DESC:FIELD OF INVENTION
The present invention discloses a multi-functional water-based waterproofing coating formulation with excellent adhesion on damp surfaces with not only superior anti-efflorescence performance for both exterior and interior surfaces of a buildings but also having crack bridging ability.
BACKGROUND ART
Waterproof coatings are known in the art but coating of damp surfaces and with absorption of moisture and preventing or reducing efflorescence together with crack bridging ability of the coating is relatively unknown.
References are drawn to the following: US 2006/0054056 which discloses a process to manufacture concrete products with reduced or no efflorescence by using one or more chemicals that can act as water absorbents, which can be absorbents, super absorbents, or thickeners, either alone or in combination with other common concrete additives.
JP 1114774 describes concrete compositions comprising water-absorbing substances, wherein efflorescence is reduced via the use of alkali carbonates.
US 5,460,648 suggests using as an additive in the concrete mix, a blend comprising a liquid water-insoluble oil (saponified tall oil fatty acid) and an aqueous calcium stearate suspension.
US 5,460,648 suggests using as an additive in the concrete mix, a blend comprising a liquid water-insoluble oil (saponified tall oil fatty acid) and an aqueous calcium stearate suspension.
US 5,460,648 suggests using as an additive in the concrete mix, a blend comprising a liquid water-insoluble oil (saponified tall oil fatty acid) and an aqueous calcium stearate suspension.
US20150203408A1 teaches a water-repellent concrete admixture water-repellent concrete admixture for the production of water-repellent masonry comprising: water; a hydrolyzable silane; at least one silicone; and an amino-functional silane, wherein said water-repellent concrete admixture is integrally incorporated into a concrete mixture.
CA2774395C is directed to a concrete mix useful for producing concrete products having anti-efflorescence properties and a method for making such concrete products whereby the concrete mix includes a hydraulic cement binder, aggregates and as an additive an ultrafine particulate material including carrier particles being surface treated with an efflorescence control agent. The method for making concrete includes a first step of mixing the hydraulic cement binder, aggregates, water and the ultrafine particulate material, a second step of pouring the mixture so obtained into a form, and a third step of curing the mixture.
CN112662344A is directed to paste viscose for a cement-free single-component ceramic tile and a production process thereof, and particularly relates to the technical field of viscose, which comprises the following components, by mass, 75-30% of anchoring force Acronal 504115%, 5-15% of styrene-acrylic emulsion, 1.5-4% of water-based tackifying resin, 2-6% of dispersing agent, 0.25-11690.1% of Rheovis HS, 0.1-0.25% of defoaming agent, 536-50% of Omyacarb 536-50%, 10-25% of Sand 70-100mesh quartz Sand, 0.02-0.08% of starch ether, 0.15-0.5% of water-retaining agent, 0.25-0.25% of Rheovis HS 11520.1, 0.1-0.35% of preservative, 2-4.5% of early strength agent, 1.5-3.5% of epoxy resin, 0.1-0.25% of flatting agent and water. The adhesive is arranged in a packaging barrel, and the water-retaining agent is adopted, so that the phenomenon of layering or solidification when the adhesive is arranged in the packaging barrel can be avoided, the storage and transportation process is more convenient and stable, the adhesive can be used immediately after opening, and the adhesive can play a role in preventing the ceramic tiles or the stone from sliding and ensure that the ceramic tiles or the stone is more stable after being adhered by adopting the starch ether.

CN115011191A is directed to interface treatment coating, which contains water-based acrylic emulsion, water-based tackifying emulsion, water-based coupling agent, synthetic fiber, dispersing agent, wetting agent, flash rust resisting agent, defoaming agent, film forming auxiliary agent, antifreezing agent, preservative, thickening agent, thixotropic agent, coarse sand, pH buffering agent and water, wherein the mass solid content of the interface treatment coating is 40-80%. The interface treatment coating provided by the invention integrates chemical tackifying and physical tackifying, simultaneously forms a physically-increased rough interface while forming an interface base layer by chemical tackifying, firmly embeds synthetic fibers for mechanical embedding into the interface base layer formed by chemical tackifying, can obviously increase the interface bonding strength through multiple synergistic interaction, has the strength of more than or equal to 0.5MPa, and meets the requirements of practical application. Also has the effects of rust prevention, bulging prevention and falling off that can be widely applied to architectural coating, in particular to indoor coating.
EP3268326B1 teaches sealing slurry and flexible cementitious waterproofing membrane produced thereof.
JP2004136283A teaches method of forming permeable water absorption-preventing layer whereby PROBLEM TO BE SOLVED: is to obtain a method of forming a permeable water absorption-preventing layer using a permeable water absorption-preventing material which can simultaneously carry out formation of a water-repelling layer in the interior of a substrate and formation of a film on the surface of the substrate when coated on a cement-based substrate, prevents a cissing on an overlay-coating section when applied, offers excellent workability, and provide a fine appearance with excellent finishing characteristic.

