thickening agent is 0.5 mass % with respect to the total mass of the coating composition. In another exemplary embodiment, the thickening agent is 0.65 mass % with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 2 minutes to 15 minutes. In an exemplary embodiment, the second predetermined time period is 10 minutes.
In a third step, a pH regulator is added to the second mixture at the first predetermined temperature, at the first predetermined stirring speed for a third predetermined time period followed by maintaining for a fourth predetermined time period to obtain a third mixture having a pH in the range of 9 to 11 to obtain a third mixture.
In an embodiment of the present disclosure, the pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines (Loramine 101) or a combination thereof. In an exemplary embodiment, the pH regulator is a mixture of 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines (Loramine 101).
In an embodiment of the present disclosure, the pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass % with respect to the total mass of the coating composition. In an exemplary embodiment, the pH regulator is present in an amount of 0.25 mass % with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the third predetermined time period is in the range of 5 minutes to 15 minutes. In an exemplary embodiment, the third predetermined time period is 10 minutes.
In an embodiment of the present disclosure, the fourth predetermined time period is in the range of 5 minutes to 15 minutes. In an exemplary embodiment, the fourth predetermined time period is 10 minutes.
In a fourth step, the stirring speed is increased from a first predetermined stirring speed to a second predetermined stirring speed followed by at least one pigment, at least one extender, water, a coalescing agent and optionally a pH regulator are added sequentially to the third mixture under stirring at the first predetermined temperature, at the second predetermined stirring speed for a fifth predetermined time period to obtain a fourth mixture by maintaining second predetermined temperature and a pH in the range of 9 to 10.5.
In an embodiment of the present disclosure, the pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate. In an exemplary embodiment, the pigment is a mixture of titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate.
In an embodiment of the present disclosure, the pigment is in an amount in the range of 2 mass % to 15 mass % with respect to the total amount of the coating composition. In an exemplary embodiment, the pigment is present in an amount of 7% with respect to the total amount of the coating composition. In another exemplary embodiment, the pigment is present in an amount of 6% with respect to the total amount of the coating composition. In yet another exemplary embodiment, the pigment is present in an amount of 5 mass % of the total mass of the coating composition.
In an embodiment of the present disclosure, the extender is at least one selected from calcium carbonate and marble powder. In an exemplary embodiment, the extender is a mixture of calcium carbonate and marble powder.
In an embodiment of the present disclosure, the extender is present in an amount in the range of 15 mass % to 25 mass % with respect to the total amount of the coating composition. In an exemplary embodiment, the extender is present in an amount of 22 mass% with respect to the total amount of the coating composition. In another exemplary embodiment, the extender is present in an amount of 21.25 with respect to the total amount of the coating composition. In yet another exemplary embodiment, the extender is present in an amount of 21 mass % with respect to the total amount of the coating composition.
In an embodiment of the present disclosure, the coalescing agent is 2,2,4- trimethyl-1,3-pentanediol monoisobutyrate (MONOISOBUTYRATE C12).
In an embodiment of the present disclosure, the coalescing agent is present in an amount in the range of 0.1 mass% to 0.8 mass % with respect to the total amount of the coating composition. In an exemplary embodiment, the coalescing agent is present in an amount of 0.3 mass% with respect to the total amount of the coating composition. In another exemplary embodiment, the coalescing agent is present in an amount of 0.4 mass% with respect to the total amount of the coating composition. In an exemplary embodiment, the coalescing agent is present in an amount of 0.5 mass% with respect to the total amount of the coating composition.
In an embodiment of the present disclosure, the pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines (Loramine 101) or a combination thereof. In an exemplary embodiment, the pH regulator is a mixture of 2-amino-2-methyl-1-propanol (AMP 95) and alkanolamines (Loramine 101).
In an embodiment of the present disclosure, the pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass % with respect to the total amount of the coating composition. In an exemplary embodiment, the pH regulator is present in an amount of 0.25 mass % with respect to the total amount of the coating composition of the total mass of the coating composition.
In an embodiment of the present disclosure, the second predetermined stirring speed is in the range of 18 m/s to 25 m/s. In an exemplary embodiment, the second predetermined stirring speed is 20 m/s.
