DESC:FIELD
The present disclosure relates to a binder composition and a process for its preparation.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The use of alkali silicates as a binder is very usual in various compositions. However, due to the high reactivity of alkali silicates and its incompatibility with other ingredients of the composition, the wider usage of alkali silicates is restricted. To improve or to overcome the incompatibility problem, the alkali silicates need to be converted into a stable composite of acrylic emulsion polymer and potassium silicate that has enhanced compatibility with the other ingredients of the composition. Unless this specific quality is achieved, the composition containing silicates exhibits gelling tendencies, undesired consistency, improper finish with grits, and low shelf-life.
To enhance the compatibility of the silicates with other ingredients of the composition, the silicates are treated prior to its use. The various treatments available are well illustrated in the prior art. However, such treatments are very specific in nature and limit the nature of the ingredients used in the composition. Commercially available coating compositions have one or more of the drawbacks such as the composition is unstable and/or have a lower wet shelf life, presence of grits, incompatibility with the other ingredients of the composition, and have limited resistance to staining and low visual sheen and/or matte in appearance. There is a continued desire for a stable binder composition that is compatible with the other ingredients of the composition and is easy to handle, safe, highly stable, has desirable wet shelf life, absence of grits, good resistance to staining and has the desired visual gloss/sheen/ matte appearance. Additionally, it is required to have the coating composition with low combustibility, low flame propagation index and have comparatively enhanced flame retardant properties.
Therefore, there is felt a need to provide a binder composition that is suitable for various applications and a process for its preparation that mitigates the drawbacks mentioned herein above.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a binder composition.
Still another object of the present disclosure is to provide a stable binder composition that provides a flexibility of having the desired matte /sheen / glossy visual appearance.
Still another object of the present disclosure is to provide a stable binder composition for coatings that has enhanced stain cleanability.
Still another object of the present disclosure is to provide a stable binder composition that has low combustibility, low flame propagation index and has comparatively improved flame retardant properties.
Yet another object of the present disclosure is to provide a process for the preparation of a binder 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 binder composition comprising an acrylic emulsion, at least one polycarbohydrate, at least one mineral powder, at least one alkali hydroxide, at least one alkali silicate and at least one additive.
The present disclosure further relates to a process for preparing a binder composition. The process comprises the step of reacting predetermined amounts of an acrylic emulsion, at least one polycarbohydrate, at least one mineral powder, at least one additive and at least one alkali hydroxide at a predetermined pH to obtain a first reaction mixture. A predetermined amount of at least one alkali silicate is added to the first reaction mixture at a predetermined temperature to obtain a second reaction mixture. The second mixture is sieved to obtain a sieved mixture. The sieved mixture is stabilized and filtered to obtain the binder composition.
DETAILED DESCRIPTION
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.
Commercially available water based paints and coating compositions comprises alkali silicates as binder that has the drawbacks such as unstability, lower wet shelf life, presence of grits, incompatibility with the other ingredients of the composition, matt look, low resistance to staining and poor stain cleanability. Alkali silicates are brittle in nature and owing to the brittle nature of the silicates, a co-binder, preferably organic origin co-binder needs to be used in the paint formulation. The use of such organic co-binders with alkali silicates renders the required flexibility of the coating composition and other specific properties such as crack resistance, early chalking resistance, and the like. However, the low compatibility of alkali silicates with other components of the composition limits the variety of co-binders that can be used in the composition. Thus, the coating composition becomes very specific with limited properties such as dead matte, porous, lower stain resistance and the like.
There is a continued desire for a stable binder composition that is compatible with the other ingredients of the composition and is easy to handle, safe, highly stable, desirable wet shelf life, absence of grits, offers the flexibility of having sheen and good stain cleanability.
The present disclosure provides a binder composition. The present disclosure further provides a process for the preparation of the binder composition. The present disclosure still further provides a coating composition containing the binder composition of the present disclosure.
