DESC:FIELD
The present disclosure relates to a matt coating composition and a process for its preparation. Particularly, the present disclosure relates to an ultraviolet curable coating composition, that provides a matt effect upon curing.
DEFINITIONS
As used in the present disclosure, the following term is generally intended to have the meaning as set forth below, except to the extent that the context in which it is used indicate otherwise.
Photoinitiator: The term “photoinitiator” refers to a molecule that creates reactive species (free radicals, cations or anions) when exposed to radiation (UV or visible).
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Recently, a radiation curing technology has taken over the conventional thermal curing. The advantages due to the radiation curing technology are that the coating is observed at a faster rate with increased energy saving and reduced cost. The radiation curing is based on the use of functional oligomers and monomers along with photoinitiators to carry out the polymerization in the presence of ultraviolet (UV) light. On exposure to UV light, a cross-linked polymer network of a hard film with a smooth and glossy surface is produced. The growing usage of radiation cured coatings in different applications necessitates the ability to control the level of gloss and also reduce the level of gloss produced.
Currently, matt surfaces are preferred for elegant appearances and aesthetics, and further for hiding imperfections on the surface. The outstanding optical effects produced by the matt surfaces have made them more desirable than glossy surfaces. The matt finishes are produced by adding matting agents to the clear lacquers. The matting agents used are organic matting agents, based on waxes, or different types of inorganic matting agents, based on silicates, fumed silica, precipitated silica, or silica gel. These matting agents may also be surface-modified by using various organic components, such as hard, microcrystalline waxes, plastifying microcrystalline waxes and/or polyethylene waxes, and/or inorganic components, such as polysiloxane.
Conventionally, to achieve the acceptable degree of matt effect, a considerable concentration of silica is added to the clear lacquer. These high levels of silica subsequently resulted in the rheological changes in the lacquer which jeopardized the performance properties of the cured film. It also impaired the optical properties of the cured film by leading to the blushing defect after 2 to 3 days. Moreover, the processing of these lacquers containing high amounts of silica possesses the disadvantage of sedimentation of matt components, resulting in the increased gloss level and poor adhesion to the coated layers.
Therefore, there is felt a need for a matt coating composition that can mitigate 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.
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 matt coating composition.
Still another object of the present disclosure is to provide an ultraviolet curable coating composition, that provides a matt effect upon curing.
Yet another object of the present disclosure is to provide a clear matt coating composition that can be cured by using UV light on a substrate.
Another object of the present disclosure is to provide a matt coating composition that can be applied on a plastic substrate as well as a coated/colored substrate.
Yet another object of the present disclosure is to provide a process for the preparation of a matt 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 matt coating composition and a process for its preparation.
The matt coating composition comprises at least one monomer in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition, at least one oligomer in an amount in the range of 40 mass% to 60 mass% with respect to the total mass of the composition, at least one matting agent in an amount in the range of 8 mass% to 15 mass% with respect to the total mass of the composition, at least one photoinitiator in an amount in the range of 2 mass% to 4 mass% with respect to the total mass of the composition and at least one additive in an amount in the range of 0.5 mass% to 10 mass% with respect to the total mass of the composition.
The process for the preparation of the matt coating composition comprises the step of mixing a predetermined amount of at least one oligomer and a predetermined amount of at least one monomer under stirring for a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first mixture. A predetermined amount of at least one additive is added into the first mixture for a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second mixture. A predetermined amount of at least one matting agent is added into the second mixture for a third predetermined speed at a third predetermined temperature for a third predetermined time period to obtain a third mixture. A predetermined amount of at least one photoinitiator is added into the third mixture for a fourth predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain the matt coating 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.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Conventionally, to achieve the acceptable degree of matt effect, a considerable concentration of silica is added to the clear lacquer. These high levels of silica subsequently resulted in the rheological changes in the lacquer which jeopardized the performance properties of the cured film. It also impaired the optical properties of the cured film by leading to the blushing defect after 2 to 3 days. Moreover, the processing of these lacquers containing high amounts of silica possesses the disadvantage of sedimentation of matt components, resulting in the increased gloss level and poor adhesion to the coated layers.
The present disclosure provides a matt coating composition and a process for its preparation. Particularly, the present disclosure relates to an ultraviolet curable coating composition that provides a matt effect upon curing.
In an aspect, the present disclosure disclosure provides a matt coating composition.
The matt coating composition comprises at least one monomer in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition, at least one oligomer in an amount in the range of 40 mass% to 60 mass% with respect to the total mass of the composition, at least one matting agent in an amount in the range of 8 mass% to 15 mass% with respect to the total mass of the composition, at least one photoinitiator in an amount in the range of 2 mass% to 4 mass% with respect to the total mass of the composition and at least one additive in an amount in the range of 0.5 mass% to 10 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the monomer is at least one selected from the group consisting of monofunctional monomer, difunctional monomer, and trifunctional monomer.
