DESC:FIELD
The present disclosure relates to a one-pack (1K) wood coating composition and a process for its preparation. Particularly, the present disclosure relates to a one-pack (1K) resin based wood coating composition and a process for its preparation.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used to indicate otherwise.
One-Pack (1K) refers to a single component coating having an excellent storability, compared to 2k system and an excellent mar proofness, nail hardness and weather resistance.
Orientation additive refers to a compound that is used in the composition for even distribution of the matting agent during the film formation.
Anti-crater additive refers to a chemical substance which is used to reduce the potential for craters/spots and crawling.
In-can stability refers that the product is stable and there should not be change in the viscosity of the product.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Conventional coatings with desirable performance are prepared by using a polyester polyol or alkyd components cured with melamine/urea formaldehyde systems and acid catalysts. The reaction of polyol or alkyd with melamine resin in the presence of the conventional acid catalysts i.e. aromatic sulphonic acids is very fast and occurs at room temperature thereby leading to a restricted in-can stability. In order to increase the in-can stability of the conventional coating composition, it is supplied as two component composition that has component A as a base resin and component B as a curing agent, which is primarily the acid catalyst. Thereafter, both the components (component A and component B) are mixed in a defined ratio and applied to form a cured film.
In the two component coating composition, the components (component A and component B) are mixed and applied at the user end. The two component coating composition has several drawbacks such as handling losses, improper handling and the like. The mixing ratios of the components A and B are inappropriate due to human errors thereby leading to the detrimental effect over the performance of the coating.
Several attempts have been made to increase the resin in-can stability of the coating composition without deteriorating the properties of the cured film. Amine salts of strong acids have been used as alternatives for the catalyst. However, viscosity increase was observed due to protonation of amino groups of melamine. In order to increase the in-can stability, blocked aromatic sulfonic acid catalysts have been explored by using different compounds. However, the blocked aromatic sulfonic acid catalysts are expensive.
Therefore, there is felt a need for a one-pack (1K) wood coating composition and a process for its preparation that can mitigate the drawbacks mentioned hereinabove or provides a useful alternative.
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 one-pack (1K) wood coating composition.
Still another object of the present disclosure is to provide a melamine based wood coating composition.
Yet another object of the present disclosure is to provide a one-pack (1K) wood coating composition that has improved performance and increased in-can stability.
Still another object of the present disclosure is to provide a one-pack (1K) wood coating composition that has characteristic to react and form surface film at an ambient temperature without application of heat.
Another object of the present disclosure is to provide a process for the preparation of a one-pack (1K) wood coating composition.
Yet another object of the present disclosure is to provide a simple and economical process for the preparation of a one-pack (1K) wood 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 one-pack (1K) wood coating composition and a process for its preparation.
In an aspect, the present disclosure relates to a one-pack (1K) wood coating composition comprises a first resin in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition, a second resin in an amount in the range of 10 mass% to 30 mass% with respect to the total mass of the composition, a catalyst in an amount in the range of 1.5 mass% to 3 mass% with respect to the total mass of the composition, a fluid medium in an amount in the range of 35 mass% to 55 mass% with respect to the total mass of the composition, an additive in an amount in the range of 0.01 mass% to 2 mass% with respect to the total mass of the composition, and a matting agent in an amount in the range of 0 mass% to 6 mass% with respect to the total mass of the composition.
In another aspect, the present disclosure relates to a process for preparing a one-pack (1K) wood coating composition.
The process comprises a step of mixing a first resin and a second resin for a first predetermined speed for a first predetermined time period to obtain a mixture. Further, at least one additive and optionally at least one matting agent are added into the mixture under stirring for a second predetermined speed for a second predetermined time period to obtain a homogeneous mixture. At least one fluid medium and at least one catalyst are added into the homogeneous mixture under stirring for a third predetermined speed for a third predetermined time period to obtain the one-pack (1K) wood 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.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Conventional coatings with desirable performance are prepared by using a polyester polyol or alkyd components cured with melamine/urea formaldehyde systems and acid catalysts. The reaction of polyol or alkyd with melamine resin in the presence of the conventional acid catalysts i.e. aromatic sulphonic acids is very fast and occurs at room temperature thereby leading to a restricted in-can stability. In order to increase the in-can stability of the conventional coating composition, it is supplied as two component composition that has component A as a base resin and component B as a curing agent, which is primarily the acid catalyst. Thereafter, both the components (component A and component B) are mixed in a defined ratio and applied to form a cured film.