SOLUTION: The method is constituted by applying the permeable water absorption-preventing composition containing 100 pts. wt. (in terms of solids) of an acrylic resin emulsion, 30-400 pts. wt. (in terms of solids) of a silane-base permeable and water absorption-preventing material and 5-50 pts. wt. of an organic solvent having a solubility parameter (SP value) of 8.5 or higher and a water solubility of 20 wt.% or higher.
CN103938656A teaches building wall surface underground waterproof construction method.
WO2012038099A1 is directed to flexible waterproof roof coatings based on on one or more mineral binders, one or more polymers, one or more fillers and, where appropriate, one or more additives for the production of roof coatings,
CA2841664C is directed to itaconic acid polymers for improved dirt and water resistance for elastomeric wall and roof coatings.
While flexible waterproof coatings are known and prevalent it is still a need in the art to provide for water based coating formulations that would not only solve the problems of waterproofing and efflorescence but would also enable crack bridging.
OBJECTS OF THE INVENTION
It is thus the basic object of the present invention to provide for multi-functional water-based waterproofing coating formulation that would favour multiple solution to the end customer for waterproofing of both interior and exterior surfaces and would also prevents or at least greatly reduce efflorescence on surfaces.
It is another object of the present invention to provide for said multi functional water based water proofing coating formulation that is cement free single component coating formulation which not only can be applied on moisture bearing surface but also would enable crack bridging ability of wider cracks.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention there is provided a multi-functional water-based waterproofing coating formulation comprising synergistically co-acting hydrophobic styrene-acrylic or acrylic or silane modified styrene-acrylic synthetic resin emulsion having Tg levels of -5 ?C to 30 ?C, hydrolysable silane or hydrolysable silane siloxane emulsion based osmotic water-absorbing material, select ratio of anti-efflorescence and pore blocking agents, adapted for highly stretchable emulsion based formulation with enhanced impact of waterproofing and efflorescence.
Preferably in said multi-functional water-based waterproofing coating formulation said formulation comprises 30-70% of highly hydrophobic styrene acrylic emulsion, 1-5% of hydrolysable long chain silane or hydrolysable silane-siloxane functionalized emulsion, pore blocking and anti-efflorescence additives in select ratio of pore blocking and anti efflorescence additives in the range from 1:4 to 4:1.
Preferably in said multi-functional water-based waterproofing coating formulation said formulation enables excellent waterproofing control over damp surface even when the moisture level of the surface is more than 50% with more than 4mm of crack bridging, 500-700% of elongation which not completely prevents or largely reduces the efflorescence but also possesses crack bridging ability.
According to another preferred aspect of the present invention there is provided a multi-functional water-based waterproofing coating formulation wherein the formulation/paint when applied on any concrete, cement mortar, bricks even at surface moisture level more than 50% for both exterior and interior surface of a building, with the paint/ coating enabling a tensile of 0.8-1.5 Mpa, Elongation of 300-700%, crack bridging ability 2.5-4.5 mm which can also withstand a minimum 6 bar positive and 4 bar negative water pressure.
Preferably in said multi-functional water-based waterproofing coating formulation is provided wherein said hydrolysable long chain silane or hydrolysable silane-siloxane functionalized emulsion are selected from Octyltrimethoxysilane, Octyltriethoxysilane, Dodecyltrichlorosilane, Dodecyltriethoxysilane, Hexadecyltriethoxysilane, octadecyltriethoxysilane, 8-Glycidoxyoctyltrimethoxysilane, 8-Glycidoxyoctyltriethoxysilane, octamethylcyclotetrasiloxane.
According to another preferred aspect of the present invention there is provided a multi-functional water-based waterproofing coating formulation wherein the anti-efflorescence control additives are selected from zinc stearate, calcium stearate, fatty acid, stearic acid salt, elotex era, a petroleum wax emulsion.
In a preferred aspect the multi-functional water-based waterproofing coating formulation is provided wherein said pore blocking agent includes Potassium sodium tartrate.
Advantageously the multi-functional water-based waterproofing coating formulation is provided wherein the doses of anti-efflorescence control additive are from 0.1-2% of total solid, wherein said formulation includes additional fiber, pigment and extenders, defoaming agents, thickening agents and wetting-dispersing additives that does not destroy the characteristics.
Preferably said multi-functional water-based waterproofing coating formulation is cement free single component water-based coating/ paint formulation that is highly stable having shelf life of 3 yrs as compared to cement based 2 component system having shelf life of 1.5-2 years.
According to another aspect of the present invention there is provided a process for manufacturing the multi-functional water-based waterproofing coating formulation comprising the steps of providing
hydrophobic styrene-acrylic or acrylic or silane modified styrene-acrylic synthetic resin emulsion having Tg levels of -5 ?C to 30 ?C,
hydrolysable silane or hydrolysable silane siloxane emulsion based osmotic water-absorbing material, and blending them in a treating the same in mill base followed by
adding said select ratio of anti-efflorescence and pore blocking agents and obtaining therefrom said water-based waterproofing coating formulation as a stable formulation.

