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.
Chalking: The term “chalking” refers to the formation of a powdery residue on the surface of the coating over time.
Hiding Power: The term “hiding power” refers to the ability of a coating composition to hide the surface on which the coating was applied.
Scrub resistance: The term “scrub resistance” refers to the ability of a dried paint or coating film to resist wear or degradation, despite exposure to chemicals or abrasive materials such as brushes.
Dirt pickup resistance (DPUR): The term “dirt pickup resistance (DPUR)” refers to an ability of coating (e.g., paint) to resist dirt when exposure to natural environments.
Weather resistance: The term “weather resistance” is the ability of a material to prevent corrosion, loss of material or any sort of deterioration due to prolonged exposure to harsh environmental and weather conditions.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Coating compositions, such as paints, varnishes, and lacquers are characterized by their physical nature or by the produced effects which includes emulsion paints, powdery paints, thixotropic paints, antifouling paints, underwater paints, luminous paints, and the like. Coating compositions are widely used in automotive, construction, architecture, wood industries, and the like for decorative and aesthetic purposes.
Sulfur oxides (SOx) and nitrogen oxides (NOx) are pollutants that have significant effect on the environment such as acid rain formation, reduced air quality, eutrophication, global warming, damage to vegetation and the like. SOx and NOx can also adversely affect the coating compositions. These adverse effects include corrosion of the metal surface, chalking, color fading, and deterioration of the binder in the coating composition. Generally, chalking is also observed on coating surfaces due to weathering, UV exposure, and other environmental factors.
Conventional pollutant neutralizer coating compositions use silicone-based binder. The silicone-based binders may have challenges in adhering to certain substrates. In addition, silicone-based coatings tend to have a low surface tension, which can lead to difficulties in wetting out and spreading evenly on certain surfaces. The silicone-based coatings are also not economically feasible solution.
Therefore, there is felt a need to provide a coating composition that obviates the drawbacks mentioned hereinabove or at least provide an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is 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 coating composition for exterior architectural coatings.
Yet another object of the present disclosure is to provide a coating composition for exterior architectural coating with nitrogen oxide (NOx) and sulfur oxide (SOx) neutralization capabilities.
Still another object of the present disclosure is to provide a coating composition that has excellent anti-chalking performance.
Yet another object of the present disclosure is to provide a coating composition that can provide excellent adhesion on cementitious substrates.
Still another object of the present disclosure is to provide a coating composition that has better storage stability.
Yet another object of the present disclosure is to provide a coating composition having a viscosity that does not change over a long period of time.
Still another object of the present disclosure is to provide simple and economical 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.
A coating composition comprises:
• an organic-inorganic hybrid binder system in an amount in the range of 10 mass% to 65 mass%
• at least one metal oxide in an amount in the range of 0.05 mass% to 10 mass%; and
• an additive in an amount in the range of 35 mass% to 85 mass%,
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
The additive is selected from the group consisting of an anti-foaming agent, a dispersing agent, a biocide, a surfactant, a pigment, a filler, at least one algaecide, at least one fungicide, at least one rheology modifier, a humectant, at least one hydrophobic additive, a coalescing agent, a first neutralizer, colloidal silica and water.
The coating composition comprises:
a) the anti-foaming agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
b) the dispersing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
c) the biocide is present in an amount in the range of 0.05 mass% to 2.5 mass%;
d) the surfactant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
e) the pigment is present in an amount in the range of 10 mass% to 30 mass%;
f) the filler is present in an amount in the range of 1 mass% to 5 mass%;
g) the algaecide is present in an amount in the range of 0.5 mass% to 6 mass%;
h) the fungicide is present in an amount in the range of 0.05 mass% to 5 mass%;
i) the rheology modifier is present in an amount in the range of 0.02 mass% to 2.5 mass%;
j) the humectant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
k) the hydrophobic additive is present in an amount in the range of 0.01 mass% to 2.5 mass%;
l) the coalescing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
m) the first neutralizer is present in an amount in the range of 0.05 mass% to 5 mass%;
n) the colloidal silica is present in an amount in the range of 1 mass% to 5 mass%; and
o) water is present in an amount in the range of 1 mass% to 35 mass%,
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
The organic-inorganic hybrid binder system comprises
• an organic binder in an amount in the range of 10 mass% to 40 mass%;
• an inorganic binder in an amount in the range of 50 mass% to 85 mass%;
• a second neutralizer in an amount in the range of 0.1 mass% to 5 mass%; and
• water in an amount in the range of 1 mass% to 10 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the organic-inorganic hybrid binder system.
The metal oxide is titanium oxide (TiO2), wherein the metal oxide has a particle size in the range of 5 nm to 2000 nm.
The anti-foaming agent is hydrocarbon oil based antifoaming agent.
The dispersing agent is polycarboxylic acid dispersant.
The biocide is selected from the group consisting of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, a mixture of chloromethyl-methylisothiazolinone and formaldehyde, a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, and a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT).
The surfactant is polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether and ethoxylated fatty alcohol.
The pigment is rutile titanium dioxide (TiO2).
The filler is silica powder 500 mesh.
The algaecide is selected from N'-(3,4-Dichlorophenyl)-N,N-dimethylurea, and encapsulated N'-(3,4-Dichlorophenyl)-N,N-dimethylurea.
The fungicide is selected from the group consisting Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione.
The rheology modifier is selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethyl cellulose surface-treated with glyoxal.
The humectant is a glycol selected from the group consisting of propylene glycol, propylene glycol momomethyl ether, hexylene glycol, butylene glycol, and glyceryl triacetate.
The hydrophobic additive is selected from hydrophobic acrylate dispersion, amine functional silane and epoxy functional silane oligomer.
The coalescing agent is an organic solvent selected from trimethyl pentanediol monoisobutyrate, butyl cellosolve, ethyl cellosolve and 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate).
The first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The organic binder is selected from the group consisting of an acrylic emulsion, a styrene-acrylic emulsion, a vinyl acetate emulsion, a vinyl acetate-ethylene copolymer emulsion (VAE emulsion), a styrene-butadiene rubber emulsion (SBR emulsion) and a vinyl acetate monomer (VAM-Acrylic).
The inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate, lithium silicate and aluminium silicate.
The second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is in the range of 1:1 to 1:5.
A process for the preparation of a coating composition, the process comprising the following steps:
i. sequentially mixing predetermined amounts of a first portion of water, a first portion of an anti-foaming agent, a dispersing agent, a first portion of a biocide and a surfactant under stirring at a first predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a first mixture;
ii. mixing predetermined amounts of a pigment, a filler, a metal oxide, a first algaecide and a first rheology modifier in the first mixture under stirring at a second predetermined speed at a time interval in the range of 5 minutes to 10 minutes to obtain a second mixture;
iii. adding a second rheology modifier and a second portion of water in the second mixture under stirring at a third predetermined speed followed by maintaining the third predetermined speed for a time period in the range of 30 minutes to 60 minutes to obtain a third mixture;
iv. sequentially adding predetermined amounts of a second portion of the anti-foaming agent, a humectant, a second portion of the biocide, a third portion of the anti-foaming agent, a first hydrophobic additive, a coalescing agent, and a first neutralizer in the third mixture under stirring at a fourth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a fourth mixture;
v. adding a predetermined amount of an organic-inorganic hybrid binder system in the fourth mixture for a time period in the range of 1 hour to 5 hours under stirring at a fourth predetermined stirring speed to obtain a fifth mixture;
vi. sequentially adding predetermined amounts of a first fungicide, colloidal silica, a second hydrophobic additive, a second fungicide, a third portion of water, a second algaecide and a fourth portion of water in the fifth mixture under stirring at a fifth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain the coating composition.
The organic-inorganic hybrid binder system is prepared by following sub-steps,
a. sequentially mixing predetermined amounts of an organic binder, a first predetermined amount of water and a second neutralizer under stirring at a speed in the range of 100 rpm to 300 rpm for a time interval in the range of 2 minutes to 15 minutes to obtain a homogeneous mixture; and
b. adding a predetermined amount of an inorganic binder in the homogeneous mixture under stirring for a time period in the range of 30 minutes to 120 minutes followed by adding a second predetermined amount of water under stirring for a time period in the range of 5 minutes to 15 minutes, followed by filtering to obtain the organic-inorganic hybrid binder system.
The metal oxide is titanium oxide (TiO2), wherein the metal oxide has a particle size in the range of 5 nm to 2000 nm.
The anti-foaming agent is hydrocarbon oil based antifoaming agent.
The dispersing agent is polycarboxylic acid dispersant.
The biocide is selected from the group consisting of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, a mixture of chloromethyl-methylisothiazolinone and formaldehyde, a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, and a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT).
The surfactant is selected from the group consisting of polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether and ethoxylated fatty alcohol.
The pigment is rutile titanium dioxide (TiO2).
The filler is silica powder 500 mesh.
The first algaecide and said second algaecide are independently selected from N'-(3,4-dichlorophenyl)-N,N-dimethylurea, and encapsulated N'-(3,4-Dichlorophenyl)-N,N-dimethylurea.
The first fungicide, and said second fungicide are independently selected from Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione.
The first rheology modifier and said second rheology modifier are independently selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethyl cellulose surface-treated with glyoxal.
The humectant is glycol selected from the group consisting of propylene glycol, propylene glycol monomethyl ether, hexylene glycol, butylene glycol, and glyceryl triacetate.
The first hydrophobic additive and second hydrophobic additive are independently selected from hydrophobic acrylate dispersion, amine functional silane, and epoxy functional silane oligomer.
The coalescing agent is an organic solvent selected trimethyl pentanediol monoisobutyrate, butyl cellosolve, ethyl cellosolve and 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate.