In accordance with an embodiment of the present disclosure, the monofunctional monomer is at least one selected from the group consisting of isobornyl acrylate (IBOA), isobornyl methacrylate (IBOMA), tetrahydrofurfuryl acrylate (THFA), and tetrahydrofurfuryl methacrylate (THFMA). In an exemplary embodiment, the monofunctional monomer is isobornyl acrylate (IBOA).
In accordance with an embodiment of the present disclosure, the monofunctional monomer is present in an amount in the range of 5 mass% to 15 mass% with respect to the total mass of the composition. In an exemplary embodiment, the monofunctional monomer is present in an amount of 8 mass%.
In accordance with an embodiment of the present disclosure, the difunctional monomer is at least one selected from the group consisting of 1,6 hexanediol diacrylate (HDDA), ethylene glycol dimethacrylate (EGDMA), and diethylene glycol dimethacrylate (DEGDMA). In an exemplary embodiment, the difunctional monomer is 1,6 hexanediol diacrylate (HDDA).
In accordance with an embodiment of the present disclosure, the difunctional monomer is present in an amount in the range of 10 mass% to 40 mass% with respect to the total mass of the composition. In an exemplary embodiment, the difunctional monomer is present in an amount of 15 mass%.
In accordance with an embodiment of the present disclosure, the trifunctional monomer is at least one selected from the group consisting of trimethylolpropane triacrylate (TMPTA), tris(2-hydroxyethyl) isocyanurate triacrylate (THEICTA), pentaerythritol triacrylate (PETA), trimethylolpropane trimethacrylate (TMPTMA), and ditrimethylolpropane tetraacrylate (DiTMP). In an exemplary embodiment, the trifunctional monomer is trimethylolpropane triacrylate (TMPTA).
In accordance with an embodiment of the present disclosure, the trifunctional monomer is in an amount in the range of 0.5 mass% to 4 mass% with respect to the total mass of the composition. In an exemplary embodiment, the trifunctional monomer is present in an amount of 2 mass%.
In accordance with an embodiment of the present disclosure, the oligomer is at least one selected from the group consisting of epoxy acrylate, epoxy diacrylate, modified epoxy acrylate, epoxy methacrylate, polyester acrylate, acrylated amine and epoxidised soyabean oil acrylate. In an exemplary embodiment, the oligomer is polyester acrylate.
The specific oligomers are used for property enhancement of the composition. The special oligomers with amine functional groups are used for enhancement of the properties such as adhesion to substrates as well as better reactivity. They also act as coinitiators to promote the film forming reaction.
In accordance with an embodiment of the present disclosure, the matting agent is at least one selected from the group consisting of amorphous silica, precipitated silica and wax-treated silica. In an exemplary embodiment, the matting agent is precipitated silica. The precipitated silica is an amorphous form of silica and appears as white, and powdery material. Silica coated with polyethylene wax imparts scratch resistance.
In accordance with an embodiment of the present disclosure, the particle size of the matting agent is in the range of 4 µm to 8 µm. In an exemplary embodiment, the particle size of the matting agent is 5 µm.
The matt coating composition of the present disclosure is prepared by utilizing a specific matting agent that provides advantages over currently available conventional photo curable matt coating composition, such as the matt coating composition of the present disclosure has a gloss value in the range of 2 to 10 at 60°, excellent dispersion stability during aging, excellent adhesion over ABS substrate, and excellent overcoat adhesion.
In accordance with an embodiment of the present disclosure, the photoinitiator is at least one selected from the group consisting of phenylketone based initiator and phosphineoxide based initiator.
In accordance with an embodiment of the present disclosure, the phosphineoxide based initiator is at least one selected from the group consisting of bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenyl phosphine oxide and the phenylketone based initiator is at least one selected from the group consisting of 2, 2-dimethoxy-1, 2diphenyletan-1-one, benzophenone, hydroxy cyclo hexyl phenyl ketone, and phenyl benzophenone. In an exemplary embodiment, the phosphineoxide based photoinitiator is bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide. In another exemplary embodiment, the phenylketone based photoinitiator is hydroxy cyclo hexyl phenyl ketone.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a wetting and dispersing agent, a flow and leveling agent, a mar resistance agent, a substrate wetting agent, and an anti-foaming agent.
