DESC:FIELD OF INVENTION
The present invention discloses interpenetrating polymers incorporating water-based waterproofing coating composition that is stable also having excellent crack bridging ability and superior adhesion on exterior concrete/ wall surfaces.

BACKGROUND ART
There is common phenomenon of penetration of water in building or concrete structure. To make coatings impervious to water there are several coating and polymer reported but when these coating or polymers are applied on surface either they give waterproofing for shorter time or only give durability and no waterproofing, or they require multiple coats. To waterproof concrete and building walls for longer time coating/polymer must have both waterproofing and durability in a single system.
In this context US20150203408A1 teaching water-repellent concrete admixture is directed to production of water-repellent masonry, such as brick, concrete block, or other building block, used to build a masonry wall. In some exemplary embodiments, the water-repellent admixture includes water, a hydrolyzable silane, at least one silicone; and an amino-functional silane. The water-repellent concrete admixture is incorporated integrally into a concrete mixture.
CN112662344A teaching paste viscose for cement-free single-component ceramic tile and production process thereof is based on technical field of viscose, in particular to paste viscose for a cement-free single-component ceramic tile and a production process thereof.
CN115011191A directed to interface treatment coating, preparation method thereof teaches 25-75 parts of water-based adhesive emulsion, 1-10 parts of water-based tackifying emulsion, 0.1-1 part of water-based coupling agent, 0.2-0.5 part of antirust agent, 0.2-0.4 part of dispersing agent, 0.2-0.6 part of defoaming agent, 0.2-5 parts of film-forming additive, 0.1-0.4 part of thickening agent, 0.2-0.5 part of thixotropic agent, 0.2-2 parts of synthetic fiber, 25-35 parts of coarse sand, 0-1 part of pH buffering agent and water; the interface treatment coating having a mass solid content of 35-85%.
EP3268326B1 on sealing slurry and flexible cementitious waterproofing membrane produced thereof is based on or sealing slurries comprising: (i) 2 - 15 weight % hydraulic binder (ii) 40 - 77 weight % silica sand; (iii) 15 - 20 weight % polymer (iv) 5 - 20 weight % limestone powder (v) 0 - 7 weight % one or more additives.
JP2004136283A discloses a method of forming permeable water absorption-preventing layer based on forming a permeable water-absorbing layer using an aqueous permeable water-absorbing material-containing composition used for protecting cement-based substrates such as concrete, cement mortar, and cement-based secondary products, with the first step being the acrylic synthetic resin emulsion that is 100 parts by weight in terms of solids, the silane-based permeable water-absorbing inhibitor is 30 to 400 parts by weight in terms of solids, and the solubility parameter (SP value) is 8.5. As described above, a composition containing a permeable water-absorbing material containing 5 to 50 parts by weight of an organic solvent having a solubility in water of 20% by weight or more is applied. As a second step, a solubility parameter (SP value) of 8.5 or more is applied. A method of forming a permeable water-absorbing prevention layer, comprising applying a synthetic resin emulsion paint containing 5 to 50 parts by weight, based on the solid content of the synthetic resin emulsion, of an organic solvent having a solubility in water of at least 20 wt%. .
CN103938656A is about the technical problem to be solved is to provide a kind of rapid constructing method of building underground waterproof engineering, this method can effectively guarantee water-repellent paint on underground wall body surface sprays rapidly and uniformly, to reach waterproof and damp-proof object, simultaneously, do not need to set up scaffold, minimizing personnel, reduction of erection time.
WO2012038099A1 on flexible waterproof roof coatings teaches polymer mixtures in the form of aqueous dispersions or water-redispersible powders comprising one or more vinyl ester polymers and one or more (Meth) acrylic ester polymers, characterized in that the vinyl ester polymers are based on one or more vinyl esters of carboxylic acids having 5 to 13 C atoms, one or more further vinyl esters and optionally one or more monomers copolymerizable therewith.
CA2841664C on Itaconic acid polymers for improved dirt and water resistance for elastomeric wall and roof coatings is about aqueous coating compositions comprising one or more emulsion copolymer made from itaconic acid, a sulfonic acid or sulfonate ester monomer and an additional acid monomer which is a carboxylic acid and having a glass transition temperature of from -45°C to -10°C, and one or more pigment, opacifier, filler, extender, or mixture of any of these at a %PVC of from 20 to 55, preferably 30 to 50, wherein coatings made from the coating compositions provide improved resistance to water swelling and dirt pickup resistance.
US7705068B2 about polyurethane dispersions in an aqueous asphalt emulsion include an aqueous asphalt mixture and polyurethane dispersion.
WO2013139019A1 scopes a process for making polyurethane/acrylic hybrid dispersions for roof coatings and their preparation based on the following steps: a) preparing polyurethane prepolymer; b) adding at least one acrylate monomer, at least one styrenic monomer, or the mixture thereof to the polyurethane prepolymer; c) adding a neutralizing agent; d)dispersing and extending the polyurethane prepolymer; and e) feeding the emulsified mixture of at least one ethylenically unsaturated nonionic monomer and acid monomer, and co-polymerizing them together.
WO1994005738 about binding book blocks to form books is disclosed. The method involves applying an aqueous composition to the spine area of a book block and removing the volatile components of the composition. The composition comprises (1) an aqueous vehicle, a film-forming polymeric resin, and a polyurethane resin or (2) an aqueous polyurethane dispersion or emulsion. The composition may also include an alkaline component.