The first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The amount of the components used for the preparation of the coating composition is provided below:
a) the organic-inorganic hybrid binder system is present in an amount in the range of 10 mass% to 65 mass%; b) the metal oxide is present in an amount in the range of 0.05 mass% to 10 mass%; c) the anti-foaming agent is present in an amount in the range of 0.05 mass% to 2.5 mass%; d) the dispersing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%; e) the biocide is present in an amount in the range of 0.05 mass% to 2.5 mass%; f) the surfactant is present in an amount in the range of 0.05 mass% to 2.5 mass%; g) the pigment is present in an amount in the range of 10 mass% to 30 mass%; h) the filler is present in an amount in the range of 1 mass% to 5 mass%; i) the first algaecide, and the second algaecide are independently present in an amount in the range of 0.5 mass% to 6 mass%; j) the first fungicide, and the second fungicide are independently present in an amount in the range of 0.05 mass% to 5 mass%; k) the first rheology modifier and the second rheology modifier are independently present in an amount in the range of 0.02 mass% to 2.5 mass%; l) the humectant is present in an amount in the range of 0.05 mass% to 2.5 mass%; m) the first hydrophobic additive, and the second hydrophobic additive are independently present in an amount in the range of 0.01 mass% to 2.5 mass%; n) the coalescing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%; o) the first neutralizer is present in an amount in the range of 0.05 mass% to 5 mass%; p) the colloidal silica is present in an amount in the range of 1 mass% to 5 mass%; and q) water is present in an amount in the range of 1 mass% to 35 mass%, wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
The first portion of the anti-foaming agent is present in an amount in the range of 20 mass% to 50 mass%; the second portion of anti-foaming agent is present in an amount in the range of 15 mass% to 25 mass%; and the third portion of anti-foaming agent is present in an amount in the range of 25 mass% to 40 mass%, wherein the mass% of each portion of the anti-foaming agent is with respect to the total mass of the anti-foaming agent.
The first portion of the biocide is present in an amount in the range of 30 mass% to 40 mass%; and the second portion of biocide is present in an amount in the range of 60 mass% to 70 mass%, wherein the mass% of each portion of the biocide is with respect to the total mass of the biocide.
The first hydrophobic additive is present in an amount in the range of 10 mass% to 30 mass%; and the second hydrophobic additive is present in an amount in the range of 70 mass% to 90 mass%, wherein the mass% of each of the hydrophobic additive is with respect to the total mass of the hydrophobic additive.
The first portion of water is present in an amount in the range of 60 mass% to 75 mass%; the second portion of water is present in an amount in the range of 5 mass% to 15 mass%; the third portion of water is present in an amount in the range of 1 mass% to 10 mass%; and the fourth portion of water is present in an amount in the range of 6 mass% to 25 mass%, wherein the mass% of each portion of water is with respect to the total mass of water.
The first predetermined stirring speed is in the range of 200 rpm to 400 rpm.
The second predetermined stirring speed is in the range of 800 rpm to 1200 rpm.
The third predetermined stirring speed is in the range of 1800 rpm to 2200 rpm.
The fourth predetermined stirring speed is in the range of 400 rpm to 600 rpm.
The fifth predetermined stirring speed is in the range of 400 rpm to 600 rpm.
The organic binder is selected from the group consisting of an acrylic emulsion, a styrene-acrylic emulsion, a vinyl acetate emulsion, a vinyl acetate-ethylene copolymer emulsion (VAE emulsion), a styrene-butadiene rubber emulsion (SBR emulsion) and a vinyl acetate monomer (VAM-Acrylic).
The inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate, lithium silicate and aluminium silicate.
The second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The organic-inorganic hybrid binder system comprising
• an organic binder is in an amount in the range of 10 mass% to 40 mass%;
• an inorganic binder is in an amount in the range of 50 mass% to 85 mass%;
• a second neutralizer is in an amount in the range of 0.1 mass% to 5 mass%; and
• water in an amount in the range of 1 mass% to 10 mass%,
wherein the mass% of each ingredient is with respect to the total mass of the organic-inorganic hybrid binder system.
The mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is in the range of 1:1 to 1: 5.
The first predetermined amount of water is in the range of 40 mass% to 75 mass%; and the second predetermined amount of water is in the range of 25 mass% to 60 mass%, wherein the mass% of each amount of water is with respect to the total mass of water.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 (A) illustrates air monitoring device from (Advance Techno systems); (B) illustrates experimental set up for the ambient air monitoring test in accordance with the present disclosure;
Figure 2 illustrates the applied wall patch and an instrument setups from Themo Environmental instruments;
Figure 3 (A) illustrates a graphical representation for the demonstration of NO2 reduction of control compared with the coating composition E1 (for 3 cycles) as prepared in accordance with the present disclosure; (B) illustrates graphical representation for the demonstration of SO2 reduction of control compared with the coating composition E1 (for 3 cycles) as prepared in accordance with the present disclosure;
Figure 4 (A) illustrates a graphical representation for the demonstration of Ambient NO2 concentration levels before painting (Control) and after the E1 is applied (post painting) as prepared in accordance with the present disclosure; (B) illustrates a graphical representation for the demonstration of the SO2 concentration levels before the painting (Control) and after the E1 is applied (post painting) as prepared in accordance with the present disclosure;
Figure 5 (A) illustrates images of demonstration of self-cleanability of designs (commercially available paint) and coating compositions (E1 and E2) prepared in accordance with the present disclosure,; (B) illustrates image of demonstration of DPUR resistance of the coatings control and E1 prepared in accordance with the present disclosure at Dirt prone areas of Northern India; and
Figure 6 (A) illustrates the chalking on commercially exposed panels C1 after 1500 hours in QUVA (Accelerated Weathering Tester, Ultraviolet range of 315-400nm); (B) illustrates the chalking on exposed panels for 1500 hours in QUVA for E1 as prepared in accordance with the present disclosure; (C) illustrates the chalking on exposed panels after 1500 hours for E2 as prepared in accordance with the present disclosure; (D) illustrates the chalking Applicator with black muslin cloth.
DETAILED DESCRIPTION
The present disclosure relates to a coating 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.
Conventional pollutant neutralizer coating compositions use silicone-based binder. The silicone-based binders have challenges in adhering to certain substrates. In addition, silicone-based coatings tend to have a low surface tension, which can lead to difficulties in wetting out and spreading evenly on certain surfaces. The silicone-based coatings are also not economically feasible solution.
The present disclosure provides a coating composition and a process for its preparation.
In a first aspect, the present disclosure provides a coating composition.
The coating composition comprises
• an organic-inorganic hybrid binder system in an amount in the range of 10 mass% to 65 mass%;
• at least one metal oxide in an amount in the range of 0.05 mass% to 10 mass%; and
• an additive in an amount in the range of 35 mass% to 85 mass%,
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
The additive is selected from the group consisting of an anti-foaming agent, a dispersing agent, a biocide, a surfactant, a pigment, a filler, at least one algaecide, at least one fungicide, at least one rheology modifier, a humectant, at least one hydrophobic additive, a coalescing agent, a first neutralizer, colloidal silica and water.
The coating composition comprises
a) the anti-foaming agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
b) the dispersing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
c) the biocide is present in an amount in the range of 0.05 mass% to 2.5 mass%;
d) the surfactant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
e) the pigment is present in an amount in the range of 10 mass% to 30 mass%;
f) the filler is present in an amount in the range of 1 mass% to 5 mass%;
g) the algaecide is present in an amount in the range of 0.5 mass% to 6 mass%;
h) the fungicide is present in an amount in the range of 0.05 mass% to 5 mass%;
i) the rheology modifier in an amount in the range of 0.02 mass% to 2.5 mass%;
j) a humectant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
k) the hydrophobic additive is present in an amount in the range of 0.01 mass% to 2.5 mass%;
l) the coalescing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
m) the first neutralizer is present in an amount in the range of 0.05 mass% to 5 mass%;
n) colloidal silica is present in an amount in the range of 1 mass% to 5 mass%; and
o) water is present in an amount in the range of 1 mass% to 35 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
In accordance with the present disclosure, the organic-inorganic hybrid binder system comprises
• an organic binder in an amount in the range of 10 mass% to 40 mass%;
• an inorganic binder in an amount in the range of 50 mass% to 85 mass%;
• a second neutralizer in an amount in the range of 0.1 mass% to 5 mass%; and
• water in an amount in the range of 1 mass% to 10 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the organic-inorganic hybrid binder system.
In accordance with the present disclosure, the organic binder is selected from the group consisting of acrylic emulsion, styrene-acrylic emulsion, vinyl acetate emulsion, vinyl acetate-ethylene copolymer emulsion (VAE emulsion),styrene-butadiene rubber emulsion (SBR emulsion), vinyl acetate monomer (VAM-Acrylic).
In accordance with the present disclosure, the inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate and aluminium silicate.
In accordance with the present disclosure, a mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is in the range of 1:1 to 1:5. In an exemplary embodiment of the present disclosure, the mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is 1:4. In another exemplary embodiment of the present disclosure, the mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is 1:2.4.
In accordance with the present disclosure, the second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The second neutralizer is used to bring the pH of the millbase to the binder adduct.
In a first exemplary embodiment of the present disclosure, the organic-inorganic hybrid binder system comprises:
• styrene acrylate emulsion (organic binder) of 18.87 mass%;
• liquid potassium silicate (inorganic binder) of 75 mass%;
• 50 % KOH solution (second neutralizer) of 0.21 mass%; and
• water of 5.92 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the organic-inorganic hybrid binder system.
In a second exemplary embodiment of the present disclosure, the organic-inorganic hybrid binder system comprises:
• styrene acrylate emulsion (organic binder) of 27.98 mass%;
• liquid potassium silicate (inorganic binder) of 67.37 mass%;
• 50 % KOH solution (second neutralizer) of 0.3 mass%; and
• water of 4.35 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the organic-inorganic hybrid binder system.
In accordance with the present disclosure, the metal oxide is titanium oxide (TiO2).
In accordance with the present disclosure, the titanium oxide (TiO2) is photocatalytic TiO2 or anatase TiO2.
The photocatalytic or anatase TiO2 act as a efficient catalyst for reducing the air pollutants namely NOx and SOx. It is used for air purification such as purification of nitrogen oxides, sulphoxides, chlorinated hydrocarbons, and the like for the outdoor application. Further, as it is regenerative type of anatase TiO2, therefore it will performs continuously without degradation.
In accordance with the present disclosure, the metal oxide has a particle size in the range of 5 nm to 2000 nm.
In accordance with the present disclosure, the anti-foaming agent is a hydrocarbon oil based antifoaming agent (TEGO® Foamex K3).