DETAILED DESCRIPTION OF THE INVENTION
As discussed hereinbefore, the present invention provides for multi-functional water-based waterproofing coating formulation that provides a unique waterproofing solution which prevents or at least greatly reduces the efflorescence of hydraulically set systems; in particular those based on cement, bricks such as e.g. in mortars, and in the case of concrete even when the coating is applied on highly damp surfaces.
In order to overcome the defects of the prior art, the present invention provides a cement free single component water-based coating/ paint formulation which comprises of 30-70% of highly hydrophobic styrene acrylic emulsion (Acronal, Vinapass) with 1-5% of long chain silane or silane-siloxane functionalized emulsion with pore blocking and anti-efflorescence additives as critical ingredients.
In an embodiment of the present invention, the coating formulation of the present invention shows an excellent waterproofing control over damp surface even when the moisture level of the surface is more than 50% with more than 4mm of crack bridging, 500-700% of elongation which not completely prevents or largely reduces the efflorescence but also possesses crack bridging ability.
In some exemplary embodiments, the waterproofing paints for concrete surface withstand a minimum of 6 bar positive side water pressure and 4 bar of negative side water pressure.
After conducting intensive studies it is found by the present invention that by involving a formulation comprising highly hydrophobic styrene-acrylic or acrylic or silane modified styrene-acrylic synthetic resin emulsion, a silane or silane siloxane based osmotic water-absorbing material, and a specific anti-efflorescence and pore blocking agents in a specific ratio, waterproofing and efflorescence problems could be solved.
In the present invention it could be demonstrated for the first time the synergistic effect of silane or silane-siloxane functionalized emulsion with pore blocking and anti-efflorescence agent with highly stretchable emulsion to get the maximum impact of waterproofing effect even when applied on damp surface which thereby completely prevents or largely reduces the efflorescence for both exterior and interior surface.
The synergistic impact of pore blocking agent along with anti-efflorescence additives together with hydrolyzed silane or silane-siloxane functionalized polymers addresses the issue of efflorescence and damp surface applications on concrete or bricks as compared to the impact of pore blocking and anti-efflorescence additives taken individually.
That is, the method for forming a permeable water absorption preventing layer of the present invention has the following features:
The water based waterproofing coating formulation of the present invention provides for coatings, with excellent anti-efflorescence performance comprising a blend of highly hydrophobic styrene acrylic emulsion in combination and hydrolysable hydrophobic silane or silane-siloxane emulsion in water with synergistic co-action and effect from pore blocking and anti-efflorescence additives in addition with fiber, pigment and extenders, defoaming agents, thickening agents and wetting-dispersing additives.
The waterproofing anti-efflorescence paint/ coating formulation is provided where the paint comprises of 30-70% of highly hydrophobic styrene-acrylic or pure acrylic emulsion or silane functionalized styrene-acrylic emulsion and 1-5% of hydrolysable silane or silane-siloxane emulsion or combination thereof.
Said waterproofing anti-efflorescence paint/ coating formulation is provided where the hydrolysable silane-siloxane emulsion is either from Silrase BS 1306, Silres BS 1052, Silres BS 1042, Silres BS 1310¸ Silres BS 1316, Silres BS 1346 or combinations thereof
Preferably said waterproofing anti-efflorescence paint/ coating formulation is provided where the efflorescence control additives includes zinc stearate, calcium stearate, fatty acid, stearic acid salt, elotex era, petroleum wax emulsion.
Preferably said waterproofing anti-efflorescence paints/ coating formulation is provided where the doses of efflorescence control additive is from 0.1-2% of total solid.
More preferably in said waterproofing anti-efflorescence paint/ coating formulation the concrete pore blocking agent is specifically said Potassium sodium tartrate ranging from 0.1% to 2% of total solid.
Preferably said waterproofing anti-efflorescence paint/ coating formulation is provided where the Tg of styrene-acrylic or pure acrylic emulsion or silane functionalized styrene-acrylic emulsion is from -5 ?C to 30 ?C.
Preferably waterproofing anti-efflorescence paint/ coating formulation is provided wherein the pigment is specifically Titanium dioxide and extenders are from calcium carbonate, zinc sulfide, barium sulphate, marble powder or combination thereof, and wherein PVC of the paints is from 25-50.
Preferably said waterproofing anti-efflorescence paint/ coating formulation is provided wherein the defoamer is from 0.1-1.2%, wetting and dispersing agents from 0.2-1.2%, cellulosic thickener from 0.1-0.8%.
According to a preferred advantageous aspect of the present invention there is provided said waterproofing anti-efflorescence paint/ coating formulation wherein the paint can be applied on any concrete, cement mortar, bricks even at surface moisture level more than 50% for both exterior and interior surface of a building, with the paint/ coating showing a tensile of 0.8-1.5 Mpa, Elongation of 300-700%, crack bridging ability 2.5-4.5 mm which can also withstand a minimum 6 bar positive and 4 bar negative water pressure.
It is thus possible for the present invention to provide for highly flexible anti-efflorescence waterproofing paint/coating formulation as a single component cement free formulation that also possesses crack bridging ability.
EXAMPLES
TABLE: 1
Water proofing formulation wt%
Ingredients
WATER 12.2
Incan biocide 0.15
Defoamer 0.1
Dispersing agent 0.7
pH neutralizer 0.4
DIETHYLENE GLYCOL 0.5