In accordance with an embodiment of the present disclosure, the wetting and dispersing agent is at least one selected from the group consisting of block copolymer with pigment affinic groups (Disper BYK 160), high molecular weight block copolymer with pigment affinic groups (Disper BYK 163), unsaturated polyamide and acid ester salts (EFKA 5044), high molecular weight modified polyurethane in butylacetate/methoxypropylacetate/xylene (EFKA 4060), modified polyacrylate (EFKA 4400), and salt of unsaturated polyamine amides and low-molecular acidic polyesters (Anti-Terra U). In an exemplary embodiment, the wetting and dispersing agent is low-molecular acidic polyesters (Anti-Terra U). The matting agent is difficult to wet, hence dispersing agent is required for wetting. The matting agent imparts the thixotropic property to the liquid lacquer hindering the proper dispersion of the matting agent, therefore the wetting and dispersing agent is used for the better wetting and dispersion of the matting agent.
In accordance with an embodiment of the present disclosure, the flow and leveling agent is at least one selected from the group consisting of polyether-modified polydimethylsiloxane (BYK 333, BYK 306), solution of a polyacrylate (BYK 354, BYK 358N), acrylic polymer (Resiflow LT) and silicone-free surface active polymer (BYK 399). In an exemplary embodiment, the flow and leveling agent is a solution of a polyacrylate (BYK 354, BYK 358N). In another exemplary embodiment, the flow and leveling agent is a silicone-free surface active polymer (BYK 399).
In accordance with an embodiment of the present disclosure, the mar resistance agent is selected from polyether-modified polydimethylsiloxane (BYK 333), and a solution of a polyether-modified polydimethylsiloxane (BYK 306). In an exemplary embodiment, the mar resistance agent is a polyether-modified polydimethylsiloxane (BYK 333). In another exemplary embodiment, the mar resistance agent is a solution of a polyether-modified polydimethylsiloxane (BYK 306).
In accordance with an embodiment of the present disclosure, the substrate wetting agent is selected from polyether-modified polydimethylsiloxane (BYK 306), solution of a polyacrylate (BYK 358 N), and silicone-free surface active polymer (BYK 399). In an exemplary embodiment, the substrate wetting agent is a polyether-modified polydimethylsiloxane (BYK 306). In another exemplary embodiment, the substrate wetting agent is a silicone-free surface active polymer (BYK 399). The substrate wetting agent decreases the surface tension of the substrate to be coated for better adhesion.
In accordance with an embodiment of the present disclosure, the anti-foaming agent is at least one selected from the group consisting of silicone-free foam-destroying polymers (BYK 052), a solution of foam-destroying polysiloxane (BYK 020), and acrylic polymer (OX-60, OX-70). In an exemplary embodiment, the anti-foaming agent is a silicone-free foam-destroying polymers (BYK 052). In another exemplary embodiment, the anti-foaming agent is a solution of foam-destroying polysiloxane (BYK 020).
The additives are added to give specific characteristics of performance enhancement such as inter-coat adhesion, substrate wetting, flow and leveling, and the like. The antifoaming additives are used to reduce or avoid air entrapment as air bubbles are generated during spray application, stirring, and curing which may lead to the film defect.
The coating composition of the present disclosure provides a clear matt coating on curing by using UV light on the substrate.
In accordance with an embodiment of the present disclosure, the substrate is at least one selected from the group consisting of Acrylonitrile-Butadiene-Styrene (ABS), polybutylene terephthalate, polypropylene, and polycarbonate. In an exemplary embodiment, the substrate is Acrylonitrile-Butadiene-Styrene (ABS). In another exemplary embodiment, the substrate is polypropylene.
In accordance with an embodiment of the present disclosure, the composition is characterized by having a gloss value in the range of 2 to 10 at 60°.
In accordance with an embodiment of the present disclosure, a mass ratio of the matting agent to the oligomer is in the range of 1:3 to 1:8. In an exemplary embodiment, the mass ratio of the matting agent to the oligomer is 1:4.
In accordance with an embodiment of the present disclosure, a mass ratio of the matting agent to the monomer is in the range of 1:1.5 to 1:5. In an exemplary embodiment, the mass ratio of the matting agent to the monomer is 1:3.
The matt coating composition can be further customized to obtain the matting effect over already coated colored substrates. The matt coating of the present disclosure provides excellent adhesion over the colored coated surface with the gloss values below 20 at 60°.
In another aspect, the present disclosure provides a process for the preparation of the matt coating composition. The process for the preparation of the matt coating composition is simple and economical.
The process is described in detail as given below:
In a first step, a predetermined amount of at least one oligomer and a predetermined amount of at least one monomer are mixed under stirring for a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first mixture.
In accordance with an embodiment of the present disclosure, the oligomer is at least one selected from the group consisting of epoxy acrylate, epoxy diacrylate, modified epoxy acrylate, epoxy methacrylate, polyester acrylate, acrylated amine and epoxidised soyabean oil acrylate. In an exemplary embodiment, the oligomer is polyester acrylate.