In an aspect of the present disclosure, a binder composition comprises:
a) an acrylic emulsion;
b) at least one polycarbohydrate;
c) at least one mineral powder;
d) at least one alkali hydroxide;
e) at least one alkali silicate; and
f) at least one additive.
In an embodiment of the present disclosure, the binder composition comprises:
a) 30 to 85 wt.% of an acrylic emulsion;
b) 0.1 to 1.0 wt.% of at least one polycarbohydrate;
c) 0.1 to 5 wt.% of at least one mineral powder;
d) 0.1 to 1.0 wt.% of at least one alkali hydroxide; and
e) 1.0 to 60 wt.% of at least one alkali silicate; and
f) 0.1 to 0.5 wt% of at least one additive,
wherein the wt.% of each of the component is with respect to the total weight of the binder composition.
The acrylic emulsion used is an emulsion of styrene acrylic polymer, wherein the monomers are selected from styrene, an acrylic acid, an acrylate, a methacrylate ((meth)acrylic acid), methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, glycidyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, a long chain alkyl (meth)acrylate (examples of which include those having an alkyl group containing 9 to 13 carbon atoms, such as nonyl, isononyl, decyl, isodecyl, dodecyl, isododecyl, tridecyl, isotridecyl) and the like.
In an exemplary embodiment, the acrylic emulsion is styrenated butyl acrylate.
In an embodiment, the solid content of the acrylic emulsion is in the range of 40 to 60 wt.%.
In accordance with the embodiments of the present disclosure, the polycarbohydrate is selected from raw starch, modified starch, a-starch and hydroxypropyl starch.
In an embodiment, the raw starch is selected from nard starch, potato starch, Japanese potato starch, tapioca starch, cone starch, wheat starch and rice starch.
In an embodiment, the modified starch is selected from dextrin, baked dextrin, enzyme-modified dextrin, cyclodextrin, dialdehyde starch, gelatinized starch, oxidized starch, esterified starch, etherified starch, cationized starch and crosslinked starch.
In an exemplary embodiment, the polycarbohydrate is dextrin starch. In another exemplary embodiment, the polycarbohydrate is tapioca starch.
In accordance with the embodiments of the present disclosure, the mineral powder is selected from tourmaline (tourmaline is a substance containing a silicon and an aluminium element as a major component), granite, heruguron-stone, thorogummite, pegmatite, BaTiO3, PbTiO3, PbZrO3, Pb(Zr,Ti)O3, KNbO3, KTaO3, K(Ta,Nb)O3, LiNbO3, Rochelle salt, glycin sulfate, potassium phosphate, a ferroelectric material (such as calcium strontium propionate and the like), negatively ionized Si, SiO2, an excitation agent, and combinations thereof. In an exemplary embodiment, the mineral powder is tourmaline.
The properties of the binding composition of the present disclosure can be enhanced by using a material having oxides and/or hydroxides, in combination with the mineral powder (containing SiO2 and Al2O3).
In accordance with the present disclosure, the alkali hydroxide is selected from potassium hydroxide and sodium hydroxide. In an exemplary embodiment, the alkali hydroxide is potassium hydroxide.
In accordance with the present disclosure, the alkali silicate is selected from lithium silicate, potassium silicate and sodium silicate. In an exemplary embodiment, the alkali silicate is potassium silicate. In an embodiment, the solid content of the alkali silicate is in the range of 27 to 37 wt%.
In accordance with the present disclosure, the additive is selected from biocide and defoamer.
In an embodiment of the present disclosure, the additive is biocide. In an exemplary embodiment, the biocide is a mixture of chlormethyl-isothiazolone, methylisothiazolone and formaldehyde, commercially available as ‘Rocima 623’.
In another embodiment of the present disclosure, the additive is defoamer. The defoamer is mineral oil.
In accordance with the present disclosure, the pH of the composition is in the range of 8 to 14.