In the two component coating composition, the components (component A and component B) are mixed and applied at the user end. The two component coating composition has several drawbacks such as handling losses, and improper handling and the like. The mixing ratios of the components A and B are inappropriate due to human errors thereby leading to the detrimental effect over the performance of the coating.
Several attempts have been made to increase the resin in-can stability of the coating composition without deteriorating the properties of the cured film. Amine salts of strong acids have been used as alternatives for the catalyst. However, viscosity increase was observed due to protonation of amino groups of melamine. In order to increase the in-can stability, blocked aromatic sulfonic acid catalysts have been explored by using different compounds. However, the blocked aromatic sulfonic acid catalysts are expensive.
The present disclosure relates to a one-pack (1K) wood coating composition and a process for its preparation.
In one aspect, the present disclosure relates to a one-pack (1K) wood coating composition.
In accordance with the present disclosure, the one-pack (1K) wood coating composition comprises:
a. a first resin in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition;
b. a second resin in an amount in the range of 10 mass% to 30 mass% with respect to the total mass of the composition;
c. a catalyst in an amount in the range of 1.5 mass% to 3 mass% with respect to the total mass of the composition;
d. a fluid medium in an amount in the range of 35 mass% to 55 mass% with respect to the total mass of the composition;
e. an additive in an amount in the range of 0.01 mass% to 2 mass% with respect to the total mass of the composition; and
f. a matting agent in an amount in the range of 0 mass% to 6 mass% with respect to the total mass of the composition.
In accordance with an embodiment of the present disclosure, the first resin is alkyd resin.
In accordance with an embodiment of the present disclosure, the alkyd resin is a reaction product of:
• at least one oil in an amount in the range of 30 mass% to 40 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin.
In an exemplary embodiment, the alkyd resin is a reaction product of:
• at least one oil in an amount of 36 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount of 26 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount of 38 mass% with respect to the total mass of the alkyd resin.
In accordance with an embodiment of the present disclosure, the oil is at least one selected from the group consisting of linseed oil, soybean oil, dehydrated castor oil, cottonseed oil, castor oil, and coconut oil. In an exemplary embodiment, the oil is soybean oil (soya fatty acid).
In accordance with an embodiment of the present disclosure, the polyol is at least one selected from the group consisting of ethylene glycol, pentaerythritol, glycerin, diethylene glycol, monoethylene glycol, and trimethylolpropane. In an exemplary embodiment, the polyol is pentaerythritol.
In accordance with an embodiment of the present disclosure, the polybasic acid is at least one selected from the group consisting of adipic acid, succinic acid, phthalic anhydride, maleic anhydride, and dimethyl terephthalate. In an exemplary embodiment, the polybasic acid is phthalic anhydride.
In accordance with an embodiment of the present disclosure, the second resin is selected from the group consisting of urea formaldehyde resin and melamine formaldehyde resin.
In accordance with an embodiment of the present disclosure, a mass ratio of the first resin to the second resin is in the range of 2:1 to 4:3.
In accordance with an embodiment of the present disclosure, the urea formaldehyde resin is selected from the group consisting of butylated urea formaldehyde resin and iso-butylated urea formaldehyde resin. In an exemplary embodiment, the urea formaldehyde resin is butylated urea formaldehyde resin. In another exemplary embodiment, the urea formaldehyde resin is iso-butylated urea formaldehyde resin.
In accordance with an embodiment of the present disclosure, the catalyst is selected from the group consisting of dodecyl benzene sulphonic acid (DDBSA) and triethyl amine. In an exemplary embodiment, the catalyst is dodecyl benzene sulphonic acid (DDBSA). In another exemplary embodiment, the catalyst is triethyl amine.