In accordance with the present disclosure, the stirring speed is increased before the addition of pigment, extenders, water and coalescing agent in order to grind the extenders properly as well as to provide proper dispersion of at least one pigment, at least one extender, a coalescing agent and optionally a pH regulator in water.
In an embodiment of the present disclosure, the fifth predetermined time period is in the range of 20 minutes to 60 minutes. In an exemplary embodiment, the fifth predetermined time period is 40 minutes.
In an embodiment of the present disclosure, the second predetermined temperature is 45 oC to 55 oC. In an exemplary embodiment, the second predetermined temperature is 50 oC.
In a fifth step, decreasing the stirring speed from the second predetermined stirring speed to the first predetermined stirring speed followed by the addition of an acrylic emulsion and a functional polysiloxane to the fourth mixture at the second predetermined temperature to obtain a fifth mixture.
In an embodiment of the present disclosure, the acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion. In an exemplary embodiment, the acrylic emulsion is styrene acrylic emulsion.
In an embodiment of the present disclosure, the acrylic emulsion is present in an amount in the range of 20 mass% to 45 mass% with respect to the total amount of the coating composition. In an exemplary embodiment, the acrylic emulsion is 30 mass% with respect to the total amount of the coating composition. In an exemplary embodiment, the acrylic emulsion is 35 mass% with respect to the total amount of the coating composition.
In an embodiment of the present disclosure, the functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane, amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin. In an exemplary embodiment, the functional polysiloxane is polydimethylsiloxane (Super 9).
In a sixth step, an aqueous first additive is added to the fifth mixture under stirring and continuing stirring at the second predetermined temperature for a sixth predetermined time period at the first pre-determined stirring speed to obtain a sixth mixture.
In an embodiment of the present disclosure, the aqueous first additive is a hydrophobic anti-efflorescence additive selected from the group consisting of aqueous zinc stearate, aqueous calcium stearate, aqueous modified rosin with fatty acid derivative, aqueous tall oil fatty acid, aqueous stearic acid salt, aqueous elotex era and an aqueous wax emulsion. In an exemplary embodiment, the first additive is modified rosin with fatty acid derivative (tall oil fatty acid).
In an embodiment of the present disclosure, the first additive is in an amount in the range of 0.5 mass % to 4 mass% with respect to the total amount of the coating composition. In an exemplary embodiment, the first additive is 1 mass% with respect to the total amount of the coating composition. In another exemplary embodiment, the first additive is 2 mass% with respect to the total amount of the coating composition.
In an embodiment of the present disclosure, the sixth predetermined time period is in the range of 25 minutes to 45 minutes. In an exemplary embodiment, the sixth predetermined time period is 35 minutes.
In final step, water is added to the sixth mixture under stirring and continuing stirring at the second predetermined temperature for a seventh predetermined time period at the first predetermined stirring speed to obtain the coating composition.
In an embodiment of the present disclosure, the seventh predetermined time period is in the range of 10 minutes to 30 minutes. In an exemplary embodiment, the seventh predetermined time period is 20 minutes.
The coating composition of the present disclosure provides a synergistic effect of styrene-acrylic emulsion, functional polysiloxane emulsion, first additive and second additive to get the maximum impact of waterproofing effect even when applied on damp surface having 40 % moisture thereby completely preventing or largely reducing the dampness on the interior surface.
In accordance with the present disclosure, the coating composition of the present disclosure is applied on cement putty, cement mortar, at a surface moisture level of not more than 50% for interior surface of a building.
In accordance with the present disclosure, the coating composition of the present disclosure has water-resistant properties and prevents dampness and efflorescence.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment 1: Process for the preparation of coating composition in accordance with the present disclosure
Example 1
In a twin shaft high speed disperser (TSHSD) 33.35 g of water (fluid medium), 0.4 g of carboxylic acid based defoaming agent (AM 1512 A) (defoaming agent), 0.5 g of sodium salt of polycarboxylic acid (Indofil 731) (dispersing agent) and 0.2 g of (Troy PI 30) and 0.3 g of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) (Biocide) were mixed at 30 ? (room temperature), at a stirring speed of 10 m/s for 10 minutes to obtain a first mixture.
0.5 g of hydroxyethyl cellulose (thickening agent) was added to the first mixture at a stirring speed of 10 m/s and maintaining for 10 minutes to obtain a second mixture.