In an embodiment of the present disclosure, the binder composition comprises acrylic emulsion in an amount in the range of 30 to 85 wt%, dextrin in an amount in the range of 0.1 to 1 wt%, tourmaline in an amount in the range of 0.1 to 5 wt%, potassium hydroxide in an amount in the range of 0.1 to 1 wt%, and potassium silicate in an amount in the range of 1 to 60 wt%.
In another aspect, the present disclosure provides a process for the preparation of a binder composition.
The process comprises the step of reacting predetermined amounts of an acrylic emulsion, at least one polycarbohydrate, at least one mineral powder, at least one additive and at least one alkali hydroxide at a predetermined pH to obtain a first reaction mixture. A predetermined amount of at least one alkali silicate is added to the first reaction mixture at a predetermined temperature to obtain a second reaction mixture. The second reaction mixture is sieved to obtain a sieved mixture. The sieved mixture is stabilized and filtered to obtain the binder composition.
In accordance with the present disclosure, the predetermined pH is in the range of 8 to 14. In an exemplary embodiment, the predetermined pH is maintained at 11.
In accordance with the present disclosure, the predetermined temperature is in the range of 25 °C to 35 °C.
In accordance with the present disclosure, the binder composition is a stable aqueous dispersion of silicates and acrylates.
The binder composition of the present disclosure is used to formulate a coating composition:
- with varied properties such as gloss/matte, porous/non-porous and the like;
- having a wet shelf life of minimum 2 years;
- having flame retardant properties with low flame propagation index meeting Class 0 requirements (classification for spread of flame);
- having FIGRA (Fire Growth Rate) (0.2) less than or equal to 120 w/s, THR (Total heat release) (600s) less than or equal to 7.5 MJ and SMOGRA (Smoke Growth Rate) of ‘S1’ with no fall of flaming droplets ‘d0’ as per BS EN 13823:2020;
- having good resistance to staining and good stain removal properties;
- having a stable consistency; and
- that can be used in the interior decorative coating.
The foregoing description of the embodiments has been provided for purposes of illustration and is 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: Preparation of a binder composition in accordance with the present disclosure
Example-1:
Acrylic emulsion of styrenated butyl acrylate (~44%), ‘Rocima 623’ (mixture of chlormethyl-/methylisothiazolone and formaldehyde) as a biocide (~ 0.1 %), mineral oil as a defoamer (~ 0.1 %) and aqueous solution of potassium hydroxide (~ 0.1 %) were mixed homogeneously at a slow speed (10-12 m/s) for 15 minutes to obtain a mass. Dextrin starch (~ 0.3 %) was added slowly at 10-12 m/s for 45 minutes to the mass followed by the addition of Tourmaline powder (~2.0%) and mixed well at 10-12 m/s for 25 minutes to obtain a first reaction mixture. Liquid potassium silicate (~44%) and mineral oil (defoamer ~0.1 %) were added slowly to the first reaction mixture at 30 °C and mixed at 10-12 m/s for 40 minutes to obtain a second reaction mixture. The second reaction mixture was sieved to obtain a sieved mixture. The sieved mixture was stabilized by slowly adding water (~ 9%) and mixing at 10-12 m/s for 25 minutes followed by filtering to obtain the binder composition. The viscosity of the binder composition was ~ 56 KU and it was ~ 57 KU after 48 h indicating a stable dispersion.
Example 2:
Acrylic emulsion of styrenated butyl acrylate (~68%), ‘Rocima 623’ (mixture of chlormethyl-/methylisothiazolone and formaldehyde) as a biocide (~ 0.1 %), mineral oil as a defoamer (~ 0.05 %), and aqueous solution of potassium hydroxide (~ 0.2 %) were mixed well at slow speed (10-12 m/s) for 15 minutes to obtain a mass. Dextrin starch (~ 0.3 %) was added slowly at 10-12 m/s for 45 minutes to the mass followed by the addition of Tourmaline powder (~2.0%)and mixed well at 10-12 m/s for 25 minutes to obtain a first reaction mixture. Liquid potassium silicate (~31%), and mineral oil as a defoamer (~0.05 %) were added slowly to the first reaction mixture at 30 °C and mixed at 10-12 m/s for 40 minutes to obtain a second reaction mixture. The second reaction mixture was sieved to obtain a sieved mixture. The sieved mixture was stabilized for 25 minutes followed by filtering to obtain the binder composition.. The viscosity of the binder composition was ~ 56 KU and it was ~ 57 after 48 h indicating a stable dispersion.