In accordance with an embodiment of the present disclosure, the fluid medium is at least one selected from the group consisting of ethyl acetate, methoxypropyl acetate, cellulose acetate, C9 solvent, xylene, para-xylene, cellosolve, butyl cellosolve, butyl acetate, toluene, and butanol. In an exemplary embodiment, the fluid medium is butanol. In another exemplary embodiment, the fluid medium is butyl cellosolve. In still another exemplary embodiment, the fluid medium is butyl acetate. In yet another exemplary embodiment, the fluid medium is toluene. In another exemplary embodiment, the fluid medium is xylene.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of anti-settling additive, orientation additive, flow additive, and anti-crater additive.
In accordance with an embodiment of the present disclosure, the anti-settling additive is hydrophobic fumed silica (aerosil 972).
In accordance with an embodiment of the present disclosure, the orientation additive is polyether-modified polydimethylsiloxane (BYK 300).
In accordance with an embodiment of the present disclosure, the flow additive is modified acrylic polymer (resiflow LF or modaflow).
In accordance with an embodiment of the present disclosure, the anti-crater additive is selected from the group consisting of polyether modified dimethylpolysiloxane copolymer (BYK- 331) and polyether-modified polydimethylsiloxane (BYK- 333).
In accordance with an embodiment of the present disclosure, the matting agent is selected from the group consisting of fume silica powder, amorphous silica (Syloid ED 50 or Syloid 906), and wax-treated precipitated silica (ACEMATT OK 412). In an exemplary embodiment, the matting agent is fume silica powder.
The presence of the matting agent in the coating composition of the present disclosure imparts a matt finish when applied on the wood.
In accordance with an embodiment of the present disclosure, when the matting agent is present in the coating composition, the coating composition has a gloss value in the range of 10 to 16 at 60º.
In an exemplary embodiment, when the matting agent is present in the coating composition, the coating composition has a gloss value of 12 at 60º. In another exemplary embodiment, when the matting agent is present in the coating composition, the coating composition has a gloss value of 15 at 60º.
In accordance with an embodiment of the present disclosure, when the matting agent is present in the coating composition, the coating composition has a viscosity in the range of 13 seconds to 30 seconds as measured by F/C 4 at 30 °C.
In an exemplary embodiment of the present disclosure, when the matting agent is present in the coating composition, the coating composition has a viscosity of 15 seconds as measured by F/C B4 (Ford cup viscometer) at 30 °C.
In accordance with an embodiment of the present disclosure, when the matting agent is absent in the coating composition, the coating composition has a gloss value of at least 80 at 60º.
In accordance with an embodiment of the present disclosure, when the matting agent is absent in the coating composition, the coating composition has a gloss value in the range of 80 to 90 at 60º.
In accordance with an embodiment of the present disclosure, when the matting agent is absent in the coating composition, the coating composition has a gloss value in the range of 80 to 85 at 60º.
In accordance with an embodiment of the present disclosure, when the matting agent is absent in the coating composition, the coating composition has a viscosity in the range of 15 seconds to 45 seconds as measured by F/C 4 at 30 °C.
In an exemplary embodiment, when the matting agent is absent in the coating composition, the coating composition has a viscosity of 20 seconds as measured by F/C 4 at 30 °C. In another exemplary embodiment, when the matting agent is absent in the coating composition, the coating composition has a viscosity of 40 seconds as measured by F/C 4 at 30 °C.
The product of the present disclosure i.e. one-pack (1K) wood coating composition is yellowish in colour, hazy in nature and shows no settling overnight thereby leading to enhanced in-can stability.
The one-pack (1K) coating composition of the present disclosure is directly used for coating of wood.
In another aspect of the present disclosure, there is provided a process for the preparation of a one-pack (1K) wood coating composition.
In a first step, a first resin and a second resin is mixed for a first predetermined speed for a first predetermined time period to obtain a mixture.
In accordance with an embodiment of the present disclosure, the first resin is alkyd resin.
In accordance with an embodiment of the present disclosure, the alkyd resin is a reaction product of:
• at least one oil in an amount in the range of 30 mass% to 40 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin.