TIO2 RUTILE R 902 PLUS 5
Extender 17
Thickener 0.2

WATER 1

Texanol 1
Biocide 1.5
Long chain Silane agent 0.4
Pore blocking agent 0.5
Anti-efflorescence additive 1.0
Panacea polyacrylonitrile fibres 0.4
Defoamer 0.3
Defoamer 0.15
Thickener 0.5
Silicon modified Sty-acrylic emulsion 55
WATER 2
100

With regard to the preparation of said water-based waterproofing coating formulation pore blocking agent and efflorescence additive needs to be added after completion of the mill base to provide for the appropriate stable formulation. Else exact impact and their synergistic co-action to improve enhanced impact of waterproofing and efflorescence could not be attained and nor the stability perspectives could be attained. Drastic variation in pore blocking agent and efflorescence additive has no immediate impact on tensile and elongation in a big way but gives very poor damp and efflorescence on after 2-3 months of actual wall applications.
Also the above formulation table of the present invention is workable based on all the variants of the ingredients mentioned in the present description in the select wt% ranges and the ratios stated.

TABLE: 2
Performance of the above coating formulations/ paints are given below as quantifiable attributes/characteristics of waterproofing and efflorescence as achieved by the invention qualifying examples against the standard method of measurement of such characteristics.
Sr. No. Parameters Test Method Present Formulation
1 Alkali Resistance ( in 8% solution) 150 micron WFT at glass plate No blister till 8-10h
2 Water Resistance (on glass plate) 150 micron WFT at glass plate No blister till 30 days
3 Tensile Strength (14 Days)
(Mpa) at RT ASTM D2370 1.25
5 % Elongation (14 Days) at RT ASTM D2370 650
6 14D Crack Bridging Ability AS/NZ 4548 3.6 mm
7 Negative side Water Resistance ASTM D 7088 Passes 5 Bars