WO2016142339A1 is based on flexible cementitious waterproofing slurry comprising (i) 1 - 45 weight % hydraulic binder (ii) 40 - 77 weight % silica sand (iii) 10 - 40 weight % polymer (iv) 5 - 20 weight % limestone powder (v) 0 - 7 weight % one or more additives.
WO2011139466A1 on a waterproofing membrane in the form of a sheet-like laminate comprises a carrier sheet, a pressure sensitive adhesive layer on one surface of the carrier sheet, and a protective coating layer on the adhesive layer, wherein the protective coating layer comprises a polymer, cement and white pigment.
CN102515662A on a polymer cement-based capillary crystalline waterproofing material suggests polymer cement base osmotic crystalline waterproof material characterized in having organic liquor material component and inorganic powder component.
CN109369094A directed to a polymer cement waterproof paint and its application method teaches buildings waterproof fields, specifically disclose a kind of polymer cement waterproof paint, that are made of liquid material and powder.
CN110528708A disclosing a kind of waterproof construction is characterized by comprising leveling component and the elastic water-proof component for being layered in the leveling component, with the leveling component including multiple leveling parts for being set to ground, and, lid is pressed on the pressure plare of multiple leveling parts.
While there are several systems known for waterproofing there is need in the art to provide for a single composition/ system that would have excellent waterproofing and durability attributes together with high flexibility, toughness, adhesion and anti-algal property.
OBJECTS OF THE INVENTION
It is thus the primary object of the present invention to provide for a single formulation/ composition having excellent waterproofing and durability attributes together with high flexibility, toughness, adhesion and anti-algal property.
It is another object of the present invention to provide for interpenetrating polymer incorporated water-based waterproofing coating composition/ system together with excellent crack bridging ability and superior adhesion on exterior concrete/ wall surfaces.
It is still another object of the present invention to provide for said formulation/ composition which in including anti-algal additives such as N-(3,4-dichlorophenyl)- N, N -dimethyl-urea to provide for anti-algal effect would yet be a stable composition for sufficient time without loss of any other attributes of the composition.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention there is provided a waterproofing coating composition comprising select levels of water based interpenetrating polymers including 2-10 % by wt. of anionic aliphatic polyester-polyurethane dispersion, 40-70 % by wt. of styrene acrylic emulsion, 0.1-1 wt.% functionalized silanes and balance water including pigments, extenders, performance additives, thickeners.

Preferably in said waterproofing composition wherein interpenetrating polymers of said composition comprise 60-80 % by wt. of the waterproofing composition that is either employed alone or blended with polyacrylic emulsion with said functionalized silanes being selected from epoxy or amine functional methoxy or ethoxy terminated silane 0.1 to 1% favouring waterproofing membrane coatings and elastomeric construction coatings.