In an exemplary embodiment, the alkyd resin is a reaction product of:
• at least one oil in an amount of 36 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount of 26 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount of 38 mass% with respect to the total mass of the alkyd resin.
In accordance with an embodiment of the present disclosure, the oil is at least one selected from the group consisting of linseed oil, soybean oil, soya fatty acid, dehydrated castor oil, cottonseed oil, castor oil, and coconut oil. In an exemplary embodiment, the oil is soyabean oil (soya fatty acid).
In accordance with an embodiment of the present disclosure, the polyol is at least one selected from the group consisting of ethylene glycol, pentaerythritol, glycerin, diethylene glycol, monoethylene glycol, and trimethylolpropane. In an exemplary embodiment, the polyol is pentaerythritol.
In accordance with an embodiment of the present disclosure, the polybasic acid is at least one selected from the group consisting of adipic acid, succinic acid, phthalic anhydride, maleic anhydride, and dimethyl terephthalate. In an exemplary embodiment, the polybasic acid is phthalic anhydride.
In accordance with an embodiment of the present disclosure, the second resin is selected from the group consisting of urea formaldehyde resin and melamine formaldehyde resin.
In accordance with an embodiment the present disclosure, a mass ratio of the first resin to the second resin is in the range of 2:1 to 4:3.
In accordance with an embodiment of the present disclosure, the urea formaldehyde resin is selected from the group consisting of butylated urea formaldehyde resin and iso-butylated urea formaldehyde resin. In an exemplary embodiment, the urea formaldehyde resin is butylated urea formaldehyde resin. In another exemplary embodiment, the urea formaldehyde resin is iso-butylated urea formaldehyde resin.
In accordance with an embodiment of the present disclosure, the first predetermined speed is in the range of 400 rpm to 800 rpm. In an exemplary embodiment, the first predetermined speed is 600 rpm.
In accordance with an embodiment of the present disclosure, the first predetermined time period is in the range of 5 minutes to 30 minutes. In an exemplary embodiment, the first predetermined time period is 10 minutes.
In a second step, at least one additive, and optionally at least one matting agent are added into the mixture under stirring for a second predetermined speed for a second predetermined time period to obtain a homogeneous mixture.
In accordance with an embodiment of the present disclosure, the catalyst is selected from the group consisting of dodecyl benzene sulphonic acid (DDBSA) and triethyl amine. In an exemplary embodiment, the catalyst is dodecyl benzene sulphonic acid (DDBSA). In another exemplary embodiment, the catalyst is triethyl amine.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of anti-settling additive, orientation additive, flow additive, and anti-crater additive.
In accordance with an embodiment of the present disclosure, the anti-settling additive is hydrophobic fumed silica (aerosil 972).
In accordance with an embodiment of the present disclosure, the orientation additive is polyether-modified polydimethylsiloxane (BYK 300).
In accordance with an embodiment of the present disclosure, the flow additive is modified acrylic polymer (resiflow LF or modaflow).
In accordance with an embodiment of the present disclosure, the anti-crater additive is selected from the group consisting of polyether modified dimethylpolysiloxane copolymer (BYK- 331) and polyether-modified polydimethylsiloxane (BYK- 333).
In accordance with an embodiment of the present disclosure, the matting agent is selected from the group consisting of fume silica powder, amorphous silica (Syloid ED 50 or Syloid 906), and wax-treated precipitated silica (ACEMATT OK 412). In an exemplary embodiment, the matting agent is fume silica powder.
In accordance with an embodiment of the present disclosure, the second predetermined speed is in the range of 500 rpm to 1000 rpm. In an exemplary embodiment, the second predetermined speed is 600 rpm. In another exemplary embodiment, the second predetermined speed is 800 rpm.
In accordance with an embodiment of the present disclosure, the second predetermined time period is in the range of 20 minutes to 60 minutes. In an exemplary embodiment, the second predetermined time period is 30 minutes. In another exemplary embodiment, the second predetermined time period is 40 minutes.