In accordance with an embodiment of the present disclosure, the predetermined amount of the oligomer is in the range of 40 mass% to 60 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the monomer is at least one selected from the group consisting of monofunctional monomer, difunctional monomer, and trifunctional monomer.
In accordance with an embodiment of the present disclosure, the predetermined amount of the monomer is in the range of 20 mass% to 40 mass% with respect to the total mass of the composition.

In accordance with an embodiment of the present disclosure, the monofunctional monomer is at least one selected from the group consisting of isobornyl acrylate (IBOA), isobornyl methacrylate (IBOMA), tetrahydrofurfuryl acrylate (THFA), and tetrahydrofurfuryl methacrylate (THFMA)). In an exemplary embodiment, the monofunctional monomer is isobornyl acrylate (IBOA).
In accordance with an embodiment of the present disclosure, the difunctional monomer is at least one selected from the group consisting of 1,6 hexanediol diacrylate (HDDA), ethylene glycol dimethacrylate (EGDMA), and diethylene glycol dimethacrylate (DEGDMA). In an exemplary embodiment, the difunctional monomer is 1,6 hexanediol diacrylate (HDDA).
In accordance with an embodiment of the present disclosure, the trifunctional monomer is at least one selected from the group consisting of trimethylolpropane triacrylate (TMPTA), tris(2-hydroxyethyl) isocyanurate triacrylate (THEICTA), pentaerythritol triacrylate (PETA), trimethylolpropane trimethacrylate (TMPTMA), and ditrimethylolpropane tetraacrylate (DiTMP). In an exemplary embodiment, the trifunctional monomer is trimethylolpropane triacrylate (TMPTA).
In accordance with an embodiment of the present disclosure, the first predetermined speed is in the range of 600 rpm to 900 rpm. In an exemplary embodiment, the first predetermined speed is 700 rpm.
In accordance with an embodiment of the present disclosure, the first predetermined temperature is in the range of 25 °C to 40 °C. In an exemplary embodiment, the first predetermined temperature is 30 °C.
In accordance with an embodiment of the present disclosure, the first predetermined time period is in the range of 30 minutes to 60 minutes. In an exemplary embodiment, the first predetermined time period is 40 minutes.
In a second step, a predetermined amount of at least one additive is added into the first mixture for a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second mixture.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a wetting and dispersing agent, flow and leveling agent, mar resistance agent, substrate wetting agent and anti-foaming agent.
In accordance with an embodiment of the present disclosure, the predetermined amount of the additive is in the range of 0.5 mass% to 10 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the second predetermined speed is in the range of 600 rpm to 900 rpm. In an exemplary embodiment, the second predetermined speed is 800 rpm.
In accordance with an embodiment of the present disclosure, the second predetermined temperature is in the range of 25 °C to 40 °C. In an exemplary embodiment, the second predetermined temperature is 30 °C.
In accordance with an embodiment of the present disclosure, the second predetermined time period is in the range of 30 minutes to 60 minutes. In an exemplary embodiment, the second predetermined time period is 40 minutes.
In a third step, a predetermined amount of at least one matting agent is added into the second mixture for a third predetermined speed at a third predetermined temperature for a third predetermined time period to obtain a third mixture.
In accordance with an embodiment of the present disclosure, the matting agent is at least one selected from the group consisting of amorphous silica, precipitated silica, and wax-treated silica. In an exemplary embodiment, the matting agent is precipitated silica.
In accordance with an embodiment of the present disclosure, the predetermined amount of the matting agent is in the range of 8 mass% to 15 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the third predetermined speed is in the range of 600 rpm to 900 rpm. In an exemplary embodiment, the third predetermined speed is 700 rpm.
In accordance with an embodiment of the present disclosure, the third predetermined temperature is in the range of 25 °C to 40 °C. In an exemplary embodiment, the third predetermined temperature is 30 °C.
In accordance with an embodiment of the present disclosure, the third predetermined time period is in the range of 20 minutes to 60 minutes. In an exemplary embodiment, the third predetermined time period is 30 minutes.
In a fourth step, a predetermined amount of at least one photoinitiator is added into the third mixture for a fourth predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain the matt coating composition.
In accordance with an embodiment of the present disclosure, the photoinitiator is at least one selected from the group consisting of phenylketone based initiator and phosphineoxide based initiator.
In accordance with an embodiment of the present disclosure, the phosphineoxide based initiator is at least one selected from the group consisting of bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenyl phosphine oxide.
In accordance with an embodiment of the present disclosure, the phenylketone based initiator is at least one selected from the group consisting of 2,2-dimethoxy-1,2diphenyletan-1-one, benzophenone, hydroxy cyclo hexyl phenyl ketone, and phenyl benzophenone. In an exemplary embodiment, the phenylketone based photoinitiator is hydroxy cyclo hexyl phenyl ketone.