0.25 g of 2-amino-2-methyl-1-propanol (AMP 95) (pH regulator) was added to second mixture at 30 ?, at the stirring speed of 10 m/s for 10 minutes followed by maintaining for 10 minutes to obtain a third mixture having a pH of 9 to obtain a third mixture.
The stirring speed was increased from 10 m/s to 20 m/s followed by the addition of 0.3 g of polyoxyethylene C12-C15 alcohol (surfactant), 5 g of titanium dioxide (rutile) (pigment), 2 g of precipitated synthetic sodium magnesium aluminosilicate (pigment), 10 g of calcium carbonate (extender), 12 g of marble powder (extender), 2 g of water, 0.3 g of 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate (MONOISOBUTYRATE C12) (coalescing agent) were sequentially added to the third mixture under stirring at 30 ? at the stirring speed 20 m/s for 40 minutes to obtain a fourth mixture by maintaining a temperature of 50 ? and a pH of 10.
Decreasing stirring speed from 20 m/s to 10 m/s followed by addition of 30 g of styrene acrylic emulsion and 1 g of polydimethylsiloxane (functional polysiloxane) to the fourth mixture at 50 ? to obtain a fifth mixture.
1 g of 40 % to 60 % of aqueous modified rosin with fatty acid derivative (aqueous hydrophobic anti-efflorescence additive) was added to the fifth mixture under stirring and continuing stirring at 50 ? for 35 minutes at a stirring speed of 10 m/s to obtain a sixth mixture.
1.3 g of water was added to the sixth mixture under stirring and continuing stirring at 50 ? for 15 minutes at a stirring speed of 10 m/s to obtain the coating composition.
Example 2
In a twin shaft high speed disperser (TSHSD) 18.3 g of water (fluid medium), 0.4 g of carboxylic acid defoaming agent (AM 1512 A) (defoaming agent), 0.5 g of sodium salt of polycarboxylic acid (Indofil 731) (dispersing agent) and 0.1 g of (Troy PI 30) and 0.25 g of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) (Biocide) were mixed at 30 ? (room temperature), at a stirring speed of 10 m/s for 10 minutes to obtain a first mixture.
0.5 g of hydroxyethyl cellulose (thickening agent) was added to the first mixture at a stirring speed of 10 m/s and maintaining for 10 minutes to obtain a second mixture.
0.25 g of 2-amino-2-methyl-1-propanol (AMP 95) (pH regulator) was added to second mixture at 30 ?, at a stirring speed of 10 m/s for 10 minutes followed by maintaining for 10 minutes to obtain a third mixture having a pH of 9 to obtain a third mixture.
The stirring speed was increased to from 10 m/s 20 m/s followed by the addition of 0.3 g of polyoxyethylene C12-C15 alcohol (surfactant), 4 g of titanium dioxide (rutile) (pigment), 2 g of precipitated synthetic sodium magnesium aluminosilicate (pigment), 9.25 g of calcium carbonate (extender), 12 g of marble powder (extender), 2 g of water, 0.4 g of 2,2,4 - trimethyl -1,3 - pentanediol monoisobutyrate (MONOISOBUTYRATE C12) (coalescing agent) were sequentially added to the third mixture under stirring at 30 ? at a stirring speed 10 m/s for 40 minutes to obtain a fourth mixture by maintaining a temperature of 50 ? and a pH of10 .
Decreasing stirring speed from 20 m/s to 10 m/s followed by addition of 30 g of styrene acrylic emulsion and 2 g of polydimethylsiloxane (functional polysiloxane) to the fourth mixture at 50 ? to obtain a fifth mixture.
1 g of 40 to 60 % of aqueous modified rosin with fatty acid derivative (aqueous hydrophobic anti-efflorescence additive) was added to the fifth mixture under stirring and continuing stirring at 50 ? for 35 minutes at a stirring speed of 10 m/s to obtain a sixth mixture.
1.55 g of water was added to the sixth mixture under stirring and continuing stirring at 50 ? for 15 minutes at a stirring speed of 10 m/s to obtain the coating composition.
Example 3
In a twin shaft high speed disperser (TSHSD) 27.7 g of water (fluid medium), 0.4 g of carboxylic acid defoaming agent (AM 1512 A) (defoaming agent), 0.5 g of sodium salt of polycarboxylic acid (Indofil 731) (dispersing agent) and 0.15 g of 3-iodo-2-propynyl-butyl carbamate (Troy PI 30) and 0.3 g of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150) (Biocide) were mixed at 30 ? (room temperature), at a stirring speed of 10 m/s for 10 minutes to obtain a first mixture.