> Elongation: 300-700% and tensile 0.8-1.5 Mpa (UTM machine)
> Positive side water pressure of 10 Bar and negative side water pressure of 5 Bar
> Efflorescence analysis through quantification of water soluble salts analysis through flame photometry and Spectroscopy was done.
> Dampness was characterized by moisture meter.
With regard to the comparatives, it was found by way of the present invention that for long term durability and crack bridging performance elongation from 300-700 and tensile 0.8-1.5 Mpa is best, if elongation increases to more than 1000% then the coating formulation will not work for interior waterproofing while again if tensile increases to more than 2 Mpa and elongation less than 300% exterior performance will not come, which all are governed by the select ratio of pore blocking agent and efflorescence additive that is surprisingly found to be very critical to get long term anti efflorescence performance, and only presence of efflorescence additive or pore blocking agent does not solve the problem.
According to an embodiment of the present invention the co-acting hydrophobic emulsion includes Styrene, MMA, Butyl acrylate, 2-Hydroxyethylacrylate, Ethyl hexyl acrylate, t-Butyl methacrylate, VTMO, VTEO, acrylamodopropyl triethoxy silane.
According to an embodiment of the present invention the hydrolysable silane or hydrolysable silane siloxane emulsion Octyltrimethoxysilane, Octyltriethoxysilane, Dodecyltrichlorosilane, Dodecyltriethoxysilane, Hexadecyltriethoxysilane, octadecyltriethoxysilane, 8-Glycidoxyoctyltrimethoxysilane, 8-Glycidoxyoctyltriethoxysilane, octamethylcyclotetrasiloxane.
It is thus possible for the Applicants present advancement to provide for simple water based paint/coating formulation that is cement free and stable providing for excellent properties towards wet surface adhesion, tensile and elongation and efflorescence resistance performance- where the said paint is highly stable and have shelf life of 3 yrs as compared to cement based 2 component system having shelf life of 1.5-2 years.
,CLAIMS:We Claim:

1. A multi-functional water-based waterproofing coating formulation comprising synergistically co-acting hydrophobic styrene-acrylic or acrylic or silane modified styrene-acrylic synthetic resin emulsion having Tg levels of -5 ?C to 30 ?C, hydrolysable silane or hydrolysable silane siloxane emulsion based osmotic water-absorbing material, select ratio of anti-efflorescence and pore blocking agents, adapted for highly stretchable emulsion based formulation with enhanced impact of waterproofing and efflorescence.

2. The multi-functional water-based waterproofing coating formulation as claimed in claim 1 wherein said formulation comprises 30-70% of highly hydrophobic styrene acrylic emulsion, 1-5% of hydrolysable long chain silane or hydrolysable silane-siloxane functionalized emulsion, pore blocking and anti-efflorescence additives in select ratio of pore blocking and anti efflorescence additives in the range from 1:4 to 4:1.

3. The multi-functional water-based waterproofing coating formulation as claimed in claims 1 or 2 wherein said formulation enables excellent waterproofing control over damp surface even when the moisture level of the surface is more than 50% with more than 4 mm of crack bridging, 500-700% of elongation which not completely prevents or largely reduces the efflorescence but also possesses crack bridging ability.

4. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-3 wherein the formulation/paint when applied on any concrete, cement mortar, bricks even at surface moisture level more than 50% for both exterior and interior surface of a building, with the paint/ coating enabling a tensile of 0.8-1.5 Mpa, Elongation of 300-700%, crack bridging ability 2.5-4.5 mm which can also withstand a minimum 6 bar positive and 4 bar negative water pressure.

5. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-4 wherein said hydrolysable long chain silane or hydrolysable silane-siloxane functionalized emulsion are selected from Octyltrimethoxysilane, Octyltriethoxysilane, Dodecyltrichlorosilane, Dodecyltriethoxysilane, Hexadecyltriethoxysilane, octadecyltriethoxysilane, 8-Glycidoxyoctyltrimethoxysilane, 8-Glycidoxyoctyltriethoxysilane, octamethylcyclotetrasiloxane.

6. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-5 wherein the anti-efflorescence control additives are selected from zinc stearate, calcium stearate, fatty acid, stearic acid salt, elotex era, a petroleum wax emulsion.

7. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-6 wherein said pore blocking agent includes Potassium sodium tartrate.

8. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-7 wherein the doses of anti-efflorescence control additive are from 0.1-2% of total solid, wherein said formulation includes additional fiber, pigment and extenders, defoaming agents, thickening agents and wetting-dispersing additives that does not destroy the characteristics.
9. The multi-functional water-based waterproofing coating formulation as claimed in claims 1-8 that is cement free single component water-based coating/ paint formulation that is highly stable having shelf life of 3 yrs as compared to cement based 2 component system having shelf life of 1.5-2 years.

10. A process for manufacturing the multi-functional water-based waterproofing coating formulation as claimed in claim 1-9 comprising the steps of providing
hydrophobic styrene-acrylic or acrylic or silane modified styrene-acrylic synthetic resin emulsion having Tg levels of -5 ?C to 30 ?C,
hydrolysable silane or hydrolysable silane siloxane emulsion based osmotic water-absorbing material, and blending them in a treating the same in mill base followed by
adding said select ratio of anti-efflorescence and pore blocking agents and obtaining therefrom said water-based waterproofing coating formulation as a stable formulation.

Dated this the 14th day of December, 2023 Anjan Sen
Of Anjan Sen and Associates
(Applicants Agent & Advocate)
IN/PA-199