In accordance with an embodiment of the present disclosure, the predetermined amount of the photoinitiator is in the range of 2 mass% to 4 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the fourth predetermined speed is in the range of 600 rpm to 900 rpm. In an exemplary embodiment, the fourth predetermined speed is 700 rpm.
In accordance with an embodiment of the present disclosure, the fourth predetermined temperature is in the range of 25 °C to 40 °C. In an exemplary embodiment, the fourth predetermined temperature is 30 °C.
In accordance with an embodiment of the present disclosure, the fourth predetermined time period is in the range of 30 minutes to 60 minutes. In an exemplary embodiment, the fourth predetermined time period is 40 minutes.
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: A process for the preparation of a matt coating composition in accordance with the present disclosure
43.92 gm of epoxy diacrylate (oligomer), 8.79 gm of acrylated amine (oligomer), 4.61 gm of 1,6 Hexanediol diacrylate (HDDA) (difunctional monomer), and 7.03 gm of isobornyl acrylate (IBOA) (monofunctional monomer) were mixed under stirring at 700 rpm at 30 °C for 40 minutes to obtain a first mixture. Then, 1.01 gm of low-molecular acidic polyesters (Anti-Terra U) (wetting and dispersing agent), 1.76 gm of a solution of a polyacrylate (BYK 354, BYK 358N) (flow and leveling agent), 1.40 gm of a polyether-modified polydimethylsiloxane (BYK 333) (mar resistance additive), 0.89 gm of a polyether-modified polydimethylsiloxane (BYK 306) (substrate wetting agent), 0.89 gm of a silicone-free foam-destroying polymers (BYK 052) (anti-foaming agent) were added into the first mixture under stirring at 800 rpm at 30 °C for 40 minutes to obtain a second mixture. Thereafter, 9.16 gm of Syloid R 2105 (precipitated silica) (matting agent) was added into the second mixture under stirring for 700 rpm at 30 °C for 30 minutes to obtain a third mixture. Finally, 3.52 gm of hydroxy cyclo hexyl phenyl ketone (photoinitiator) was added into the third mixture under stirring for 700 rpm at 30 °C for 40 minutes to obtain the matt coating composition.
Experiment 2-12: Matt coating composition in accordance with the present disclosure
The same experimental process was followed for preparing the matt coating composition as disclosed in experiment 1, except the amount used is as mentioned in Table 1.
Comparative Experiment 1-2: Matt coating composition
The same experimental process was followed for preparing the matt coating composition as disclosed in experiment 1, except the amount used is as mentioned in Table 1.
UV Matt Performance Testing
UV matt performance testing was carried out on ABS substrates. ABS substrate were coated with matt coating and exposed to UV radiation from UV lamp source. The cured ABS substrates were tested for its various performance tests.

Table 1: Matt coating composition and UV Matt Performance Testing

Raw materials Expt 1 Expt 2 Expt 3 Expt 4 Expt 5 Expt 6 Expt 7 Expt 8 Expt 9 Expt 10 Expt 11
Expt 12
Comparative Expt 1
Comparative Expt 2

Monomers
Difunctional Monomer 24.61 35.16 35.33 35.28 35.31 35.31 35.05 34.72 30.65 24.65 31.87 15.04 0 4.13
Monofunctional Monomer 7.03 2.25 2.3 2.29 1.77 1.77 1.75 2.22 6.52 12.26 7.97 6.82 45.53 14.46
Trifunctional Monomer 0 0 0 0 0 0 0 0 0 0 0 1.05 0 2.07
Oligomers
Epoxy Diacrylate 43.92 40.54 40.63 40.58 40.61 40.61 40.31 40.03 34.69 29.2 17.43 25.04 20.47 20.83
Polyester Acrylate 0 0 0 0 0 0 0 0 6.6 11.58 17.43 25.04 20.47 41.64
Acrylated Amine 8.79 2.81 2.83 2.82 2.83 2.83 2.8 2.78 2.27 2.77 7.97 9.01 0 6.51
Photoinitiator
Phenylketone Based Initiator 3.52 3.52 3.53 3.53 3.53 3.53 3.51 3.47 3.47 3.47 2.12 2.94 3.85 3.17
Phosphineoxide Based Initiator 0 0 0 0 0 0 0 0 0 0 1.1 0.88 0 0

Matting Agent
Matting Agent 1 (Fine Particle Size) 9.16 12.8 12.9 13.23 13.24 13.26 13.67 13.89 14.1 14.74 0 0 0 0
Matting Agent 2 (Medium Particle Size) 0 0 0 0 0 0 0 0 0 0 13.12 13.19 6.5 6.19
Additives
Wetting and dispersing agent 1.01 0.88 0.44 0.22 0.66 0.66 0.88 0.87 0.22 0 0 0 0 0
Flow and leveling agent 1.76 0.44 0.44 0.44 0.44 0.44 0.44 0.43 0.44 0.44 0.05 0.17 1.02 0
Mar resistance additive 1.4 1.41 1.41 1.41 1.41 1.41 1.4 1.39 0.85 0.71 0.85 0.7 2.05 0.97
Substrate Wetting Agent 0.89 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.01 0.07 0.06 0.02
Anti-foaming agent 0.89 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.08 0.06 0.05 0.01