Experiment 2: Preparation of a coating composition by using the binder composition of the present disclosure
Example-A: DM water (~17%), ‘Rocima 623’ (mixture of chlormethyl-/methylisothiazolone and formaldehyde) as a biocide (~0.1%), propylene glycon (~4.5%), halogen free phosphorous based flame retardant additive (~2.75%), and hydrocarbon oil-based defoamer (0.2) were mixed well at slow speed (10-12 m/s) for 15 minutes to obtain a first mass. Hydroxyethylcellulose based rheology modifier (~0.4%), aqueous solution of potassium hydroxide as a pH control agent (~0.09%) were added to the first mass and mixed well for 20 minutes to obtain a second mass. Polycarboxylic acid based surfactant (~0.45%) and alcohol ethoxylate based surfactant (~0.25%) were added to the second mass and mixed well for 10 minutes to obtain a third mass. TiO2 (~15%), Zn Borate (~2.6%), tourmaline mineral powder (~4.5%), and DM water (~1 %) were added to the third mass and grinding was performed at high speed (20-22 m/s) for 45 minutes to obtain a slurry. Alcohol ethoxylate based surfactant (~0.05%), 2,2,4-Trimethyl-1,3-pentanediol monoisobutyrate based coalescing agent (~0.45%), combination of Carbendazim, isothiozolinone and zinc pyrithione based biocides (~0.6%) were added to the slurry and mixed well at slow speed (10-12 m/s) for 15 minutes followed by addition of acrylic emulsion polymer (~28%), and acrylic polymer additive (~7.5%), hydrocarbon oil-based defoamer (~0.2%), and water (~5%) and mixed well at slow speed (10-12 m/s) for 25 minutes to obtain a homogeneous mixture. The pH of the homogeneous mixture was maintained using aqueous solution of potassium hydroxide (pH controller) (~0.09%). The binder composition (~21%) of example 1 was added to the homogeneous mixture with hydrocarbon oil-based defoamer (~0.3) at 3 intervals and mixed well at medium speed (15-18 m/s) for about 30 min each time to have better distribution to obtain a formulation. The formulation was completed with acrylic emulsion (~3%), and DM water (~2%) and mixed well at slow speed (10-12 m/s) for 15 minutes to obtain a coating composition.
Example B: DM water (~12%), ‘Rocima 623’ (mixture of chlormethyl-/methylisothiazolone and formaldehyde) as a biocide (~0.1%), propylene glycon (~4%), halogen free phosphorous based flame retardant additive (~9.5%), and hydrocarbon oil-based defoamer (0.2) were mixed well at slow speed (10-12 m/s) for 15 minutes to obtain a first mass. Hydroxyethylcellulose based rheology modifier (~0.4%), aqueous solution of potassium hydroxide as a pH control agent (~0.1%) were added to the first mass and mixed well for 20 minutes to obtain a second mass. Polycarboxylic acid based surfactant (~0.45%) and alcohol ethoxylate based surfactant (~0.2%) were added to the second mass and mixed well for 10 minutes to obtain a third mass. TiO2 (~14.2%), Zn Borate (~2.6%), and tourmaline mineral powder (~2.3%) were added to the third mass and grinding was performed at high speed (20-22 m/s) for 45 minutes to obtain a slurry. Alcohol ethoxylate based surfactant (~0.1%), 2,2,4-Trimethyl-1,3-pentanediol monoisobutyrate based coalescing agent (~0.4%), combination of Carbendazim, isothiozolinone and zinc pyrithione based biocides (~0.6%) were added to the slurry and mixed well at slow speed (10-12 m/s) for 15 minutes followed by addition of acrylic emulsion polymer (~15%), and acrylic polymer additive (~4.35%), hydrocarbon oil-based defoamer (~0.2%) and aqueous solution of potassium hydroxide as pH controller (~0.1%) and mixed well at slow speed (10-12 m/s) for 25 minutes to obtain a homogeneous mixture. The pH of the homogeneous mixture was maintained using aqueous solution of potassium hydroxide (pH controller) (~0.09%). The binder composition (~14%) of example 2 was added to the homogeneous mixture with hydrocarbon oil-based defoamer (~0.2) at 3 intervals and mixed well at medium speed (15-18 m/s) for about 30 min each time to have better distribution to obtain a formulation. The formulation was completed with acrylic emulsion (~13%), and DM water (~1%) and mixed well at slow speed (10-12 m/s) for 15 minutes to obtain a coating composition.