According to another preferred aspect of the present invention there is provided said waterproofing composition wherein said coating composition include pigments 5-10%, extenders 10-20% and performance additives 2-4%, with the pigments comprising Titanium dioxide, said extender comprising dehydroxylated aluminium silicate, calcium carbonate, marble powder, said additive comprising 0.1-1.2% defoaming agents, 0.1-0.8% thickening agents including cellulosic thickener and 0.2-1.2% wetting-dispersing additives, between 0.1-0.5% polyacrylonitrile fibers and N-(3,4-dichlorophenyl)- N, N -dimethyl-urea as anti-algal additive.

Preferably said waterproofing composition is provided wherein said composition includes 0.1 to 2% anti-algal additives N-(3,4-dichlorophenyl)-N, N-dimethyl-urea as critical ingredient for incorporation in said coating composition to provide for anti-algal effect and yet be a stable composition for upto 5 years for sufficient time without loss of any other waterproofing attributes of the composition.

According to another preferred aspect of the present invention there is provided said waterproofing composition wherein said waterproofing coating composition includes Titanium dioxide 5-10% and extenders including calcium carbonate 2-5%, marble powder 3-6%, dehydroxylated aluminium silicate 3-5% and combinations thereof, and have pigment volume concentration of the said coating is between 15-25% and is suitable for coating wide variety of substrates of concrete, cement mortar, plaster of exterior surface of a building in having coating tensile strength of 1.0 to 2.0 Mpa, Elongation of 200-400%, 1.0-2.0 mm crack bridging ability that can also withstand a minimum 7 bar positive pressure with such attributes based on the testing standards of ASTM D 2370 for Elongation and Tensile, ASNZ 4548 for Crack Bridging ability, DIN 1048 for positive pressure.

According to an aspect of the present invention there is provided said process of manufacturing the waterproofing composition as a stable composition comprising the steps of
(i) adding thickener in water base and stabilizing the pH to >9;
(ii) adding pigments, anti-algal additive, and extenders followed by adding thickener and water and processing for 30-45 mins for stabilization of the dispersion;
(iii) maintaining the pH levels between 9-10.5 by addition of neutralizer including alkanolamines, amino compounds and controlling the temperature at ?55 Deg C followed by adding said interpenetrating polymers including select levels of styrene acrylic emulsion and said anionic aliphatic polyester-polyurethane dispersion,
(iv) straining the emulsion through 40 mesh sieve followed by discharging the batch in a mixer;
(v) adding said functionalized silanes followed by adding fibers carrying out mixing for ensuring homogeneity followed by adding balance water for viscosity adjustment of 124-138 KU at 25-40 ?C to obtain said coating composition therefrom.

DETAILED DESCRIPTION OF THE INVENTION
As described hereinbefore, the present invention provides for a waterproofing coating composition/system with ultra-durability together with high flexibility, toughness, adhesion and anti-algal property out of said single system based on the incorporation of water based interpenetrating polymers, pigments, extenders and performance additives also with the attributes of excellent crack bridging ability, 1 to 2 mm, at a same time 200-400% of elongation at a deposition of 100 ± 20 microns thickness indicating high flexibility of the coating.
Advantageously, the coating composition of the present invention is able to withstand a minimum of 7 bar positive side water pressure depicting ultra-durability of coating developed.
It was significantly found by way of the present invention that a waterproofing coating composition can be attained based on select ratio of water based interpenetrating polymers, pigments, extenders, and performance additives. Interpenetrating polymers within the meaning of the present invention comprises select emulsion including Styrene acrylic emulsion and select polyurethane dispersion having number average molecular weight in the range of 8000-15000 together with silanes.

Key advantageous attributes being: 1 to 2 mm coating have crack bridging ability along with 200-400% of elongation at a deposition of 100 ± 20 microns thickness. Coating with withstand a minimum of 7 bar positive side water pressure.