Total
100 100 100 100 100
100 100 100 100 100 100 100 100 100

UV Matt Performance Testing
Film Appearance Matt Matt Matt Matt Matt Matt Matt Matt Matt Matt Matt Matt Matt Matt
Gloss Value @ 60° 10 7 6.63 6.17 6.12 6 6.1 5.9 5.5 3.03 5.4 5.2 16.2 15.8
Adhesion
(1mm X 1mm) Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass
Finish Smooth Smooh Smooh Smooh slight haze Smooth slight haze Smooth slight haze Smooth slight haze Not smooth orange peel Not smooth orange peel Not smooth orange peel Smooh Smooth Smooth Smooth
Viscosity by F/ C NO. 4 @ 30°C after thinning 13 Sec 15 Sec 14 Sec 14 Sec 14 Sec 14 Sec 14 Sec 14 Sec 13 Sec 14 Sec 14 Sec 14 Sec 13 Sec 13 Sec
Mar Proofness Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark Nail Mark No No No No
Polishing No No No No No No No No No No No No No No

From Table 1, it is evident that, the matt coating composition having a gloss value in the range of 2 to 10 at 60° exhibited excellent dispersion stability during aging, excellent adhesion over ABS substrate, and excellent overcoat adhesion. Further, the matt coating composition of the present disclosure exhibited excellent mar proofness. The step of polishing is not required while coating the matt coating composition of the present disclosure on the substrate due to the properties such as efficient, cost effective and environment friendly thereby providing desired matt finish to the substrate.
Table 2: Product specification which is based on experiments 1 to 12 as mentioned in Table 1
Physical Parameters
Appearance Clear liquid
Viscosity by F/ C NO. 4 @ 30°C after thinning 14 ± 2 Sec
UV Instrument Specification
UV Lamp Power 120 (Watt/cm)
UV Lamp Energy 1.1 to 1.3 (J/CM2) OR 1.1 to 1.3 (W/CM2)
Conveyer Belt Speed 4.5- 5.0 m/min
Final Film Properties
DFT (micron) 10 to 15 microns
Finish Matt & Smooth
Gloss @ 60° Less than 10
Cross Cut Adhesion Test (1mmX1mm) Pass
Application Details
Substrates ABS, PC, PBT
Application Method Conventional Spraying
Curing Mechanism Exposure to UV Light
Application Viscosity Sprayable
Flash-off Time 90 Seconds
Recommended Thinner Alcohol based, Acetate based, Aromatic hydrocarbon,
high boiling aromatic hydrocarbon solvents (Approx. 40%)
Surface Preparation Surface should be free from oily matter, moisture, dust
Application Method i. Clean and dry Wipe substrate with alcohol based
solvent
ii. Apply UV Clear Matt Lacquer
iii. Flash off at 60ºc for 90 seconds
iv. UV Curing
v. Testing

*ABS-Acrylonitrile-Butadiene-Styrene, *PC- polycarbonate, and *PBT-polybutylene terephthalate
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a matt coating composition that has:
• a gloss value in the range of 2 to 10 at 60°;
• excellent dispersion stability during aging;
• excellent adhesion over ABS substrate;
• excellent overcoat adhesion;
• a clear matt coating on curing by using UV light on the substrate; and
• a clear coating composition containing a grade of matting agent that provides matt coating to the substrate.
and
A process for preparing the matt coating composition:
• is simple and economical
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.
One of the objects of the Patent Law is to provide protection to new technologies in all fields and domain of technologies. The new technologies shall or may contribute in the country economy growth by way of involvement of new efficient and quality method or product manufacturing in India.
To provide the protection of new technologies by patenting the product or process will contribute significant for innovation development in the country. Further by granting patent the patentee can contribute in manufacturing the new product or
new process of manufacturing by himself or by technology collaboration or through the licensing.
The applicant submits that the present disclosure will contribute in country economy, which is one of the purposes to enact the Patents Act, 1970. The product in accordance with present invention will be in great demand in country and worldwide due to novel technical features of a present invention is a technical advancement in the matt coating composition. The technology in accordance with present disclosure will provide product cheaper, saving in time of total process of manufacturing. The saving in production time will improve the productivity, and cost cutting of the product, which will directly contribute to economy of the country.