Experiment 3: Characterization of the coating composition
The coating composition of Example A was tested in accordance with BS EN 13823:2020 for fire performance which include fire growth rate (FIGRA), smoke growth rate (SMOGRA), total heat release (THR), and total smoke production (TSP) and the results are tabulated in Table 1.
Table 1:
FIGRA (w/s) THR 600s (MJ) SMOGRA (m2/s2) TSP 600s (m2)
(0.2 MJ) (0.2 MJ) 0.68 0.00 10.87
1.60 1.60
The coating composition of Example B was tested in accordance with BS EN 13823:2020 for fire performance which include fire growth rate (FIGRA), smoke growth rate (SMOGRA), total heat release (THR), and total smoke production (TSP) and the results are tabulated in Table 2.
Table 2:
FIGRA (w/s) THR 600s (MJ) SMOGRA (m2/s2) TSP 600s (m2)
(0.2 MJ) (0.2 MJ) 0.40 0.00 2.43
0.00 0.00
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a binder composition that is:
• compatible with other ingredients in the coating composition;
• easy to handle;
• can be used to formulate the coating composition:
- with varied properties viz., gloss/matte, porous/non-porous and the like;
- having a wet shelf life of minimum 2 years;
- having flame retardant properties with low flame propagation index meeting Class 0 requirements;
- having FIGRA less than or equal to 120 w/s, THR (600s) less than or equal to 7.5 MJ and SMOGRA of ‘S1’ with no fall of flaming droplets ‘d0’ as per BS EN 13823:2020;
- having good resistance to staining and good stain removal properties;
- having a stable consistency; and
- that can be used in the interior decorative coating.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising, will be understood to imply the inclusion of a stated element, integer or step,” or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1) A binder composition comprising:
i. an acrylic emulsion;
ii. at least one polycarbohydrate;
iii. at least one mineral powder;
iv. at least one alkali hydroxide;
v. at least one alkali silicate; and
vi. at least one additive.
2) The composition as claimed in claim 1, wherein said composition comprises:
i. 30 to 85 wt.% of an acrylic emulsion;
ii. 0.1 to 1.0 wt.% of at least one polycarbohydrate;
iii. 0.1 to 5 wt.% of at least one mineral powder;
iv. 0.1 to 1.0 wt.% of at least one alkali hydroxide; and
v. 1.0 to 60 wt.% of at least one alkali silicate; and
vi. 0.1 to 0.5 wt% of at least one additive,
wherein the wt% of each of the components is with respect to the total weight of the binder composition.
3) The composition as claimed in claims 1 and 2, wherein said acrylic emulsion is an emulsion of styrene acrylic polymer, wherein the monomers are selected from styrene, an acrylic acid, an acrylate, a methacrylate, methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, glycidyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, C9-C13 alkyl (meth)acrylate.