0.65 g of hydroxyethyl cellulose (thickening agent) was added to the first mixture at a stirring speed of 10 m/s and maintaining for 10 minutes to obtain a second mixture.
0.25 g of 2-amino-2-methyl-1-propanol (AMP 95) (pH regulator) was added to second mixture at 30 ?, at a stirring speed of 10 m/s for 10 minutes followed by maintaining for 10 minutes to obtain a third mixture having a pH of 9 to obtain a third mixture.
The stirring speed was increased from 10 m/s to 20 m/s followed by the addition of 4 g of titanium dioxide (rutile) (pigment), 1 g of precipitated synthetic sodium magnesium aluminosilicate (pigment), 9 g of calcium carbonate (extender), 12 g of marble powder (extender), 2 g of water, 0.5 g of 2,2,4 - trimethyl -1,3 - pentanediol monoisobutyrate (MONOISOBUTYRATE C12) (coalescing agent) were sequentially added to the third mixture under stirring at 30 ? at a stirring speed 10 m/s for 40 minutes to obtain a fourth mixture by maintaining a temperature of 50 ? and a pH of 10.
Decreasing stirring speed from 20 m/s to 10 m/s followed by addition of 35 g of styrene acrylic emulsion and 1 g of functional polysiloxane (polydimethylsiloxane) to the fourth mixture at 50 ? to obtain a fifth mixture.
2 g of 40 to 60 % of aqueous modified rosin with fatty acid derivative (aqueous hydrophobic anti-efflorescence additive) was added to the fifth mixture under stirring and continuing stirring at 50 ? for 35 minutes at a stirring speed of 10 m/s to obtain a sixth mixture.
3.6 g of water was added to the sixth mixture under stirring and continuing stirring at 50 ? for 15 minutes at a stirring speed of 10 m/s to obtain the coating composition.
The coating compositions of the comparative examples 1 to 7 (C1 to C7) were prepared by similar procedure as provided in example 1 except the use of first additive.
The coating compositions of comparative examples were prepared without the use of first additives i.e. functional polysiloxane and also varying the amounts of other ingredients.
The ingredients and their amounts in the coating composition for examples 1, 2 and 3 prepared in accordance with the present disclosure and comparative examples 1 to 7 have been summarized in Table 1.
Further, the properties of the coating compositions for examples 1, 2 and 3 prepared in accordance with the present disclosure and comparative examples 1 to 7 have been summarized in Table 2:

Table 1: Ingredients and their amounts in the coating composition for examples 1, 2 and 3 prepared in accordance with the present disclosure and comparative examples 1 to 7
Coating composition prepared in accordance with the present disclosure Comparative examples
Description Example 1 Example 2 Example 3 C1 C2 C3 C4 C5 C6 C7 C8 C9
Water 36.65 37.3 33.3 31.95 24.55 35 27.45 32.8 27.45 26.75 36.65 37.3
Biocide [Troy PI 30] 0.2 0.1 0.15 0.1 0.1 0.1 0.1 0.15 0.1 0.1 0.2 0.1
Kathon LX 150] 0.3 0.25 0.3 0.05 0.05 0.05 0.05 0.15 0.05 0.05 0.3 0.25
HEC thickener [Hydroxyethyl cellulose] 0.5 0.5 0.65 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.5 0.5
Wetting agent/Dispersing additive indofil 731 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
pH stabilizer Loramine 101/AMP 95 0.25 0.25 0.25 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.25 0.25
Defoamer -AM 1512 A 0.4 0.4 0.4 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.4 0.4
TITANIUM DIOXIDE RUTILE 5 4 4 3.5 2.5 3.5 3 3 3 2.7 5 4
Calcium carbonate 10 9.25 9 12 15 15 20 19.5 19.5 20 10 9.25
Marble powder 12 12 12 22 25 17 16 12 11 15 12 12
Precipitated synthetic sodium magnesium aluminosilicate 2 2 1 1 2 3 2 3 8 2 2 2
modified rosin with fatty acid derivative (tall oil fatty acid) hydrophobic anti-efflorescence additive 1 1 2 0.5 0.5 0.85 0.5 0.5 1 0.5 1 1