In a third step, at least one fluid medium and at least one catalyst are added into the homogeneous mixture under stirring for a third predetermined speed for a third predetermined time period to obtain the one-pack (1K) wood coating composition.
In accordance with an embodiment the present disclosure, the fluid medium is at least one selected from the group consisting of ethyl acetate, methoxypropyl acetate, cellulose acetate, C9 solvent, xylene, para-xylene, cellosolve, butyl cellosolve, butyl acetate, toluene, and butanol. In an exemplary embodiment, the fluid medium is butanol. In another exemplary embodiment, the fluid medium is butyl cellosolve. In still another exemplary embodiment, the fluid medium is butyl acetate. In yet another exemplary embodiment, the fluid medium is toluene. In another exemplary embodiment, the fluid medium is xylene.
In accordance with an embodiment of the present disclosure, the third predetermined speed is in the range of 500 rpm to 1000 rpm. In an exemplary embodiment, the third predetermined speed is 600 rpm. In another exemplary embodiment, the third predetermined speed is 800 rpm.
In accordance with an embodiment of the present disclosure, the third predetermined time period is in the range of 5 minutes to 40 minutes. In an exemplary embodiment, the third predetermined time period is 30 minutes. In another exemplary embodiment, the third predetermined time period is 35 minutes.
The process for the preparation of the one-pack (1K) wood coating composition is simple and economical.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
EXPERIMENTAL DETAILS
Example 1: Preparation of one-pack (1K) wood coating composition (gloss) in accordance with the process of the present disclosure.
Example A: Preparation of a first resin.
36 mass% of soybean oil (oil- soya fatty acid), 26 mass% of pentaerythritol (polyol), and 38 mass% of phthalic anhydride (polybasic acid) were esterified at 235 ºC for 5 hours to obtain an alkyd resin (first resin).
Preparation of one-pack (1K) wood coating composition (gloss)
The alkyd resin (first resin) obtained in example A and a second resin were mixed at 600 rpm for 10 minutes to obtain a mixture. Additives, were added into the mixture under stirring at 600 rpm for 30 minutes to obtain a homogeneous mixture. Butanol (fluid medium) and catalyst were added into the homogeneous mixture under stirring at 600 rpm for 10 minutes to obtain the one-pack (1K) wood coating composition (gloss). The amounts of the ingredients are given in Table 1.
Examples 2 to 5: Preparation of one-pack (1K) wood coating composition (gloss) in accordance with the process of the present disclosure
Same procedure was followed as in Example 1 except for a change in the amounts of the ingredients as given in Table 1
Table 1:
Ingredients Examples (unit-gms)
Example 1 Example 2 Example 3 Example 4 Example 5
Alkyd Resin (first resin) 34.02 34.02 34.02 34.55 34.550
Urea Formaldehyde Resin Butylated/ Iso butylated (second resin) 22.88 22.88 22.88 22.55 22.55
Butyl Acetate (fluid medium) 1.00 1.00 1.00 0 0
Resiflow LF (Flow and leveling additive) 0.05 0.05 0.05 0.05 0.05
Melamine Formaldehyde Resin (second resin) 1.33 1.33 1.33 1.33 1.33
Cellosolve (fluid medium) 1.5 1.5 1.5 7 7
Trimethylamine (catalyst) 0.25 0.35 0.20 0.2 0.24
Dodecylbenzene sulfonic acid (catalyst) 1.5 1.5 1.50 1.55 1.5
Toluene (fluid medium) 17 17 17 13.77 8
Butanol (fluid medium) 10 10 10 16 18.08
Ethyl Acetate (fluid medium) 4.06 4 4 0 0
Butyl Celloslove (fluid medium) 3.40 2.37 2.40 3 6.7
Xylene (fluid medium) 3.01 4.00 4.12 0 0
Total 100 100 100 100 100
Product parameters
Colour visual Yellowish Yellowish Yellowish Yellowish Yellowish
Clarity Clear Clear Clear Clear Clear
Viscosity on F/C b4 at 30 ° C 15 sec 15 sec 15 sec 15 sec 15 sec
Performance
Surface dry 25-30 min 25-30 min 25-30 min 20-25 min 20-25 min