The product will contribute new concept in the matt coating composition wherein patented process/product will be used. The present disclosure will replace the whole concept of matt coating compositions being used in this area from decades. The product is developed in the national interest and will contribute to country economy.
The economy significance details requirement may be called during the examination. Only after filing of this Patent application, the applicant can work publically related to present disclosure product/process/method. The applicant will disclose all the details related to the economic significance contribution after the protection of invention.
,CLAIMS:WE CLAIM:
1. A matt coating composition comprises:
a. at least one monomer in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition;
b. at least one oligomer in an amount in the range of 40 mass% to 60 mass% with respect to the total mass of the composition;
c. at least one matting agent in an amount in the range of 8 mass% to 15 mass% with respect to the total mass of the composition;
d. at least one photoinitiator in an amount in the range of 2 mass% to 4 mass% with respect to the total mass of the composition; and
e. at least one additive in an amount in the range of 0.5 mass% to 10 mass% with respect to the total mass of the composition.
2. The composition as claimed in claim 1, wherein said monomer is at least one selected from the group consisting of monofunctional monomer, difunctional monomer, and trifunctional monomer.
3. The composition as claimed in claim 2, wherein said monofunctional monomer is at least one selected from the group consisting of isobornyl acrylate (IBOA), isobornyl methacrylate (IBOMA), tetrahydrofurfuryl acrylate (THFA), and tetrahydrofurfuryl methacrylate (THFMA).
4. The composition as claimed in claim 2, wherein said monofunctional monomer is present in an amount in the range of 1 mass% to 15 mass% with respect to the total mass of the composition.
5. The composition as claimed in claim 2, wherein said difunctional monomer is at least one selected from the group consisting of 1,6 hexanediol diacrylate (HDDA), ethylene glycol dimethacrylate (EGDMA), and diethylene glycol dimethacrylate (DEGDMA).
6. The composition as claimed in claim 2, wherein said difunctional monomer is present in an amount in the range of 10 mass% to 40 mass% with respect to the total mass of the composition.
7. The composition as claimed in claim 2, wherein said trifunctional monomer is at least one selected from the group consisting of trimethylolpropane triacrylate (TMPTA), tris(2-hydroxyethyl) isocyanurate triacrylate (THEICTA), pentaerythritol triacrylate (PETA), trimethylolpropane trimethacrylate (TMPTMA), and ditrimethylolpropane tetraacrylate (DiTMP).
8. The composition as claimed in claim 2, wherein said trifunctional monomer is present in an amount in the range of 0.5 mass% to 2 mass% with respect to the total mass of the composition.
9. The composition as claimed in claim 1, wherein said oligomer is at least one selected from the group consisting of epoxy acrylate, epoxy diacrylate, modified epoxy acrylate, epoxy methacrylate, polyester acrylate, acrylated amine and epoxidised soyabean oil acrylate.
10. The composition as claimed in claim 1, wherein said matting agent is at least one selected from the group consisting of amorphous silica, precipitated silica, and wax treated silica.
11. The composition as claimed in claim 1, wherein a particle size of said matting agent is in the range of 4 µm to 8 µm.
12. The composition as claimed in claim 1, wherein said photoinitiator is at least one selected from the group consisting of phenylketone based initiator and phosphineoxide based initiator.
13. The composition as claimed in claim 12, wherein said phosphineoxide based initiator is at least one selected from the group consisting of bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenyl phosphine oxide; and said phenylketone based initiator is at least one selected from the group consisting of 2,2-dimethoxy-1,2diphenyletan-1-one, benzophenone, hydroxy cyclo hexyl phenyl ketone, and phenyl benzophenone.
14. The composition as claimed in claim 1, wherein said additive is at least one selected from the group consisting of a wetting and dispersing agent, flow and leveling agent, mar resistance agent, substrate wetting agent and anti-foaming agent.
15. The composition as claimed in claim 14, wherein said wetting and dispersing agent is at least one selected from the group consisting of block copolymer with pigment affinic groups (Disper BYK 160), high molecular weight block copolymer with pigment affinic groups (Disper BYK 163), unsaturated polyamide and acid ester salts (EFKA 5044), high molecular weight modified polyurethane in butylacetate/methoxypropylacetate/xylene (EFKA 4060), modified polyacrylate (EFKA 4400), and salt of unsaturated polyamine amides and low-molecular acidic polyesters (Anti-Terra U); said flow and leveling agent is at least one selected from the group consisting of polyether-modified polydimethylsiloxane (BYK 333, BYK 306), solution of a polyacrylate (BYK 354, BYK 358N), acrylic polymer (Resiflow LT), and silicone-free surface active polymer (BYK 399); said mar resistance agent is selected from polyether-modified polydimethylsiloxane (BYK 333) and a solution of a polyether-modified polydimethylsiloxane (BYK 306); said substrate wetting agent is at least one selected from the group consisting of polyether-modified polydimethylsiloxane (BYK 306), solution of a polyacrylate (BYK 358 N) and silicone-free surface active polymer (BYK 399); and said anti-foaming agent is at least one selected from the group consisting of silicone-free foam-destroying polymers (BYK 052), a solution of foam-destroying polysiloxane (BYK 020), silicone-free foam-destroying polymers (BYK 052) and acrylic polymer (OX-60, OX-70).