Styrene acrylic emulsion 30 30 35 28 29.4 24.6 30 28 29 32 30 30
Polydimethylsiloxane (Functional polysiloxane) 1 2 1 0
0
0
0
0
0
0 1 2
2,2,4 - trimethyl -1,3 - pentanediol monoisobutyrate (Monoisobutyrate C12) 0.3 0.4 0.5 0.3 0.3

0.4

0.4
0.5 0.5 0.5 0.3 0.4
Polyoxyethylene C12-C15 alcohol (Surfactant)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
100 100 100 100 100 100 100 100 100 100 100 100
Waterproofing properties Passes Passes Passes Fails Fails Fails Fails Fails Fails Fails Passes Passes

Table 2 below discloses the properties of the coating composition in examples 1, 2 and 3 prepared in accordance with the present disclosure and the properties of comparative examples 1 to 7 (C1 to C7)
Coating compositions in accordance with present disclosure
(Thickness of 30 microns to 60 microns applied on cement putty)
Comparative examples
(Thickness of 300 microns to 500 microns applied on cement plaster )
Sr. No. Test parameter Example 1 Example 2 Example 3 C1 C2 C3 C4 C5 C6 C7
1 Weight per litre (WPL), Kg/ Lit 1.19 1.24 1.27 1.2 1.24 1.20 1.18 1.17 1.23 1.18
2 Stormer viscosity, KU 80 95 115 101 112 99 101 98 117 105
3 % Non volatile matter (NVM) 43 45 49 52.5 59.2 50.8 56 51.5 56 55.7
4 Volume solids, % 28 30 35 34.2 39.5 36.3 36.5 34.3 40.0 36.3
5 Coverage, Sqft/ Lit (vertical surface) 100 100 100 100 100 100 100 100 100 100
6 Negative side Water resistance (ASTM D 7088), Bar 2.5 2.5 2.5 2 2 2 2 2 2 2
7 Water Absorption by Rilem tube (72 HRS) @ 100 sqft/Ltr 0.3 ml 0.3 ml 0.4 ml 0.4 ml 0.35 ml 0.4 ml 0.42 ml 0.35 ml 0.4 ml 0.45 ml
8 Water resistance on glass plate @150 micron Passes 1 month Passes 1 month Passes 1 month Passes 1 month Passes 15 days Passes 1 month Passes 15 days Passes 1 month Passes 15 days Passes 15 days
9 Alkali Resistance on glass plate@150 micron 2.5 hours 2.5 hours 2.5 hours 2 hours 3 hours 4 hours 5 hours 6 hours 7 hours 8 hours
10 Ease of application by brush/ Roller Good Good Good Good Good Good Good Good Good Good
11 Dampness after application of primer /waterproofing properties Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
12 water vapor transmission rate in the range 0.4 g/m2/day. 0.5 g/m2/day 0.4 g/m2/day. 0.3 g/m2/day 0.42 g/m2/day 0.4 g/m2/day 0.35 g/m2/day 0.35 g/m2/day 0.40 g/m2/day 0.45 g/m2/day
13 PVC
36 to 38

32 to 36
36 to 38
42 to 46 42 to 46 40 to 45 42 to 46 42 to 46 42 to 46 42 to 46

The coating compositions prepared in accordance with the present disclosure were applied on cement putty with a thickness in the range of 30 microns to 60 microns. Though the cement putty has high water absorption property as compared to cement plaster, even the lower thickness of the coating composition of the present disclosure gives desired results such as less amount of generation of non-volatile matter, less percentage of volume solids % along with desired water resistance property.
On the contrary, the coating compositions of comparative examples C1 to C7 were required to be applied with a thickness in the range of 300 microns to 500 microns on cement plaster, which is comparatively thicker than the thickness of the coating composition of the present disclosure. From Table 2, it is seen that, even though the thickness of the coating composition of comparative examples is too high, the percentage of non-volatile matter is high and hence not environment friendly and hazardous.
It is observed that the coating compositions of the present disclosure provide the desired properties even at lower thickness (30 microns to 60 microns) on highly water absorptive substrates such as cement putty as compared to the coating compositions of comparative examples that are applied at higher thickness (300 microns to 500 microns) on less water absorptive surfaces such as cement plaster.