The anti-foaming agent is used to reduce the foam during the preparation of a coating composition.
In accordance with the present disclosure, the dispersing agent is polycarboxylic acid dispersant (poly(acrylic acid-co-methacrylic acid),).
Dispersing agent is used to form a uniform dispersion of pigment and extenders in the coating composition.
In accordance with the present disclosure, the biocide is selected from the group consisting of mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150), a mixture of chloromethyl-methylisothiazolinone and formaldehyde (Rocima 623), a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT) and ProtecZen BMD.
The biocide is used as preservative in the coating composition.
In accordance with the present disclosure, the surfactant is polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether and ethoxylated fatty alcohol (ATPOL 5731).
The surfactant is used to reduce the surface tension and to provide steric stabilization for pigments and extenders in the coating composition. It also improves the shelf life /stability of the coating composition.
In accordance with the present disclosure, the pigment is rutile titanium dioxide (TiO2). Rutile titanium dioxide is an inorganic pigment.
Pigment is used to improve whiteness and hiding of a surface.
In accordance with the present disclosure, the filler is silica powder 500 mesh.
Fillers or extenders are used in coating composition to optimise the cost of the paint. Silica powder 500 mesh improves the dry hiding of the surface. It is also used as a critical extender since it does not get gelled with the inorganic binder system. Further, Fillers/extenders help to improve the application properties of the coating composition.
In accordance with the present disclosure, the algaecide is selected from N'-(3,4-Dichlorophenyl)-N,N-dimethylurea (Diuron Technical), and encapsulated N'-(3,4-Dichlorophenyl)-N,N-dimethylurea (encapsulated diuron).
Algaecide, particularly Diuron Technical provides anti-algal properties to the dry film of coatings. Further, it leaches out to the surface when there is algal attack on the surface of the coatings and stops the photosynthesis for the algal growth. Algaecide also governs the performance of coating in exterior weather conditions. Thor ADA 20 is encapsulated diuron and provides high antialgal efficacy.
In accordance with the present disclosure, the fungicide is selected from the group consisting Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione.
In accordance with the present disclosure, the rheology modifier is selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethylcellulose surface-treated with glyoxal (Natrosol 250 HHBR 5070).
Rheology modifier is used to optimise the viscosity to the coating composition. Further, it also helps in stability of the coating system for longer period thereby improving the shelf life of the coating composition.
Xanthan gum is a polysaccharide produced by the fermentation of carbohydrates and hydroxyethyl cellulose (HEC) is chemically modifying cellulose through the addition of hydroxyethyl groups.
In accordance with the present disclosure, the humectant is a glycol selected from the group consisting of propylene glycol, propylene glycol monomethyl ether, xylene glycol, butylene glycol, and glyceryl triacetate.
The humectant is used to increase open time of coating composition. Open time refers to the period during which the coating composition remains wet or workable, allowing the painter to adjust, blend, or smooth the surface before it starts to dry or set. Humectants help to increase this time by slowing down the evaporation of water or solvents in the coating composition.
In accordance with the present disclosure, the hydrophobic additive is selected from the group consisting of hydrophobic acrylate dispersion, amine functional silane, and epoxy functional silane oligomer.
The hydrophobic additive is used in the coating compositions to enhance the water resistance capacity of the coating composition.
In accordance with the present disclosure, the coalescing agent is an organic solvent selected from trimethyl pentanediol monoisobutyrate (TMPD-monoisobutyrate C12), butyl cellosolve (2-butoxyethanol), ethyl cellosolve (2-ethoxyethanol) and 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate (Optifilm OE300).
The coalescing agent is helps to form a film of high glass transition temperature (Tg) organic binder in coating composition.
In accordance with the present disclosure, the first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
The first neutralizer is used to bring the pH of the millbase to the binder adduct. Millbase is the initial mixture of pigments, solvents, and dispersing agents that is ground together in a mill to break down the pigment particles into a fine dispersion. The millbase is an intermediate product in the production of paints or coatings.
In accordance with the present disclosure, the colloidal silica is neutral aqueous dispersion of colloidal silica solution. The colloidal silica is used as co-crosslinker which helps to improve dirt pick up resistance (DPUR) by network formation, surface energy modification and enhancing the durability of the coating layer.
In a first exemplary embodiment of the present disclosure, the coating composition comprises:
a) the organic-inorganic hybrid binder system of 42 mass%;
b) photocatalytic titanium dioxide (TiO2) of 1.25 mass%;
c) TEGO® Foamex K3 (anti-foaming agent) of 0.47 mass%;
d) poly(acrylic acid-co-methacrylic acid (dispersing agent) of 0.62 mass%;
e) Rocima 623 (biocide) of 0.3 mass%;
f) ATPOL 5731 (surfactant) of 0.62 mass%;
g) Rutile titanium dioxide (TiO2) of 21.5 mass%;
h) silica powder 500 mesh (filler) of 2 mass%;
i) Diuron technical(algaecide) of 1 mass%, and Thor ADA 20 (algaecide) of 1 mass%;
j) Zinc pyrithione (fungicide) of 0.1 mass% and Iodopropynyl butyl carbamate (IPBC) (fungicide) of 0.3 mass%;
k) Xanthum gum powder (rheology modifier) of 0.04 mass% and Natrosol 250 HHBR 5070 (rheology modifier) of 0.4 mass%;
l) Propylene glycol monomethyl ether (humectant) of 0.5 mass%;
m) Coatosil MP 200 (hydrophobic additive) of 0.05 mass% and ADD AC 3001(hydrophobic additive) 0.2 mass%;
n) TMPD-monoisobutyrate C12 (coalescing agent) of 0.4 mass%;
o) 50 % KOH solution (first neutralizer) in an amount in the range of 0.26 mass%;
p) colloidal silica 2 mass%; and
q) water of 24.97 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
In a second exemplary embodiment of the present disclosure, the coating composition comprises:
a) the organic-inorganic hybrid binder system of 46.75 mass%;
b) photocatalytic titanium dioxide (TiO2) of 1.25 mass%;
c) TEGO® Foamex K3 (anti-foaming agent) of 0.47 mass%;
d) poly(acrylic acid-co-methacrylic acid (dispersing agent) of 0.62 mass%;
e) Rocima 623 (biocide) of 0.3 mass%;
f) ATPOL 5731 (surfactant)of 0.62 mass%;
g) Rutile titanium dioxide (TiO2) of 21.5 mass%;
h) silica powder 500 mesh (filler) of 2 mass%;
i) Diuron technical (algaecide) of 1.5 mass%, and Thor ADA 20 (algaecide) of 1.5 mass%;
j) Zinc pyrithione (fungicide) of 0.1 mass% and Iodopropynyl butyl carbamate (IPBC) (fungicide ) of 0.3 mass%;
k) xanthum gum powder (rheology modifier) of 0.04 mass% and Natrosol 250 HHBR 5070 (rheology modifier) of 0.4 mass%;
l) propylene glycol monomethyl ether (humectant) of 0.52 mass%;
m) Coatosil MP 200 (hydrophobic additive) of 0.05 mass % and ADD SC 3001 (hydrophobic additive) 0.2 mass%;
n) TMPD-monoisobutyrate C12 (coalescing agent) of 0.4 mass%;
o) 50% KOH solution (first neutralizer) of 0.26 mass%;
p) colloidal silica 2 mass%; and
q) water of 22.77 mass%;
wherein the mass% of each ingredient is with respect to the total mass of the coating composition.
In accordance with the present disclosure, the coating composition is characterized by having improved NOx/ SOx reduction, improved chalking resistance, air quality improvement and improved dirt pick up resistance.
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 the coating composition comprises the following steps:
i. sequentially mixing predetermined amounts of a first portion of water, a first portion of an anti-foaming agent, a dispersing agent, a first portion of a biocide and a surfactant under stirring at a first predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a first mixture;
ii. mixing predetermined amounts of a pigment, a filler, a metal oxide, a first algaecide and a first rheology modifier in the first mixture under stirring at a second predetermined speed at a time interval in the range of 5 minutes to 10 minutes to obtain a second mixture;
iii. adding a second rheology modifier and a second portion of water in the second mixture under stirring at a third predetermined speed followed by maintaining the third predetermined speed for a time period in the range of 30 minutes to 60 minutes to obtain a third mixture;
iv. sequentially adding predetermined amounts of a second portion of the anti-foaming agent, a humectant, a second portion of the biocide, a third portion of the anti-foaming agent, a first hydrophobic additive, a coalescing agent, and a first neutralizer in the third mixture under stirring at a fourth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a fourth mixture;
v. adding a predetermined amount of an organic-inorganic hybrid binder system in the fourth mixture for a time period in the range of 1 hour to 5 hours under stirring at a fourth predetermined stirring speed to obtain a fifth mixture;
vi. sequentially adding predetermined amounts of a first fungicide, colloidal silica, a second hydrophobic additive, a second fungicide, a third portion of water, a second algaecide and a fourth portion of water in the fifth mixture under stirring at a fifth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain the coating composition.
The process is described in detail.
In a first step, predetermined amounts of a first portion of water, a first portion of an anti-foaming agent, a dispersing agent, a first portion of a biocide and a surfactant are sequentially mixed under stirring at a first predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a first mixture.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 1 mass% to 35 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the predetermined amount of water is 24.97 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first portion of water is in the range of 60 mass% to 75 mass% with respect to the total mass of water. In an exemplary embodiment of the present disclosure, the first portion of water is 70.52 mass% with respect to the total mass of water.
In an embodiment of the present disclosure, the anti-foaming agent is hydrocarbon oil based antifoaming agent (TEGO® Foamex K3).
In an embodiment of the present disclosure, the anti-foaming agent in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, an anti-foaming agent is 0.47 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first portion of the anti-foaming agent is in the range of 20 mass% to 50 mass% with respect to the total mass of the anti-foaming agent. In an exemplary embodiment of the present disclosure, the first portion of the anti-foaming agent is 44.68 mass% with respect to the total mass of the anti-foaming agent.
In an embodiment of the present disclosure, the dispersing agent is polycarboxylic acid dispersant (poly(acrylic acid-co-methacrylic acid)).