4) The composition as claimed in claims 1 and 2, wherein said polycarbohydrate is selected from a raw starch, a modified starch, a-starch and an hydroxypropyl starch; wherein raw starch is selected from nard starch, potato starch, Japanese potato starch, tapioca starch, cone starch, wheat starch and rice starch; and wherein said modified starch is selected from dextrin, baked dextrin, enzyme-modified dextrin, cyclodextrin, dialdehyde starch, gelatinized starch, oxidized starch, esterified starch, etherified starch, cationized starch and crosslinked starch.
5) The composition as claimed in claims 1 and 2, wherein said mineral powder is selected from tourmaline, granite, heruguron-stone, thorogummite, pegmatite, BaTiO3, PbTiO3, PbZrO3, Pb(Zr,Ti)O3, KNbO3, KTaO3, K(Ta,Nb)O3, LiNbO3, Rochelle salt, glycin sulfate, potassium phosphate, a ferroelectric material, negatively ionized Si, SiO2, and combinations thereof.
6) The composition as claimed in claims 1 and 2, wherein said alkali hydroxide is selected from potassium hydroxide and sodium hydroxide.
7) The composition as claimed in claims 1 and 2, wherein said alkali silicate is selected from lithium silicate, potassium silicate and sodium silicate.
8) The composition as claimed in claims 1 and 2, wherein said additive is selected from biocide and defoamer.
9) The composition as claimed in claim 8, wherein said biocide is a mixture of chlormethyl-isothiazolone, methylisothiazolone and formaldehyde.
10) The composition as claimed in claim 8, wherein said defoamer is mineral oil.
11) A process for preparing a binder composition; said process comprising the following steps:
a) reacting predetermined amounts of an acrylic emulsion, at least one polycarbohydrate, at least one mineral powder, at least one additive and at least one alkali hydroxide at a predetermined pH to obtain a first reaction mixture;
b) adding a predetermined amount of at least one alkali silicate to said first reaction mixture at a predetermined temperature to obtain a second reaction mixture;
c) sieving said second reaction mixture to obtain a sieved mixture; and
d) stabilizing said sieved mixture followed by filtering to obtain said binder composition.
12) The process as claimed in claim 11, wherein said acrylic emulsion is an emulsion of styrene acrylic polymer wherein the monomers are selected from styrene, an acrylic acid, an acrylate, a methacrylate, methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, glycidyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, C9-C13 alkyl (meth)acrylate.
13) The process as claimed in claim 11, wherein said polycarbohydrate is selected from raw starch, modified starch, a-starch and hydroxypropyl starch; wherein raw starch is selected from nard starch, potato starch, Japanese potato starch, tapioca starch, cone starch, wheat starch and rice starch; said modified starch is selected from dextrin, baked dextrin, enzyme-modified dextrin, cyclodextrin, dialdehyde starch, gelatinized starch, oxidized starch, esterified starch, etherified starch, cationized starch and crosslinked starch.
14) The process as claimed in claim 11, wherein said mineral powder is selected from tourmaline, granite, heruguron-stone, thorogummite, pegmatite, BaTiO3, PbTiO3, PbZrO3, Pb(Zr,Ti)O3, KNbO3, KTaO3, K(Ta,Nb)O3, LiNbO3, Rochelle salt, glycin sulfate, potassium phosphate, a ferroelectric material, negatively ionized Si, SiO2, an excitation agent and combinations thereof.
15) The process as claimed in claim 11, wherein said additive is selected from biocide and defoamer.
16) The process as claimed in claim 15, wherein said biocide is a mixture of chlormethyl-isothiazolone, methylisothiazolone and formaldehyde.
17) The process as claimed in claim 15, wherein said defoamer is mineral oil.
18) The process as claimed in claim 11, wherein said alkali hydroxide is selected from potassium hydroxide and sodium hydroxide.
19) The process as claimed in claim 11, wherein said predetermined pH is in the range of 8 to 14.
20) The process as claimed in claim 11, wherein said alkali silicate is selected from lithium silicate, potassium silicate and sodium silicate.
21) The process as claimed in claim 11, wherein said predetermined temperature is in the range of 25 °C to 35 °C.
Dated this 29th day of October, 2021

_______________________________
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