Experiment 3:Comparative study
A comparative study of the properties of the conventional coating composition comprising silane-siloxane functionalized emulsion and the coating composition comprising functional polysiloxane in accordance with the present disclosure was carried out. The results have been tabulated in Table 3 below:
Table 3: Comparison of properties of conventional coating compositions and the coating compositions prepared in accordance with the present disclosure
Property Conventional coating compositions having silane-siloxane functionalised emulsion Coating compositions prepared in accordance with the present disclosure Remark
Tg Based on styrene-acrylicor acrylic or silane modified styrene-acrylic synthetic resin emulsion having glass transition temperature (Tg) levels in the range of -5 °C to 10 °C Based on the acrylic emulsion having glass transition temperature (Tg) levels in the range of 10 °C to 30 °C Higher Tg leads to fast drying
Water absorption, Rileum tube No absorption at higher thickness in the range of 300 microns to 500 microns No absorption at thickness in the range of 30 microns to 60 microns No water absorption even at lower thickness
Negative water pressure Passes 5 bar at higher thickness in the range of 300 microns to 500 microns Passes 2.5 bar at thickness in the range of 30 microns to 60 microns Passes for higher negative water pressure even at lower thickness
Application on moisture content Application more than 50 % on cement plaster- Applied on less water absorptive cement plaster with a thickness of 300 microns to 500 microns Application upto 40 % on cement putty- Applied on highly water absorptive cement putty with a thickness of 30 microns to 60 microns Coating composition in accordance with the present disclosure passes upto 40 % moisture at lower thickness
Paint topcoat application

Not recommended for direct paint topcoat application Direct paint topcoat application Conventional coating compositions not recommended for direct paint topcoat application

From Table 3, it is seen that the coating compositions comprising functional polysiloxane prepared in accordance with the present disclosure have desired water resistance properties even when applied on highly water absorptive surfaces such as cement putty with a lower thickness in the range of 30 microns to 60 microns as compared the conventional coating compositions which are applied on lower water absorptive surfaces such as cement plaster with a thickness in the range of 300 mcrons to 500 microns.
The functional polysiloxanes in the coating composition of the present disclosure strongly bind to the polymeric backbone of the styrene acrylic emulsion and do not migrate within the primer film, thereby providing enhanced waterproofing properties. Whereas the conventional coating compositions comprising silane-siloxane functionalised emulsion easily migrate within the coating film and thereby do not provide the desired waterproofing properties.
Experiment 3: Test Method - Waterproofing Performance
Example 1: Continuous panel exposure in Tap Water
The coating composition of Example 1 prepared in accordance with the present disclosure was applied on panel 1 of dimensions 6 inches’ width x 6 inches’ length x 1-inch thickness having an optimized substrate porosity of 1:4 cement: sand ratio and panel 2 of dimensions 6 inches’ width x 6 inches’ length x 1-inch thickness having an optimized substrate porosity of 1:5 cement: sand ratio. Then these panel 1 and panel 2 were exposed to tap water for 3 months such that the back panel moisture level is controlled around 40 % to 50 % by using sponge. The panels 1 and 2 exposed to sponge soaked in tap water are illustrated in Figure 1.
From Figure 1 it is seen that no moisture was observed on the surface of panels 1 and 2 coated with the coating composition in accordance with the present disclosure.
Example 2: Intermittent exposure with water mist (Rain simulation).
The coating composition of Example 1 prepared in accordance with the present disclosure was applied on panel 1 of size 12 inches’ width x 12 inches’ length x 1-inch thickness, panel 2 of size 12 inches’ width x 12 inches’ length x 1-inch thickness and panel 3 of 12 inches’ width x 12 inches’ length x 1 inch.
Water was sprayed at a specified interval on the back side of the coated panels 1, 2 and 3 in the form of mist/shower such that the moisture was maintained at 40% as illustrated in Figure 2.
From Figure 2 it is seen that no moisture was observed on the coated panels 1, 2 and 3 prepared in accordance with the present disclosure on intermittent exposure to water mist.
Example 3: Portable Wall-Intermittent exposure with water
Water was sprayed at a specified interval on the back side of i) uncoated wall having a thickness of 0.5 feet, ii) a wall coated with primer putty and iii) a wall coated with the coating composition of Example 1 prepared in accordance with the present disclosure such that the moisture was maintained at 40% as shown in Figures 3 (a), 3 (b), 3 (c).