EXAMPLES:
General process of preparation of the composition
and Raw material incorporation
PBW (parts by wt.)
Processing on TSHSD (Twin shaft high speed disperser)
WATER, Defoamer and Biocide 10-10.5
Start Cowl stirrer and maintain tip speed of 10-12 m/s. an then add the following
HEC thickener Hydroxyethyl cellulose 0.2-0.5
Run for 5-10 minutes to disperse the thickener powder uniformly. Then add the following:
pH stabilizer including alkanolamine-AMP 95, amino compound -Loramine 101 0.2-0.5
Mix well under same speed for 10 minutes. Check the pH using pH meter, adjust to 9.0+ to get a uniform jelly, to check the uniformity of jelly, apply a drawdown on glass plate & ensure the jelly is free from or with few scattered bits. Then add the following:
Mix well under same tip speed for 10 Minutes. Then increase the stirring speed
TITANIUM DIOXIDE RUTILE 6-8
Anti-algal additive including N-(3,4-dichlorophenyl)- N, N -dimethyl-urea 1-2
Silicate 5-6
Calcium carbonate 9-10
Clean the walls of TSHSD & Anchor with the following:
WATER, coalescing agent & HEC thickener 4-6
Process for 30-45 minutes under the same stirring speed in the given order for stabilization of the mill base dispersion and ensure uniform mixing.
Styrene acrylic emulsion 40-50
Interpenetrating polymers including -
Anionic aliphatic polyester-polyurethane dispersion,
(Bayhydrol 2864), Number average mol. wt.
in the range of 8000-15000 2-5
Ensure that the pH is 9-10.5 prior to addition of emulsion. If required adjust the pH with neutralizer. Ensure that the mill base temperature is less than 55 Deg.C prior to addition of emulsion. Discharge the batch in mixer. Strain the emulsion through 40 mesh sieve. Emulsion can be added partially both at TSHSD OR Mixer stage. When adding emulsion
in TS-HSD, mixing to be done only at slow speed.
Functionalized silanes 0.1-1
Mix well for about 20 minutes and ensure homogeneity. Then add the following to mixer.
Polyacrylonitrile fibers 0.1-0.5
Mix well for about 30-40 minutes and ensure homogeneity.
Check fibre distribution on glass plate by applying
a draw down with 6 mil applicator. Dense but
uniform distribution of fibres should be ensured.
Then add water. Mix for 15-20 min.
Water 22.4 to balance 100

According to an embodiment of the present invention there is provided a waterproofing coating composition comprising 60-80 % interpenetrating polymers including acrylic and/ or styrene acrylic emulsion (40-70%); specially designed polyurethane dispersion (2-10%) and functionalized silanes (0.1-1%) and the rest being coating ingredients.

According to a preferred aspect of the present invention there is provided in said coating composition pigments 5-10%, extenders 10-20% and performance additives 2-4%, with the pigments comprising Titanium dioxide, said extender comprising dehydroxylated aluminium silicate, calcium carbonate, marble powder, said additive comprising defoaming agents, thickening agents and wetting-dispersing additives, polyacrylonitrile fibers and N - (3,4-dichlorophenyl)- N, N -dimethyl-urea.

According to yet another embodiment of the present invention there is provided said waterproofing coating composition wherein the coating comprises 0.1 to 2% anti-algal additives N-(3,4-dichlorophenyl)- N, N -dimethyl-urea as critical ingredient for incorporation in said coating composition to provide for anti-algal effect and yet be a stable composition for sufficient time without loss of any other attributes of the composition.

According to yet another preferred embodiment of the present invention there is provided said waterproofing coating composition wherein the functionalized silane is selected either from epoxy or amine functional methoxy or ethoxy terminated silane 0.1 to 1%
According to yet another preferred embodiment of the present invention there is provided said waterproofing coating composition wherein the pigment is Titanium dioxide 5-10% and extenders are from calcium carbonate 2-5%, marble powder 3-6%, dehydroxylated aluminium silicate 3-5% or combination thereof.
Preferably in said waterproofing coating composition the pigment volume concentration of the said coating is between 15-25%.
More preferably in said waterproofing coating composition the doses of defoamer is between 0.1-1.2%, wetting and dispersing agents between 0.2-1.2% and cellulosic thickener between 0.1-0.8%.

Preferably said waterproofing coating composition is provided wherein the doses of polyacrylonitrile fibers between 0.1-0.5% and is effective for coating wide variety of substrates of concrete, cement mortar, plaster of exterior surface of a building.