In an embodiment of the present disclosure, the dispersing agent in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the dispersing agent is 0.62 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the biocide is selected from the group consisting of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Kathon LX 150), a mixture of chloromethyl-methylisothiazolinone and formaldehyde (Rocima 623), a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT) and ProtecZen BMD.
In an embodiment of the present disclosure, the biocide in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the biocide is 0.3 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first portion of the biocide is in the range of 30 mass% to 40 mass% with respect to the total mass of the biocide. In an exemplary embodiment of the present disclosure, the first portion of the biocide is 33.33 mass% with respect to the total mass of the biocide.
In an embodiment of the present disclosure, the surfactant is polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether) and ethoxylated fatty alcohol.
In an embodiment of the present disclosure, the surfactant in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the surfactant is 0.62 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first predetermined stirring speed is in the range of 200 rpm to 400 rpm. In an exemplary embodiment of the present disclosure, the first predetermined stirring speed is 300 rpm.
In an embodiment of the present disclosure, the time interval is the time period of stirring after the addition of each ingredient.
In an exemplary embodiment of the present disclosure, the time interval for first step is 5 minutes.
In a second step, predetermined amounts of a pigment, a filler, a metal oxide, a first algaecide and a first rheology modifier are mixed in the first mixture under stirring at a second predetermined speed at a time interval in the range of 5 minutes to 10 minutes to obtain a second mixture.
In an embodiment of the present disclosure, the pigment is an inorganic pigment rutile titanium dioxide.
Pigment of the present disclosure is used to improve whiteness and hiding of a coating composition.
In an embodiment of the present disclosure, the pigment in an amount in the range of 10 mass% to 30 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the pigment is 21.5 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the filler is silica powder 500 mesh.
In an embodiment of the present disclosure, the filler in an amount in the range of 1 mass% to 5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the filler is 2 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the metal oxide is titanium oxide (TiO2).
In accordance with the present disclosure, the metal oxide has a particle size in the range of 5 nm to 2000 nm.
In an embodiment of the present disclosure, the metal oxide in an amount in the range of 0.05 mass% to 10 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the metal oxide is 1.25 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first algaecide is N'-(3,4-dichlorophenyl)-N,N-dimethylurea (Diuron).
In an embodiment of the present disclosure, the first algaecide is in an amount in the range of 0.5 mass% to 3 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the first algaecide is 1 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first rheology modifier is selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethylcellulose surface-treated with glyoxal (Natrosol 250 HHBR 5070). In an exemplary embodiment of the present disclosure, the first rheology modifier is xanthum gum.
In accordance with the present disclosure, xanthum gum is a polysaccharide produced by the fermentation of carbohydrates.
In an embodiment of the present disclosure, the first rheology modifier in an amount in the range of 0.02 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the first rheology modifier is 0.04 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second predetermined stirring speed is in the range of 800 rpm to 1200 rpm. In an exemplary embodiment of the present disclosure, the second predetermined stirring speed is 1000 rpm.
In an exemplary embodiment of the present disclosure, the time interval for second step is 8 minutes.
In a third step, predetermined amounts of a second rheology modifier and a second portion of water are added in the second mixture under stirring at a third predetermined speed followed by maintaining the third predetermined speed for a time period in the range of 30 minutes to 60 minutes to obtain a third mixture;
In an embodiment of the present disclosure, the second rheology modifier is selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethyl cellulose surface-treated with glyoxal (Natrosol 250 HHBR 5070). In an exemplary embodiment of the present disclosure, the second rheology modifier is hydroxyethyl cellulose surface-treated with glyoxal (Natrosol 250 HHBR 5070).
In accordance with the present disclosure, hydroxyethyl cellulose (HEC) is a chemically modified cellulose obtained through the addition of hydroxyethyl groups.
In an embodiment of the present disclosure, the second rheology modifier in an amount in the range of 0.02 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the second rheology modifier is 0.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second portion of water is in the range of 5 mass% to 15 mass% with respect to the total mass of water. In an exemplary embodiment of the present disclosure, the second portion of water is 12.01 mass% with respect to the total mass of water.
In an embodiment of the present disclosure, the third predetermined stirring speed is in the range of 1800 rpm to 2200 rpm. In an exemplary embodiment of the present disclosure, the third predetermined stirring speed is 2000 rpm.
In an exemplary embodiment of the present disclosure, the predetermined time period for third step is 45 minutes.
In a fourth step, predetermined amounts of a second portion of the anti-foaming agent, a humectant, a second portion of the biocide, a third portion of the anti-foaming agent, a first hydrophobic additive, a coalescing agent, and a first neutralizer are sequentially added in the third mixture under stirring at a fourth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a fourth mixture.
In an embodiment of the present disclosure, the second portion of anti-foaming agent is in the range of 15 mass% to 25 mass% with respect to the total mass of the anti-foaming agent. In an exemplary embodiment of the present disclosure, the second portion of anti-foaming agent is 21.27 mass% with respect to the total mass of the anti-foaming agent.
In an embodiment of the present disclosure, the humectant is glycol selected from the group consisting of propylene glycol, propylene glycol monomethyl ether, hexylene glycol, butylene glycol, and glyceryl triacetate. In an exemplary embodiment of the present disclosure, the humectant is propylene glycol monomethyl ether.
In an embodiment of the present disclosure, the humectant in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the humectant is 0.52 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second portion of biocide is in the range of 60 mass% to 70 mass% with respect to the total mass of the biocide. In an exemplary embodiment of the present disclosure, the second portion of biocide is 66.66 mass% with respect to the total mass of the biocide.
In an embodiment of the present disclosure, the third portion of anti-foaming agent is in the range of 25 mass% to 40 mass% with respect to the total mass of the anti-foaming agent. In an exemplary embodiment of the present disclosure, the third portion of anti-foaming agent is 34.04 mass% with respect to the total mass of the anti-foaming agent.
In an embodiment of the present disclosure, the first hydrophobic additive is selected from hydrophobic acrylate dispersion (ADD SC 3001), amine functional silane, and epoxy functional silane oligomer (CoatoSil MP 200). In an exemplary embodiment of the present disclosure, the first hydrophobic additive is epoxy functional silane oligomer (CoatoSil MP 200).
In an embodiment of the present disclosure, the first hydrophobic additive in an amount in the range of 0.01 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the first hydrophobic additive is 0.05 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first hydrophobic additive is in the range of 10 mass% to 30 mass% with respect to the total mass of the hydrophobic additive. In an exemplary embodiment of the present disclosure, the first hydrophobic additive is 20 mass% with respect to the total mass of the hydrophobic additive.
In an embodiment of the present disclosure, the coalescing agent is an organic solvent selected from trimethyl pentanediol monoisobutyrate (TMPD-monoisobutyrate C12), butyl cellosolve (2-butoxyethanol), ethyl cellosolve (2-ethoxyethanol) and 2,2-dimethyl-1-(methylethyl)-1,3-propanediyl bis(2-methylpropanoate (Optifilm OE300). In an exemplary embodiment of the present disclosure, the coalescing agent is trimethyl pentanediol monoisobutyrate (TMPD isobutyrate C12).
In an embodiment of the present disclosure, the coalescing agent in an amount in the range of 0.05 mass% to 2.5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the coalescing agent is 0.4 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide. In an exemplary embodiment of the present disclosure, the first neutralizer is aqueous potassium hydroxide (50% KOH).
In an embodiment of the present disclosure, the first neutralizer in an amount in the range of 0.05 mass% to 5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the first neutralizer is 0.26 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the fourth predetermined stirring speed is in the range of 400 rpm to 600 rpm. In an exemplary embodiment of the present disclosure, the fourth predetermined stirring speed is 500 rpm.
In an exemplary embodiment of the present disclosure, the time interval for fourth step is 5 minutes.
In a fifth step, a predetermined amount of an organic-inorganic hybrid binder system is added in the fourth mixture for a time period in the range of 1 hour to 5 hours under stirring at a fourth predetermined stirring speed to obtain a fifth mixture.
In an embodiment of the present disclosure, the organic-inorganic hybrid binder system in an amount in the range of 10 mass% to 65 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the organic-inorganic hybrid binder system is 40.75 mass% with respect to the total mass of the coating composition. In another exemplary embodiment of the present disclosure, the organic-inorganic hybrid binder system is 42.94 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the organic-inorganic hybrid binder system is prepared by following sub-steps,
a. sequentially mixing predetermined amounts of an organic binder, a first predetermined amount of water and a second neutralizer under stirring at a speed is in the range of 100 rpm to 300 rpm for a time interval in the range of 2 minutes to 15 minutes to obtain a homogeneous mixture; and
b. adding a predetermined amount of an inorganic binder in the homogeneous mixture under stirring for a time period in the range of 30 minutes to 120 minutes followed by adding a second predetermined amount of water under stirring for a time period in the range of 5 minutes to 15 minutes, followed by filtering to obtain solids of the organic-inorganic hybrid binder system.

The process of preparation of organic-inorganic hybrid binder system described in detail.
In a sub-step a, predetermined amounts of an organic binder, a first portion water and a second neutralizer are sequentially mixed under stirring at a speed that is in the range of 100 rpm to 300 rpm for a time interval in the range of 2 minutes to 15 minutes to obtain a homogeneous mixture.
In an embodiment of the present disclosure, the organic binder is selected from the group consisting of an acrylic emulsion, a styrene-acrylic emulsion, a vinyl acetate emulsion, a vinyl acetate-ethylene copolymer emulsion (VAE emulsion), a styrene-butadiene rubber emulsion (SBR emulsion) and a vinyl acetate monomer (VAM-Acrylic). In an exemplary embodiment of the present disclosure, the organic binder is styrene-acrylic emulsion.
In an embodiment of the present disclosure, the organic binder in an amount in the range of 10 mass% to 40 mass%. In an exemplary embodiment of the present disclosure, the organic binder is 18.87 mass% with respect to the total mass of the organic-inorganic hybrid binder system.
In an embodiment of the present disclosure, water in an amount in the range of 1 mass% to 10 mass% with respect to the total mass of the organic-inorganic hybrid binder system. In an exemplary embodiment of the present disclosure, water is 5.92 mass% with respect to the total mass of the organic-inorganic hybrid binder system.