From Figures 3(a), 3(b) and 3(c) it is seen that moisture is seen on uncoated wall and wall coated with primer putty. Whereas moisture was not observed on wall coated with the coating composition of Example 1 prepared in accordance with the present disclosure.
TECHNICAL ADVANCES AND ECONOMIC SIGNIFICANCE
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of
? a coating composition that:
• provides water proofing property even when applied on surfaces having moisture upto 40%;
• is effective on damp surfaces;
• is user friendly; and
• is economical; and
? a process for the preparation of a coating composition that:
• simple, economical, environment friendly; and
• commercially scalable.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A coating composition comprising:
i. 25 mass % to 40 mass % of an acrylic emulsion;
ii. 0.5 mass % to 4 mass % of a functional polysiloxane;
iii. 0.5 mass % to 4 mass % of a first additive;
iv. 25 mass % to 40 mass % of at least one second additive; and
v. 25 mass % to 40 mass % of water;
wherein mass% of each ingredient is w.r.t the total mass of said coating composition.
2. The coating composition as claimed in claim 1, wherein said acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion.
3. The coating composition as claimed in claim 1, wherein said functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane, amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin.
4. The coating composition as claimed in claim 1, wherein said first additive is a hydrophobic anti-efflorescence additive selected from the group consisting of zinc stearate, calcium stearate, modified rosin with fatty acid derivative, tall oil fatty acid, stearic acid salt, elotex era and a wax emulsion.
5. The coating composition as claimed in claim 1, wherein said second additive is at least one selected from the group consisting of biocide, pigment, extender, defoaming agent, thickening agent, wetting agent, dispersing agent, surfactant, coalescing agent and pH regulator.
6. The coating composition as claimed in claim 5, wherein
• said biocide is at least one selected from 3-iodo-2-propynyl-butyl carbamate and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one;
• said pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate;
• said extender is at least one selected from calcium carbonate and marble powder;
• said defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent such as carboxylic acid based defoaming agent;
• said thickening agent is a cellulosic thickener such as hydroxyethyl cellulose;
• said dispersing agent is selected from ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid;
• said surfactant is polyoxyethylene C12-C15 alcohol;
• said coalescing agent is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate; and
• said pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol and alkanolamines.
7. The coating composition as claimed in claims 5 and 6, wherein
• said biocide is present in an amount in the range of 0.1 mass % to 0.6 mass %;
• said pigment is present in an amount in the range of 2 mass % to 15 mass %;
• said extender is present in an amount in the range of 15 mass % to 25 mass %;
• said defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass %;
• said thickening agent is present in an amount in the range of 0.1 mass % to 0.8 mass %;
• said dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass %;
• said surfactant is present in an amount in the range of 0.1 mass % to 1 mass %; and
• said coalescing agent is present in an amount in the range of 0.1 mass % to 0.8 mass %; and
• said pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass %;
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.
8. The coating composition as claimed in claim 1 is characterized by at least one of the following:
• pigment volume concentration (PVC) in the range of 30 to 38;
• water vapor transmission rate in the range of 0.3 g/m2 /day to 0.5 g/m2 /day; and
• withstands at a negative water pressure in the range of 2 bar to 2.5 bar.

9. A process for the preparation of a coating composition, said process comprising the following steps:
i. mixing water, a defoaming agent, a dispersing agent and a biocide at a first predetermined temperature at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;
ii. adding a thickening agent to said first mixture at said first predetermined stirring speed and maintaining for a second predetermined time period to obtain a second mixture;
iii. adding a pH regulator to said second mixture at said first predetermined temperature, at said first predetermined stirring speed for a third predetermined time period followed by maintaining for a fourth predetermined time period to obtain a third mixture having a pH in the range of 9 to 11 to obtain a third mixture;
iv. increasing stirring speed from a first predetermined stirring speed to a second predetermined stirring speed followed by adding at least one surfactant, at least one pigment, at least one extender, water, a coalescing agent and optionally a pH regulator sequentially to said third mixture under stirring at said first predetermined temperature, at said second predetermined stirring speed for a fifth predetermined time period to obtain a fourth mixture by maintaining a second predetermined temperature and a pH in the range of 9 to 10.5;
v. decreasing stirring speed from said second predetermined stirring speed to said first predetermined stirring speed followed by adding an acrylic emulsion and a functional polysiloxane to said fourth mixture at said second predetermined temperature to obtain a fifth mixture;
vi. adding an aqueous first additive to said fifth mixture under stirring and continuing stirring at said second predetermined temperature for a sixth predetermined time period at said first predetermined stirring speed to obtain a sixth mixture;
vii. adding water to said sixth mixture under stirring and continuing stirring at said second predetermined temperature for a seventh predetermined time period at said first predetermined stirring speed to obtain said coating composition.