16. The composition as claimed in claim 1 is characterized by having a gloss value in the range of 2 to 10 at 60°.
17. The composition as claimed in claim 1, wherein a mass ratio of said matting agent to said oligomer is in the range of 1:3 to 1:8.
18. The composition as claimed in claim 1, wherein a mass ratio of said matting agent to said monomer is in the range of 1:1.5 to 1:5.
19. A process for the preparation of a matt coating composition as claimed in claim 1, said process comprising the following steps:
a. mixing a predetermined amount of at least one oligomer and a predetermined amount of at least one monomer under stirring for a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first mixture;
b. adding a predetermined amount of at least one additive into said first mixture for a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second mixture;
c. adding a predetermined amount of at least one matting agent into said second mixture for a third predetermined speed at a third predetermined temperature for a third predetermined time period to obtain a third mixture; and
d. adding a predetermined amount of at least one photoinitiator into said third mixture for a fourth predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain the matt coating composition.
20. The process as claimed in claim 19, wherein said oligomer is at least one selected from the group consisting of epoxy acrylate, epoxy diacrylate, modified epoxy acrylate, epoxy methacrylate, polyester acrylate, acrylated amine and epoxidised soyabean oil acrylate; and said monomer is at least one selected from the group consisting of monofunctional monomer, difunctional monomer, and trifunctional monomer.
21. The process as claimed in claim 20, wherein said monofunctional monomer is at least one selected from the group consisting of isobornyl acrylate (IBOA), isobornyl methacrylate (IBOMA), tetrahydrofurfuryl acrylate (THFA), and tetrahydrofurfuryl methacrylate (THFMA); said difunctional monomer is at least one selected from the group consisting of 1,6 hexanediol diacrylate (HDDA), ethylene glycol dimethacrylate (EGDMA), and diethylene glycol dimethacrylate (DEGDMA); and said trifunctional monomer is at least one selected from the group consisting of trimethylolpropane triacrylate (TMPTA), tris(2-hydroxyethyl) isocyanurate triacrylate (THEICTA), pentaerythritol triacrylate (PETA), trimethylolpropane trimethacrylate (TMPTMA), and ditrimethylolpropane tetraacrylate (DiTMP).
22. The process as claimed in claim 19, wherein said first predetermined speed is in the range of 600 rpm to 900 rpm; said first predetermined temperature is in the range of 25 °C to 40 °C; and said first predetermined time period is in the range of 30 minutes to 60 minutes.
23. The process as claimed in claim 19, wherein said additive is at least one selected from the group consisting of a wetting and dispersing agent, a flow and leveling agent, a mar resistance agent, a substrate wetting agent and anti-foaming agent.
24. The process as claimed in claim 19, wherein said second predetermined speed is in the range of 600 rpm to 900 rpm; said second predetermined temperature is in the range of 25 °C to 40 °C; and said second predetermined time period is in the range of 30 minutes to 60 minutes.
25. The process as claimed in claim 19, wherein said matting agent is at least one selected from the group consisting of an amorphous silica, a precipitated silica, and a wax treated silica.
26. The process as claimed in claim 19, wherein said third predetermined speed is in the range of 600 rpm to 900 rpm; said third predetermined temperature is in the range of 25 °C to 40 °C; and said third predetermined time period is in the range of 20 minutes to 60 minutes.
27. The process as claimed in claim 19, wherein said photoinitiator is at least one selected from the group consisting of phenylketone based initiator and phosphineoxide based initiator.
28. The process as claimed in claim 27, wherein said phosphineoxide based initiator is at least one selected from the group consisting of bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenyl phosphine oxide; and said phenylketone based initiator is at least one selected from the group consisting of 2,2-dimethoxy-1,2diphenyletan-1-one, benzophenone, hydroxy cyclo hexyl phenyl ketone, and phenyl benzophenone.
29. The process as claimed in claim 28, wherein said fourth predetermined speed is in the range of 600 rpm to 900 rpm; said fourth predetermined temperature is in the range of 25 °C to 40 °C; and said fourth predetermined time period is in the range of 30 minutes to 60 minutes.

Dated this 16th day of July, 2022

_______________________________
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