In an embodiment of the present disclosure, the first predetermined amount of water is in the range of 40 mass% to 75 mass% with respect to the total mass of water. In an exemplary embodiment of the present disclosure, the first predetermined amount of water is 70.77 mass% with respect to the total mass of water.
In an embodiment of the present disclosure, the second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide. In an exemplary embodiment of the present disclosure, the second neutralizer is aqueous potassium hydroxide (50 % KOH).
In an embodiment of the present disclosure, the second neutralizer in an amount in the range of 0.1 mass% to 5 mass% with respect to the total mass of the organic-inorganic hybrid binder system. In an exemplary embodiment of the present disclosure, the second neutralizer is 0.21 mass% with respect to the total mass of the organic-inorganic hybrid binder system.
In an exemplary embodiment of the present disclosure, the predetermined stirring speed for sub-step a is 200 rpm.
In an exemplary embodiment of the present disclosure, the time interval for sub-step a, is 10 minutes.
In a sub-step b, a predetermined amount of an inorganic binder is added in the homogeneous mixture under stirring for a time period in the range of 30 minutes to 120 minutes followed by adding a second portion of water under stirring for a time period in the range of 5 minutes to 15 minutes, followed by filtering to obtain solids of the organic-inorganic hybrid binder system.
In an embodiment of the present disclosure, the inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate, lithium silicate and aluminium silicate. In an exemplary embodiment of the present disclosure, the inorganic binder is potassium silicate.
In an embodiment of the present disclosure, the inorganic binder is in liquid form.
In an embodiment of the present disclosure, the inorganic binder in an amount in the range of 50 mass% to 85 mass% with respect to the total mass of the organic-inorganic hybrid binder system. In an exemplary embodiment of the present disclosure, the inorganic binder is 75 mass% with respect to the total mass of the organic-inorganic hybrid binder system.
In an embodiment of the present disclosure, the second predetermined amount of water is in the range of 25 mass% to 60 mass% with respect to total amount of water. In an exemplary embodiment of the present disclosure, the second predetermined amount of water is 29.22 mass% with respect to total amount of water.
In an embodiment of the present disclosure, the mass ratio of the organic binder to the inorganic binder in the organic-inorganic hybrid binder system is in the range of 1:1 to 1:5.
In an embodiment of the present disclosure, the fourth predetermined stirring speed is in the range of 400 rpm to 600 rpm. In an exemplary embodiment of the present disclosure, the fourth predetermined stirring speed is 500 rpm.
In an exemplary embodiment of the present disclosure, the time interval for fourth step is 5 minutes.
In a sixth step, predetermined amounts of a first fungicide, colloidal silica, a second hydrophobic additive, a second fungicide, a third portion of water, a second algaecide and a fourth portion of water are sequentially added in the fifth mixture under stirring at a fifth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain the coating composition.
In an embodiment of the present disclosure, the colloidal silica in an amount in the range of 1 mass% to 5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the colloidal silica is 2 mass% with respect to the total mass of the coating composition.
The colloidal silica is used as co-crosslinker which helps to improve dirt pick up resistance (DPUR) by network formation, surface energy modification and enhancing the durability of the coating layer.
In an embodiment of the present disclosure, the first fungicide, and second fungicide is independently selected from Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione.
In an exemplary embodiment of the present disclosure, the first fungicide is Zinc pyrithione. In an exemplary embodiment of the present disclosure, the second fungicide is Iodopropynyl butyl carbamate (IPBC).
In an embodiment of the present disclosure, the first fungicide, and the second fungicide are independently in an amount in the range of 0.05 mass% to 5 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the first fungicide is 0.1 mass% with respect to the total mass of the coating composition. In an exemplary embodiment of the present disclosure, the second fungicide is 0.3 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second algaecide is encapsulated N'-(3,4-dichlorophenyl)-N,N-dimethylurea. In an embodiment of the present disclosure, the second algaecide is 1 mass% with respect to the total mass of the coating composition.
In an embodiment of the present disclosure, the second hydrophobic additive is selected from hydrophobic acrylate dispersion (ADD SC 3001) and epoxy functional silane oligomer (CoatoSil MP 200). In an exemplary embodiment of the present disclosure, the second hydrophobic additive is ADD SC 3001.
In an embodiment of the present disclosure, the second hydrophobic additive is in the range of 70 mass% to 90 mass% with respect to the total mass of the hydrophobic additive. In an exemplary embodiment of the present disclosure, the second hydrophobic additive is 80 mass% with respect to the total mass of the hydrophobic additive.
In an embodiment of the present disclosure, the third portion of water is in the range of 1 mass% to 10 mass% with respect to the total mass of water. In an exemplary embodiment of the present disclosure, the third portion of water is 2 mass% with respect to the total mass of water.
In an embodiment of the present disclosure, the fourth portion of water is in the range of 6 mass% to 25 mass% with respect to the total mass of water. In an exemplary embodiment of the present disclosure, the fourth portion of water is 15.45 mass% with respect to the total mass of water.
In an embodiment of the present disclosure, the fifth predetermined stirring speed is in the range of 400 rpm to 600 rpm. In an exemplary embodiment of the present disclosure, the fifth predetermined stirring speed is 500 rpm.
Still in another aspect of the present disclosure, an active content in the paint composition is solid material (solid content) present in the paint/coating composition, excluding water. The solid material also includes organic-inorganic hybrid binder along with additives, considering binder has active roles to provide suitable anchoring.
In an embodiment of the present disclosure, the active content in the coating composition is in the range of 20 mass% to 70 mass%.
In an embodiment of the present disclosure, the coating composition is maintaining viscosity over a long time period, thus having excellent storage stability.
In an embodiment of the present disclosure, the coating composition is maintaining pH over a long time period.
In an embodiment of the present disclosure, the coating composition is showing excellent nitrogen oxides (NOx) and sulfur oxide (SOx) neutralization capability without compromising essential coating properties such as hiding power, whiteness, dirt pickup resistance (DPUR), scrub resistance, and weather resistance and stability of the coating composition.
In an embodiment of the present disclosure, the coating composition is providing excellent anti-chalking performance.
In an embodiment of the present disclosure, the coating composition is providing excellent adhesive performance on cementitious substrates.
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 the coating composition in accordance with the present disclosure
Step 1: Process for the preparation of the emulsion organic-inorganic hybrid binder system in accordance with the present disclosure.
General procedure: The predetermined amounts of an organic binder, a first predetermined amount of water and a second neutralizer were sequentially mixed under stirring at a speed in the range of 100 rpm to 300 rpm for a time interval in the range of 2 minutes to 15 minutes to obtain a homogeneous mixture. The predetermined amount of an inorganic binder was added in the homogeneous mixture under stirring for a time period in the range of 30 minutes to 120 minutes followed by adding a second predetermined amount of water under stirring for a time period in the range of 5 minutes to 15 minutes, followed by filtering to obtain solids of the organic-inorganic hybrid binder system.
The organic-inorganic hybrid binder systems were prepared in Examples A1 and A2 by following the general procedure as above. The predetermined amounts of the specific ingredients of the organic-inorganic hybrid binder system are as given in Table 1.
Table 1: Composition of the organic-inorganic hybrid binder system (A1) and (A2)
Sr. No. Ingredients and their function Organic-inorganic hybrid binder system (A1)
(amount in grams) Organic-inorganic hybrid binder system (A2)
(amount in grams)
Ingredients Function
1 Styrene Acrylate Emulsion Organic binder 188.7 279.8
2 Water First predetermined amount of water 41.9 18.5
3 50% KOH solution Second neutralizer 2.1 3
4 Liquid Potassium Silicate Inorganic binder 750 673.7
5 Water Second predetermined amount of water 17.3 25
Step 2: Process for the preparation of the coating composition in accordance with the present disclosure
General procedure: The predetermined amounts of a first portion of water, a first portion of an anti-foaming agent, a dispersing agent, a first portion of a biocide and a surfactant were sequentially mixed under stirring at 300 rpm at a time interval of 5 minutes to obtain a first mixture. The predetermined amounts of a pigment, a filler, a metal oxide, a first algaecide and a first rheology modifier were mixed in the first mixture under stirring at 1000 rpm at a time interval of 8 minutes to obtain a second mixture. The predetermined amounts of a second rheology modifier and a second portion of water were added in the second mixture under stirring at 2000 rpm followed by maintaining the stirring of 2000 rpm for 45 minutes to obtain a third mixture. The predetermined amounts of a second portion of the anti-foaming agent, a humectant, a second portion of the biocide, a third portion of the anti-foaming agent, a first hydrophobic additive, a coalescing agent, and a first neutralizer were sequentially added in the third mixture under stirring at 500 rpm for a time interval 5 minutes to obtain a fourth mixture. A predetermined amount of an organic-inorganic hybrid binder system prepared in step 1 of the present disclosure was added in the fourth mixture for 3 hours under stirring at 500 rpm to obtain a fifth mixture. The predetermined amounts of a first fungicide, colloidal silica, a second hydrophobic additive, a second fungicide, a third portion of water, a second algaecide and a fourth portion of water were sequentially added in the fifth mixture under stirring at 500 rpm at a time interval of 5 minutes to obtain the coating composition.
The coating composition were prepared in Examples E1 and E2 by following the general procedure as above. The predetermined amounts of the specific ingredients of the coating composition are as given in Table 2.