10. The process as claimed in claim 9, wherein
• said defoaming agent is selected from silicone based defoaming agent and mineral oil based defoaming agent such as carboxylic acid based defoaming agent;
• said dispersing agent is selected from the group consisting of ethoxylated non-ionic branched alcohol and sodium salt of polycarboxylic acid;
• said biocide is at least one selected from 3-iodo-2-propynyl-butyl carbamate and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one;
• said thickening agent is a cellulosic thickener such as hydroxyethyl cellulose;
• said pH regulator is an amine based pH regulator selected from 2-amino-2-methyl-1-propanol and alkanolamines or a combination thereof.;
• said pigment is at least one selected from titanium dioxide (rutile) and precipitated synthetic sodium magnesium aluminosilicate;
• said extender is at least one selected from calcium carbonate and marble powder;
• said coalescing agent is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate;
• said acrylic emulsion is selected from the group consisting of styrene acrylic emulsion, acrylic emulsion and silane functionalized styrene acrylic emulsion;
• said functional polysiloxane is selected from the group consisting of amino functional polysiloxane, epoxy functional polysiloxane, polyether functional polysiloxane, alkyl functional polysiloxane, amino silicone emulsion, phenyl functional polysiloxane and functional polysiloxane modified with functional silicone resin.
• aqueous first additive is a hydrophobic anti-efflorescence additive selected from the group consisting of aqueous zinc stearate, aqueous calcium stearate, aqueous modified rosin with fatty acid derivative, aqueous tall oil fatty acid, aqueous stearic acid salt, aqueous elotex era and an aqueous wax emulsion.
11. The process as claimed in claim 9, wherein
• said defoaming agent is present in an amount in the range of 0.1 mass % to 0.8 mass %;
• said dispersing agent is present in an amount in the range of 0.2 mass % to 1.2 mass %;
• said biocide is present in an amount in the range of 0.1 mass % to 0.6 mass %;
• said thickening agent is present in an amount in the range of 0.1 mass % to 0.8 mass %;
• said pH regulator is present in an amount in the range of 0.1 mass % to 0.5 mass %;
• said pigment is present in an amount in the range of 2 mass % to 15 mass %;
• said extender is present in an amount in the range of 15 mass % to 25 mass %;
• said coalescing agent is present in an amount in the range of 0.1 mass % to 0.8 mass %;
• said acrylic emulsion is present in an amount in the range of 20 mass % to 45 mass %;
• said functional polysiloxane is present in an amount in the range of 0.5 mass % to 4 mass %; and
• said first additive is present in an amount in the range of 0.5 mass % to 4 mass %;
wherein mass % of each ingredient is with respect to the total mass of said coating composition.
12. The process as claimed in claim 9, wherein
• said first predetermined temperature is in the range of 25 oC to 40 oC; and
• said second predetermined temperature is in the range of 45 oC to 55oC.

13. The process as claimed in claim 9, wherein
• said first predetermined stirring speed is in the range of 8 m/s to 14 m/s; and
• said second predetermined stirring speed is in the range of 18 m/s to 25 m/s.
14. The process as claimed in claim 9, wherein
• said first predetermined time period is in the range of 5 minutes to 20 minutes;
• said second predetermined time period is in the range of 2 minutes to 15 minutes;
• said third predetermined time period is in the range of 5 minutes to 15 minutes;
• said fourth predetermined time period is in the range of 5 minutes to 15 minutes;
• said fifth predetermined time period is in the range of 20 minutes to 60 minutes;
• said sixth predetermined time period is in the range of 25 minutes to 45 minutes; and
• said seventh predetermined time period is in the range of 10 minutes to 30 minutes.

Dated this 30th day of November, 2024

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

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, MUMBAI