More preferably in said waterproofing coating composition said coating have tensile strength of 1.0 to 2.0 Mpa, Elongation of 200-400%, crack bridging 1.0-2.0 mm that can also withstand a minimum 7 bar positive pressure with such attributes based on the testing standards of ASTM D 2370 for Elongation and Tensile, ASNZ 4548 for Crack Bridging ability, DIN 1048 for positive pressure.

Said coating is also stable for upto 5 years without any change of viscosity and also loss of attributes of the composition based on the ingredients employed and its select inclusion in necessary wt.% ranges.

It is thus possible by way of the present invention to provide for interpenetrating polymer incorporated water-based waterproofing coating composition/ system together with excellent crack bridging ability and superior adhesion on exterior concrete/ wall surfaces.
,CLAIMS:We Claim:

1. A waterproofing coating composition comprising select levels of water based interpenetrating polymers including 2-10 % by wt. of anionic aliphatic polyester-polyurethane dispersion, 40-70 % by wt. of styrene acrylic emulsion, 0.1-1 wt.% functionalized silanes and balance water including pigments, extenders, performance additives, thickeners.

2. The waterproofing composition as claimed in claim 1 wherein interpenetrating polymers of said composition comprise 60-80 % by wt. of the waterproofing composition that is employed alone or blended with polyacrylic emulsion with said functionalized silanes being selected from epoxy or amine functional methoxy or ethoxy terminated silane 0.1 to 1% favouring waterproofing membrane coatings and elastomeric construction coatings.

3. The waterproofing composition as claimed in claims 1 or 2 wherein said coating composition include pigments 5-10%, extenders 10-20% and performance additives 2-4%, with the pigments comprising Titanium dioxide, said extender comprising dehydroxylated aluminium silicate, calcium carbonate, marble powder, said additive comprising 0.1-1.2% defoaming agents, 0.1-0.8% thickening agents including cellulosic thickener and 0.2-1.2% wetting-dispersing additives, between 0.1-0.5% polyacrylonitrile fibers and N-(3,4-dichlorophenyl)- N, N -dimethyl-urea as anti-algal additive.

4. The waterproofing composition as claimed in claims 1-3 wherein said composition includes 0.1 to 2% anti-algal additives N-(3,4-dichlorophenyl)-N, N-dimethyl-urea as critical ingredient for incorporation in said coating composition to provide for anti-algal effect and yet be a stable composition for upto 5 years for sufficient time without loss of any other waterproofing attributes of the composition.

5. The waterproofing composition as claimed in claims 1-4 wherein said waterproofing coating composition includes Titanium dioxide 5-10% and extenders including calcium carbonate 2-5%, marble powder 3-6%, dehydroxylated aluminium silicate 3-5% and combinations thereof, and have pigment volume concentration of the said coating is between 15-25% and is suitable for coating wide variety of substrates of concrete, cement mortar, plaster of exterior surface of a building in having coating tensile strength of 1.0 to 2.0 Mpa, Elongation of 200-400%, 1.0-2.0 mm crack bridging ability that can also withstand a minimum 7 bar positive pressure with such attributes based on the testing standards of ASTM D 2370 for Elongation and Tensile, ASNZ 4548 for Crack Bridging ability, DIN 1048 for positive pressure.

6. A process of manufacturing the waterproofing composition as claimed in claims 1-5 as a stable composition comprising the steps of
(i) adding thickener in water base and stabilizing the pH to >9;
(ii) adding pigments, anti-algal additive, and extenders followed by adding thickener and water and processing for 30-45 mins for stabilization of the dispersion;
(iii) maintaining the pH levels between 9-10.5 by addition of neutralizer including alkanolamines, amino compounds and controlling the temperature at ?55 Deg C followed by adding said interpenetrating polymers including select levels of styrene acrylic emulsion and said anionic aliphatic polyester-polyurethane dispersion,
(iv) straining the emulsion through 40 mesh sieve followed by discharging the batch in a mixer;
(v) adding said functionalized silanes followed by adding fibers carrying out mixing for ensuring homogeneity followed by adding balance water for viscosity adjustment of 124-138 KU at 25-40 ?C to obtain said coating composition therefrom.

Dated this the 8th day of March, 2024 Anjan Sen
(Applicants Agent)
IN/PA-199