Table 2: Coating compositions prepared in accordance with the present disclosure
Sr. No. Ingredients Function E1 (in grams) E2 (in grams)
1. Water First portion of water 176.1 156.1
2. Hydrocarbon oil based antifoaming agent (TEGO® Foamex K3) First portion of anti-foaming agent 2.1 2.1
3. Polycarboxylic acid dispersant (poly(acrylic acid-co-methacrylic acid) Dispersing Agent 6.2 6.2
4. Rocima 623 First portion of biocide 1 1
5. Polyoxyethylene (9) isotridecanol (ATPOL 5731) Surfactant 6.2 6.2
6. rutile titanium dioxide (TiO2) Pigment 215 215
7. Silica powder 500 mesh Filler 20 20
8. Photocatalytic TiO2 Metal oxide 12.5 12.5
9. N'-(3,4-dichlorophenyl)-N,N-dimethylurea (Diuron technical) First algaecide 10 15
10. Xanthum Gum Powder First rheology modifier 0.4 0.4
11. Hydroxyethylcellulose surface-treated with glyoxal (Natrosol 250 HHBR 5070) Second rheology modifier 4 4
12. Water Second portion of water 30 15
13. Hydrocarbon oil based antifoaming agent (TEGO® Foamex K3) Second portion of anti-foaming agent 1 1
14. Propylene Glycol Monomethyl Ether Humectant 5.2 5.2
15. Rocima 623 Second portion of biocide 2 2
16. Hydrocarbon oil based antifoaming agent (TEGO® Foamex K3) Third portion of anti-foaming agent 1.6 1.6
17. Coatosil MP 200 First Hydrophobic additive 0.5 0.5
18. TMPD-monoisobutyrate C12 Coalescing agent 4 4
19. 50 % KOH solution First Neutralizer solution 2.6 2.6
20. Organic-inorganic hybrid binder system A1 or organic-inorganic hybrid binder system A2 organic-inorganic hybrid binder systems A1 and A2 prepared in Example 1A of the present disclosure 420 467.5
21. Zinc pyrithione First fungicide 1 1
22. Silica dispersion (30% solids), sterically stabilized and the amorphous silica particles Colloidal silica 20 20
23. ADD SC 3001 (hydrophobic acrylate dispersion) Second Hydrophobic additive 2 2
24. Iodopropynyl butyl carbamate (IPBC) Second fungicide 3 3
25. Water Third portion of water 5 5
26. Encapsulated N'-(3,4-dichlorophenyl)-N,N-dimethylurea (encapsulated diuron) Second algaecide 10 15
27. Water Fourth portion of water 38.6 16.1
For the sake of brevity, multiple number of experiments are not included in the specification. However, the other ingredients having similar functionality can be used in the preparation of the coating composition of the present disclosure and the coating composition will give similar results.
Experiment 2: Performance study of the coating composition prepared in accordance with the present disclosure
The coating compositions E1 and E2 were prepared in the step 2 of Experiment 1 of the present disclosure. E1 and E2 coating composition were prepared by using an organic-inorganic hybrid binder system A1 and A2, respectively.
Moreover, in order to study the performances of coating compositions E1 and E2, the performances of the conventional coating compositions such as control (C) and control with photolytic TiO2 (C1) were considered. The details of these coating composition is represented in the following Table 3.
Table 3: Details of the coating compositions
Sr. No. Code Sample Binder composition
1 C Control
(Conventional coating composition) Pure organic binder
2 C1 Control+ photocatalytic TiO2 (1.25%)
(Conventional coating composition) Pure organic binder with 1.25% of photocatalytic titanium dioxide (TiO2)
3 E1 Coating composition 1
(In accordance with the present disclosure) organic-inorganic hybrid binder system (A1) having organic binder and inorganic binder
4 E2 Coating composition 2
(In accordance with the present disclosure) organic-inorganic hybrid binder system (A2) having organic binder and inorganic binder

The samples of Table 3, were subjected for performance studies in order to study the various parameters including coat finish, viscosity, drying time, shade-2, settling, non-volatile matter (NVM), weight per liter (WPL) density, Natural storage, Accelerated study, SOx reduction, NOx reduction and Dirt Pick Up Resistance (DPUR). The results are tabulated in the following Table 4.
Table 4: Performance studies of the coating compositions C, C1, E1 and E2
Sr. No. Parameter C C1 E1 E2
1 Finishing Smooth and uniform Smooth and Uniform Matt, Smooth and Uniform Matt, Smooth and Uniform
2 Viscosity
(Ku) 90 90 97 95
3 Drying Time (hours) 4 4 4 4
4 Shade-2 White White White White
5 Settling2 NIL NIL NIL NIL
6 Non-Volatile Matter (NVM) 47.05 48.45 41.803 44.32
7 Weight Per litre (WPL) 1.25 1.25 1.33 1.34
8 Natural storage 1
Initial Viscosity: 90 KU
Viscosity after 60 Days: 105 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity: 92 KU
Viscosity after 60 Days: 107 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity : 97 KU
Viscosity after 60 Days: 117 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity : 97 KU
Viscosity after 60 Days: 117 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
9 Accelerated stability
Initial Viscosity : 90 KU
Viscosity after 60 Days: 105 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity : 90 KU
Viscosity after 60 Days: 105KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity : 97 KU
Viscosity after 60 Days: 117 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
Initial Viscosity : 97 KU
Viscosity after 60 Days: 117 KU
Settling - Nil
Synerisis - Nil
Gelling - Nil
10 SOx Reduction in concentration 10481.1 7860.9 0 µg/m3 0 µg/m3
11 NOx Reduction in concentration 5644.8 1881.6 0 µg/m3 0 µg/m3
12 Dirt Pick UP Resistance (DPUR) 5 5 8 8
Viscosity was measured at 30±1°C, drying was carried out at % RH = 65±5 %; 30±1 °C, accelerated stability was conducted at 55 °C. The WHO guidelines for SOX reduction is 40 µg/m3, and NOx is 25 µg/m3. For DPUR, ratings on wall was given out of 10 (R=1 represents poor DPUR resistance, R=10 represents best DPUR).
From Table 4, it is observed that the coating compositions E1 and E2, prepared in accordance with the present disclosure shows improved finishing, viscosity, weight pickup loss (WPL), natural storage, accelerated stability, SOx reduction, NOx reduction and dirt pick up resistance (DPUR) as compared to the conventional coating compositions (C and C1).
Thus, the performance properties of the coating compositions (E1 and E2) of the present disclosure are found to be better than the conventionally used coating compositions (C and C1).
Experiment 3:
Sample preparation for ambient air quality testing (In Chamber test)
• W-C: Wooden box (1 cubic feet and 5mm thickness) was prepared and coated with 1 coat of exterior primer and 2 coats of standard exterior emulsion paint (Control); and
• W-E: Wooden box (1 cubic feet and 5mm thickness) was prepared and coated with 1 coat of exterior primer and 2 coats of E1 prepared in accordance with the present disclosure.
Experiment 3 (A): Study for reduction of NO2
The modified Jacob & Hochheiser method
Indian Standard Methods for Reduction of NO2 (IS5182 Part 6: Oxides of Nitrogen: Methods for Measuring Air Pollution)
30 ml of absorbing material was taken by using an impinger and connected to the sampling manifold of sampling device. Air was drawn at sampling rate of 1 Lpm for a duration of 4 hours. Volume of sample was checked at the end and recorded. 10 ml aliquot of the sample was taken in volumetric flask of 50ml, similarly 10 ml of unexposed samples were taken in 50ml of volumetric flask and to which 1 ml of H2O2 was added and sulphanilamide was 10 ml added after which 1.4 ml of NEDA is added. Distilled water was added to make the make it up to 50ml and reaction is allowed to happen for 10 minutes. Spectrophotometer with distilled water was set at zero. Absorbance was measured at 540nm. Concentration was calculated using calibration graph.
Nitrogen dioxide concentration is measured in µg/m3. It was observed that the values of NO2 was 2.7 µg/m3 after 7days after which it was below the detection limit [minimum detection limit of NO2 <2.5µg/m3] for E1 coating composition.
Experiment 3 (B): Study for reduction of SO2
IS 5182 Part 2 Method of Measurement of Air Pollution: Sulfur Dioxide Modified West & Gaeke Method.
An absorbing media of 30ml was taken in an impinger and connected to gas sampling device. Air was collected at uniform flow rate of 1Lpm for a duration of 4 hours. Volume of the sample was checked and recorded at the end. 10 ml to 20ml of Aliquot sample was taken in 25ml volumetric Flask. Similarly, 10 ml to 20ml of unexposed sample was taken in 25ml of volumetric flask. 1 ml of Sulphamic acid was added and kept for 10 minutes and 2 ml of formaldehyde was added. 2 ml of pararosaniline was added and rest was made up with distilled water. It was kept for 30 minutes for the reaction. Spectrophotometer with distilled water is set at zero. Absorbance was measured at 540nm. Concentration is calculated using calibration graph.
Sulphur dioxide concentration is measured in µg/m3. It was observed that the values of SO2 was 14.2 µg/m3 after 7days after which it was below detection limit [minimum detection limit of SO2 <6µg/m3] for E1 coating composition.
Experiment 3 (C): Ambient Air Quality Monitoring on actual walls representing the real-life scenario
Laboratory set up created to study Ambient Air Quality
Air cleaning performance was tested on wooden test box(1 sq. ft x 5 sides) coated with premium exterior emulsion paint white followed by application of two coats of conventional coating composition (control) and coating composition (E1) prepared in accordance with the present disclosure.
The panels were cured for 7 days and then tested for their relative NO2 and SO2 absorption performance in a close chamber equipped with the air quality measurement device and D65 artificial sunlight and UV light of wavelength 280nm as shown in Figure 1B.
The known amount of the test gases (NO2 and SO2) was injected in a closed glass chamber having the air quality measurement device (Advanced Techno systems) as shown in Figure 1A.
The reduction of the test gases at each 15 minutes interval was measured and recorded to ascertain the relative performance of toxic gas absorption, the % reduction in NO2 and SO2 are shown in Figures 3 (A) and (B) that demonstrates the reduction potential of the coating composition of the present disclosure with respect to commercially available coating composition (Control).
(i) NOx Reduction Study
Nitrogen dioxide gas was purged inside an airtight chamber at uniform flow rate 1L/min by using a canister of 250ppm for 10 minutes in a chamber size of 10 cubic feet and monitored for 15 minutes to stabilize the reading after which the control test box (coated with conventional coating composition) was inserted, and readings were monitored for 60 minutes at 15 minutes interval. The control test panel showed around 40% reduction in NO2 level.