Tack free 4 hrs 15 min 4 hrs 15 min 4 Hrs 3 hrs 45 min 3 hrs 45 min
Hard Dry Over Night Over Night Over Night Over Night Over Night
Gloss @ 60 º 81 82 83 84 85
Finish Smooth Smooth Smooth Smooth Smooth
Nail Hardness after 24 hrs OK OK OK OK OK
Accelerated In-can stability at 60 ° C (viscosity on F/C 4 at 30 °C)
Initial viscosity 15 sec 15 sec 15 sec 15 sec 15 sec
Viscosity after 3 days 16 sec 15 sec 16 sec 15 sec 15 sec
Viscosity after 5 days 18 sec 16 sec 16 sec 16 sec 16 sec
Viscosity after 10 days 17 sec 17 sec 17 sec 17 sec 17 sec
Viscosity after 15 days 20 sec 20 sec 21 sec 18 sec 18 sec
Viscosity after 20 days 38 sec 40 sec 40 sec 20 Sec 19 Sec
Inference:
It is evident from table 1 that examples 1 to 5 showed the improved performance, increased in-can stability. Further, examples 1 to 5 showed better accelerated in-can stability even after 20 days of the storage and no gel was formed. The improved performance and accelerated in-can stability was achieved by optimizing the amounts of the ingredients such as alkyd resin, urea formaldehyde resin, the trimethylamine (catalyst) and the fluid medium (butyl cellosolve and butanol) of the coating composition (gloss) of the present disclosure.
Examples 6 to 10: Comparative examples
Examples 6 to 10 were prepared in similar way as that of examples 1 to 5 except for the change in the amounts of all the ingredients to evaluate the in-can stability, accelerated stability and the performance of the one-pack (1K) wood coating composition in comparison to examples 1 to 5, given in Table 2.
Table 2:
Ingredients Examples (unit-gms)
Example 6 Example 7 Example 8 Example 9 Example 10
Alkyd Resin (first resin) 35.02 35.02 35.02 35.02 35.02
Urea Formaldehyde Resin Butylated/ Iso butylated (second resin) 21.88 21.88 21.88 21.88 21.88
Butyl Acetate (fluid medium) 1.00 1.00 1.00 1.00 1.00
Flow & Leveling Additive (additive) 0.03 0.03 0.03 0.03 0.03
Melamine Formaldehyde Resin (second resin) 1.33 1.33 1.33 1.33 1.33
Cellosolve (fluid medium) 5.90 5.90 5.90 5.90 5.90
trimethylamine (catalyst) 0.17 0.17 0.17 0.17 0.17
Dodecylbenzene sulfonic acid (catalyst) 0.00 2.00 2.00 1.50 1.50
Para Toluene Sulphonic Acid (catalyst) 2.00 0.00 0.00 0.00 0.00
Toluene (fluid medium) 20.36 19.86 19.86 20.36 20.36
Butanol (fluid medium) 12.31 12.81 12.81 12.81 12.81
Ethyl Acetate (fluid medium) 0 0 0 0 0
Butyl Celloslove (fluid medium) 0 0 0 0 0
Xylene (fluid medium) 0 0 0 0 0
Total 100 100 100 100 100
Product parameters
Colour visual Yellowish Yellowish Yellowish Yellowish Yellowish
Clarity Clear Clear Clear Clear Clear
Viscosity on F/C b4 at 30 ° C 16 sec 16 sec 16 sec 16 sec 16 sec
Performance
Surface dry 15 - 20 min 15 - 20 min 15 - 20 min 15 - 20 min 15 - 20 min
Tack free 1 hrs 30 min 1 hrs 30 min 2 hrs 2 hrs 30 min 3 hrs
Hard Dry Over Night Over Night Over Night Over Night Over Night
Gloss @ 60 80 80 80 80 80
Finish Smooth Smooth Smooth Smooth Smooth
Nail Hardness after 24 hrs OK OK OK OK OK
Accelerated In-can stability at 60 ° C (viscosity on F/C 4 at 30 °C)
Initial viscosity 16 sec 16 sec 16 sec 16 sec 16 sec
Viscosity after 3 days Gelled 37 sec 17 sec 17 sec 16 sec
Viscosity after 5 days Gelled 33 sec 22 sec 17 Sec
Viscosity after 10 days Gelled 30 sec 20 sec
Viscosity after 15 days Gelled 31 sec
Viscosity after 20 days Gelled
Inference:
It is evident from table 2 that examples 6 to 10 showed poor performance as lower in-can stability was observed in comparison to examples 1 to 5. Further, examples 6 to 10 showed poor accelerated in-can stability even after 3 days, 5 days followed by 10 days, 15 days and 20 days of the storage and a gel was formed. This poor performance was due to unoptimized or variations (either lower or higher) in the amounts of the ingredients such as alkyd resin, urea formaldehyde resin, the amine (catalyst) and the fluid medium (butyl cellosolve and butanol) of the coating composition of the present disclosure.