After which the control test box was removed. Then similar process was followed for experimental coating composition (E1) and nitrogen dioxide gas was purged inside at uniform flow rate 1L/min using a canister of 250 ppm for 10 minutes in chamber size of 10 cubic feet and after stabilization of readings the E1 coated wooden box was inserted inside the chamber and readings were observed after 15 minutes interval for 60 minutes. After 1 hour the E1 composition showed 100% reduction in NO2 levels. The process was repeated for experimental composition 2 more times. The results were recorded as shown in figure 3 (A).
Figure 3A illustrates graphical representation for the demonstration of NO2 reduction of Control compared with the E1 (for 3 cycles) as prepared in accordance with the present disclosure.
(ii) SOx Reduction Properties
Sulphur dioxide gas was purged inside the same airtight chamber at uniform flow rate 1L/min by using a canister of 250ppm for 10 minutes in a chamber size of 10 cubic feet and monitored for 15 minutes to stabilize the reading after which the control test box was inserted, and readings were monitored for 60 minutes at 15 minutes interval. The control test panel showed around 20% reduction in SO2 level. After which the control test box was removed. Then similar process was followed for experimental composition (E 1) and nitrogen dioxide gas was purged inside at uniform flow rate 1L/min using a canister of 250 ppm for 10 minutes in chamber size of 10 cubic feet and after stabilization of readings the E1 coated wooden box was inserted inside the chamber and readings were observed after 15minutes interval for 60 minutes. After 1 hour the E1 composition showed 100% reduction in SO2 levels. The process was repeated for experimental composition 2 more times. The results were recorded as shown in Figure 3 (B).
Figure 3 (B) illustrates graphical representation for the demonstration of SO2 reduction of Control compared with the E1 (for 3 cycles) as prepared in accordance with the present disclosure
Experiment 3 (D): Ambient Air Quality Monitoring on actual walls representing the real-life scenario (Pre-painting)
A 50 ft (length) x 40 ft (breadth) wall was selected at an Industrial Site (MIDC, Navi Mumbai) because of various vehicular and industrial sources. It acted as a model location to demonstrate the reduction potential of the experimental samples for the gases specifically NO2, SO2 in real-life scenario.
The wall surface was initially coated with 1 coat of Exterior water-based primer followed by 2 coats of experimental composition E1. The Pre and Post painting readings of the site were taken using Ambient Air Monitoring Machine (Themo Environmental Instruments) as shown in Figure 2. Readings for 1 feet away from the wall and 15 feet away from the wall were taken to check the efficacy of reduction from the wall surface and data points were monitored over a period of 4 months.
The wall surface painted with 1 coat of exterior water based primer followed by 2 top coats of E1 is shown in Figure 2 below along with the air quality measurement instrument from Thermo Environmental.
Ambient Air quality improvement performance on actual walls (Post painting)
The Ambient Air Quality improvement performance at Industrial Site (MIDC, Navi Mumbai) away from wall at 15ft exhibited the concentration of gases below the specified limit of WHO after 4 months. The lowest detection limit for NO2 is 2.5µg/m3 and SO2 is 6µg/m3. WHO limits for NO2 =25 (24-hour average), SO2 = 40µg/m3 (24 hour average).
Figure 4 (A) and (B) illustrates a graphical presentation of the air quality improvement performances (in terms of reduction of NOx and SOx gas concentration) of the experimental patch on actual wall in comparison with control (the measurement for the conventional emulsion paint, measured before the application of the experimental patch). Significant improvement is clearly seen also in a sustained manner for 7 days to 120 days.
Experiment 4: Dirt pick up resistance (DPUR) performance study
One coat of exterior primer followed by 2 coats each of the below experimental designs were applied at high rainfall areas in western part of India, to study the performance of the experimental paints under natural high rain climate and in Northern part of India to study dirt pick up resistance (DPUR) performance of these paints in a real-life condition. Various Prototypes of photocatalytic paint systems were applied (Commercially available paint with varying photocatalytic TiO2 are Control Paint compositions and (E1, E2, represents inorganic organic hybrid paint system with varying pigment volume concentration (PVC). For E1, the PVC equals to 66 and for E2, the PVC equals to 55.
The organic-inorganic hybrid coating systems (E1 and E2) demonstrated superior DPUR and self-cleanability in comparison to the acrylic systems as evidenced in Figure 5 (A) and (B).
Experiment 5: Accelerated weathering study of the experimental samples
The accelerated weathering of the experimental sets were studied in the laboratory using the QUV A (?=340 nm) Alternate cycles of 4 hours UV radiation and 4 hours of condensation was exposed on the panels. UV temperature maintained at 50+10C and condensation temperature of 45+10C. UV radiation source: UVA 340 EL and Irradiance level was maintained at 0.55+0.01 watt/m2/nm.
Cementitious fiber wood panels of dimensions (7.5cm x 15cm) were applied with 1 coat of exterior primer followed by 2 coats of exterior emulsion paint (Control) using a conventional application tool like brush and cured for 7 days at normal room temperature and pressure, post which they were exposed at QUVA (340 nm and 550C) for 1500 hours. Similar application was done for C1, E1 and E2 paint composition and exposed at 340nm and 550C for 1500hours.
Apparatus required and test procedure includes a muslin cloth & Black cloth. Standard block of 1Kg ± 50g weight taken covered with a black cloth. The block was lightly rubbed on the test panels above for 20 cycles (one cycle consists of block movement) and the chalking is compared to the master sample. The extent of chalking is rated visually and shown in Figure 6 (A to D) and expressed in Table 5.
Rating [R = 0 (worst) and R = 10 (no chalking)].
Table 5: The chalk resistance ratings of the different samples.
Sr. No. Code Sample Chalk Resistance Ratings
1 C Control 9
2 C1 Control+ photocatalytic TiO2 (1.25%) 3
3 E1 Stabilized organic-inorganic hybrid paint composition 1 9
4 E2 Stabilized organic-inorganic hybrid paint composition 2 7

The ratings demonstrate that the conventional organic coatings C1 that is coating composition based on pure organic binder with photocatalytic TiO2 have lower chalking resistance whereas the inorganic-organic hybrid paint (E1 and E2) have a higher chalking resistance.
Thus, the stable coating compositions (E1 and E2) based on the photocatalytic TiO2 as efficient catalyst for reducing the air pollutants namely NOx and SOx were prepared in accordance with the present disclosure. These compositions showed excellent self-cleaning performance along with the air cleaning. These coatings also demonstrated non-chalking performance due to balanced inorganic-organic hybrid comprising organic-inorganic hybrid binder system approach.
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:
• has capability to neutralize pollutants such as nitrogen oxides and sulfur oxides;
• has excellent anti-chalking performance;
• is suitable for architectural and exterior coatings; and
• is stable and economically feasible,
a process for preparation of coating composition is simple, economical and environment friendly.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
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.
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 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:
• an organic-inorganic hybrid binder system in an amount in the range of 10 mass% to 65 mass%;
• at least one metal oxide in an amount in the range of 0.05 mass% to 10 mass%; and
• an additive in an amount in the range of 35 mass% to 85 mass%,
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.
2. The coating composition as claimed in claim 1, wherein said additive is selected from the group consisting of an anti-foaming agent, a dispersing agent, a biocide, a surfactant, a pigment, a filler, at least one algaecide, at least one fungicide, at least one rheology modifier, a humectant, at least one hydrophobic additive, a coalescing agent, a first neutralizer, colloidal silica and water.
3. The coating composition as claimed in claims 1 and 2, wherein
a) said anti-foaming agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
b) said dispersing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
c) said biocide is present in an amount in the range of 0.05 mass% to 2.5 mass%;
d) said surfactant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
e) said pigment is present in an amount in the range of 10 mass% to 30 mass%;
f) said filler is present in an amount in the range of 1 mass% to 5 mass%;
g) said algaecide is present in an amount in the range of 0.5 mass% to 6 mass%;
h) said fungicide is present in an amount in the range of 0.05 mass% to 5 mass%;
i) said rheology modifier is present in an amount in the range of 0.02 mass% to 2.5 mass%;
j) said humectant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
k) said hydrophobic additive is present in an amount in the range of 0.01 mass% to 2.5 mass%;
l) said coalescing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
m) said first neutralizer is present in an amount in the range of 0.05 mass% to 5 mass%;
n) said colloidal silica is present in an amount in the range of 1 mass% to 5 mass%; and
o) water is in an amount in the range of 1 mass% to 35 mass%,
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.
4. The coating composition as claimed in claim 1, wherein said organic-inorganic hybrid binder system comprises:
• an organic binder in an amount in the range of 10 mass% to 40 mass%;
• an inorganic binder in an amount in the range of 50 mass% to 85 mass%;
• a second neutralizer in an amount in the range of 0.1 mass% to 5 mass%; and
• water in an amount in the range of 1 mass% to 10 mass%;
wherein said mass% of each ingredient is with respect to the total mass of said organic-inorganic hybrid binder system.
5. The coating composition as claimed in claims 1 and 2, wherein
• said metal oxide is titanium oxide (TiO2), wherein said metal oxide has a particle size in the range of 5 nm to 2000 nm;
• said anti-foaming agent is hydrocarbon oil based antifoaming agent;
• said dispersing agent is polycarboxylic acid dispersant;
• said biocide is selected from the group consisting of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, a mixture of chloromethyl-methylisothiazolinone and formaldehyde, a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, and a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT);
• said surfactant is polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether and ethoxylated fatty alcohol;
• said pigment is rutile titanium dioxide (TiO2);
• said filler is silica powder 500 mesh;
• said algaecide is selected from N'-(3,4-Dichlorophenyl)-N,N-dimethylurea, and encapsulated N'-(3,4-Dichlorophenyl)-N,N-dimethylurea;
• said fungicide is selected from Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione;
• said rheology modifier is selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethylcellulose surface-treated with glyoxal;
• said humectant is a glycol selected from the group consisting of propylene glycol, propylene glycol monomethyl ether, hexylene glycol, butylene glycol, and glyceryl triacetate;
• said hydrophobic additive is selected from the group consisting of hydrophobic acrylate dispersion, amine functional silane and epoxy functional silane oligomer;
• said coalescing agent is an organic solvent selected from trimethyl pentanediol monoisobutyrate, butyl cellosolve, ethyl cellosolve and 2,2-dimethyl-1-(methylethyl)-1,3-propanediylbis(2-methyl propanoate); and
• said first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
6. The coating composition as claimed in claim 4, wherein
• said organic binder is selected from the group consisting of an acrylic emulsion, a styrene-acrylic emulsion, a vinyl acetate emulsion, a vinyl acetate-ethylene copolymer emulsion (VAE emulsion), a styrene-butadiene rubber emulsion (SBR emulsion) and a vinyl acetate monomer (VAM-Acrylic);
• said inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate, lithium silicate and aluminium silicate; and
• said second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
7. The coating composition as claimed in claim 4, wherein a mass ratio of said organic binder to said inorganic binder in said organic-inorganic hybrid binder system is in the range of 1:1 to 1:5.
8. A process for the preparation of a coating composition, said process comprising the following steps:
i. sequentially mixing predetermined amounts of a first portion of water, a first portion of an anti-foaming agent, a dispersing agent, a first portion of a biocide and a surfactant under stirring at a first predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a first mixture;
ii. mixing predetermined amounts of a pigment, a filler, a metal oxide, a first algaecide and a first rheology modifier in said first mixture under stirring at a second predetermined speed at a time interval in the range of 5 minutes to 10 minutes to obtain a second mixture;
iii. adding a second rheology modifier and a second portion of water in said second mixture under stirring at a third predetermined speed followed by maintaining said third predetermined speed for a time period in the range of 30 minutes to 60 minutes to obtain a third mixture;
iv. sequentially adding predetermined amounts of a second portion of said anti-foaming agent, a humectant, a second portion of said biocide, a third portion of said anti-foaming agent, a first hydrophobic additive, a coalescing agent, and a first neutralizer in said third mixture under stirring at a fourth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain a fourth mixture;
v. adding a predetermined amount of an organic-inorganic hybrid binder system in said fourth mixture for a time period in the range of 1 hour to 5 hours under stirring at said fourth predetermined stirring speed to obtain a fifth mixture;
vi. sequentially adding predetermined amounts of a first fungicide, colloidal silica, a second hydrophobic additive, a second fungicide, a third portion of water, a second algaecide and a fourth portion of water in said fifth mixture under stirring at a fifth predetermined speed at a time interval in the range of 3 minutes to 10 minutes to obtain said coating composition.
9. The process as claimed in claim 8, wherein said organic-inorganic hybrid binder system is prepared by following sub-steps,
a. sequentially mixing predetermined amounts of an organic binder, a first predetermined amount of water; and a second neutralizer under stirring at a speed in the range of 100 rpm to 300 rpm for a time interval in the range of 2 minutes to 15 minutes to obtain a homogeneous mixture; and
b. adding a predetermined amount of an inorganic binder in said homogeneous mixture under stirring for a time period in the range of 30 minutes to 120 minutes followed by adding a second predetermined amount of water under stirring for a time period in the range of 5 minutes to 15 minutes, followed by filtering to obtain said organic-inorganic hybrid binder system.
10. The process as claimed in claim 8, wherein
• said metal oxide is titanium oxide (TiO2), wherein said metal oxide has a particle size in the range of 5 nm to 2000 nm;
• said anti-foaming agent is hydrocarbon oil based antifoaming agent;
• said dispersing agent is polycarboxylic acid dispersant;
• said biocide is selected from the group consisting of a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, a mixture of chloromethyl-methylisothiazolinone and formaldehyde, a combination of CIT/MIT (5-Chloro-2-Methyl-4-isothiazolineone or 2-Methyl-4- isothiazlinone) and formaldehyde, a blend of 2-methyl-4-isothiazolin-3-one (MIT) and 1,2-benzisothiazolin-3-one (BIT);
• said surfactant is polyoxyethylene (9) isotridecanol, alkyl aryl polyglycol ether and ethoxylated fatty alcohol;
• said pigment is rutile titanium dioxide (TiO2);
• said filler is silica powder 500 mesh;
• said first algaecide and said second algaecide are independently selected from N'-(3,4-dichlorophenyl)-N,N-dimethylurea, and encapsulated N'-(3,4-Dichlorophenyl)-N,N-dimethylurea;
• said first fungicide, and said second fungicide are independently selected from Iodopropynyl butyl carbamate (IPBC) and Zinc pyrithione;
• said first rheology modifier and said second rheology modifier are independently selected from the group consisting of anionic polysaccharide, hydroxy ethyl cellulose, xanthum gum and hydroxyethylcellulose surface-treated with glyoxal;
• said humectant is glycol selected from the group consisting of propylene glycol, propylene glycol monomethyl ether, hexylene glycol, butylene glycol, and glyceryl triacetate;
• said first hydrophobic additive and second hydrophobic additive are independently selected from hydrophobic acrylate dispersion, amine functional silane, and epoxy functional silane oligomer;
• said coalescing agent is an organic solvent selected from trimethyl pentanediol monoisobutyrate, butyl cellosolve, ethyl cellosolve and 2,2-dimethyl-1-(methylethyl)-1,3-propanediylbis(2-methylpropanoate; and
• said first neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
11. The process as claimed in claim 8, wherein
a) said organic-inorganic hybrid binder system is present in an amount in the range of 10 mass% to 65 mass%;
b) said metal oxide is present in an amount in the range of 0.05 mass% to 10 mass%;
c) said anti-foaming agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
d) said dispersing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
e) said biocide is present in an amount in the range of 0.05 mass% to 2.5 mass%;
f) said surfactant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
g) said pigment is present in an amount in the range of 10 mass% to 30 mass%;
h) said filler is present in an amount in the range of 1 mass% to 5 mass%;
i) said first algaecide and said second algaecide are independently present in an amount in the range of 0.5 mass% to 6 mass%;
j) said first fungicide and said second fungicide are independently present in an amount in the range of 0.05 mass% to 5 mass%;
k) said first rheology modifier and said second rheology modifier are independently present in an amount in the range of 0.02 mass% to 2.5 mass%;
l) said humectant is present in an amount in the range of 0.05 mass% to 2.5 mass%;
m) said first hydrophobic additive and second hydrophobic additive are independently present in an amount in the range of 0.01 mass% to 2.5 mass%;
n) said coalescing agent is present in an amount in the range of 0.05 mass% to 2.5 mass%;
o) said first neutralizer is present in an amount in the range of 0.05 mass% to 5 mass%;
p) said colloidal silica is present in an amount in the range of 1 mass% to 5 mass%; and
q) water is present in an amount in the range of 1 mass% to 35 mass%,
wherein said mass% of each ingredient is with respect to the total mass of said coating composition.
12. The process as claimed in claim 8, wherein
• said first portion of said anti-foaming agent is present in an amount in the range of 20 mass% to 50 mass%;
• said second portion of anti-foaming agent is present in an amount in the range of 15 mass% to 25 mass%; and
• said third portion of anti-foaming agent is present in an amount in the range of 25 mass% to 40 mass%,
wherein said mass% of each portion of said anti-foaming agent is with respect to the total mass of said anti-foaming agent.
13. The process as claimed in claim 8, wherein
• said first portion of said biocide is present in an amount in the range of 30 mass% to 40 mass%; and
• said second portion of said biocide is present in an amount in the range of 60 mass% to 70 mass%,
wherein said mass% of each portion of said biocide is with respect to the total mass of said biocide.
14. The process as claimed in claim 8, wherein
• said first hydrophobic additive is present in an amount in the range of 10 mass% to 30 mass%; and
• said second hydrophobic additive is present in an amount in the range of 70 mass% to 90 mass%,
wherein said mass% of each of said first hydrophobic additive and said second hydrophobic additive is with respect to the total mass of said hydrophobic additive.
15. The process as claimed in claim 8, wherein
• said first portion of water is present in an amount in the range of 60 mass% to 75 mass%;
• said second portion of water is present in an amount in the range of 5 mass% to 15 mass%;
• said third portion of water is present in an amount in the range of 1 mass% to 10 mass%;
• said fourth portion of water is present in an amount in the range of 6 mass% to 25 mass%,
wherein said mass% of each portion of water is with respect to the total mass of water.
16. The process as claimed in claim 8, wherein
• said first predetermined stirring speed is in the range of 200 rpm to 400 rpm;
• said second predetermined stirring speed is in the range of 800 rpm to 1200 rpm;
• said third predetermined stirring speed is in the range of 1800 rpm to 2200 rpm;
• said fourth predetermined stirring speed is in the range of 400 rpm to 600 rpm; and
• said fifth predetermined stirring speed is in the range of 400 rpm to 600 rpm.
17. The process as claimed in claim 9, wherein
• said organic binder is selected from the group consisting of an acrylic emulsion, a styrene-acrylic emulsion, a vinyl acetate emulsion, a vinyl acetate-ethylene copolymer emulsion (VAE emulsion), a styrene-butadiene rubber emulsion (SBR emulsion) and a vinyl acetate monomer (VAM-Acrylic);
• said inorganic binder is a metal silicate selected from the group consisting of potassium silicate, sodium silicate, potassium methyl siliconate, lithium silicate and aluminium silicate; and
• said second neutralizer is selected from the group consisting of aqueous sodium hydroxide, aqueous potassium hydroxide and aqueous lithium hydroxide.
18. The process as claimed in claim 9, wherein said organic-inorganic hybrid binder system comprises:
• said organic binder is in an amount in the range of 10 mass% to 40 mass%;
• said inorganic binder is in an amount in the range of 50 mass% to 85 mass%;
• said second neutralizer is in an amount in the range of 0.1 mass% to 5 mass%; and
• water in an amount in the range of 1 mass% to 10 mass%,
wherein said mass% of each ingredient is with respect to the total mass of said organic-inorganic hybrid binder system.
19. The process as claimed in claim 9, wherein a mass ratio of said organic binder to said inorganic binder in said organic-inorganic hybrid binder system is in the range of 1:1 to 1:5.
20. The process as claimed in claim 9, wherein
• said first predetermined amount of water is present in the range of 40 mass% to 75 mass%; and
• said second predetermined amount of water is present in the range of 25 mass% to 60 mass%,
wherein said mass% of each amount of water is with respect to the total mass of water.
Dated this 11th Day of December 2024

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

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