Example 11: Preparation of one-pack (1K) wood coating composition (matt), in accordance with the process of the present disclosure.
Example B: Preparation of a first resin.
36 mass% of soybean oil (oil- soya fatty acid), 26 mass% of pentaerythritol (polyol), and 38 mass% of phthalic anhydride (polybasic acid) were reacted at 235 ºC for 5 hours to obtain an alkyd resin (first resin).
Preparation of one-pack (1K) wood coating composition (matt)
The alkyd resin (first resin) obtained in example B and a second resin was mixed at 600 rpm for 10 minutes to obtain a mixture. Additives and matting agent were added into the mixture under stirring at 600 rpm for 30 minutes to obtain a homogeneous mixture. Butanol (fluid medium) and catalyst were added into the homogeneous mixture under stirring at 600 rpm for 10 minutes to obtain the one-pack (1K) wood coating composition (matt). The amounts of the ingredients are given in Table 3.
Examples 12 to 15: Preparation of one-pack (1K) wood coating composition (matt), in accordance with the process of the present disclosure.
Same procedure was followed as in Example 11 except for a change in the amounts of the ingredients as given in Table 3.

Table 3:
Ingredients Examples (unit-gms)
Example 11 Example 12 Example 13 Example 14 Example 15
Alkyd Resin (first resin) 25.00 25.00 25.00 25.00 25.00
Urea Formaldehyde Resin (second resin) 16.00 16.00 16.00 16.00 16.00
Fume silica powder (Matting Agent) 4.00 4.00 4.00 4.00 4.00
Aerosil 972 (Anti Settling additive) 0.30 0.30 0.30 0.30 0.30
Cellosolve (fluid medium) 4.00 7.00 4.50 7.00 7.00
Butyl Cellosolve (fluid medium) 10.00 0.00 12.00 0.00 0.00
Butyl Acetate (fluid medium) 0.00 0.00 0.00 0.00 0.00
BYK 300 (Orientation additive) 0.05 0.05 0.05 0.05 0.05
Resiflow LF (Flow and leveling additive) 1.00 1.00 1.00 1.00 1.00
Melamine Formaldehide Resin (second resin) 0.70 0.70 0.70 0.70 0.70
Trimethylamine (catalyst) 0.25 0.25 0.25 0.25 0.25
Dodecylbenzene sulfonic acid (catalyst) 1.50 1.50 1.50 1.50 1.50
Toluene (fluid medium) 22.20 27.20 13.70 26.20 25.20
Butanol (fluid medium) 15.00 17.00 21.00 18.00 19.00
Total 100 100 100 100 100
Product parameters
Colour visual Yellowish Yellowish Yellowish Yellowish Yellowish
Clarity Hazy Hazy Hazy Hazy Hazy
HG 7 7 7 7 7
Viscosity on F/C b4 at 30 ° C 15 sec 15 sec 15 sec 15 sec 15 sec
In can stability over night No settling No settling No settling No settling No settling
Performance
Surface dry 35 min 30 min 25 min 20 min 16 min
Tack free 3 hrs 2 hrs 45 min 3 hrs 2 hrs 15 min 2 hrs 15 min
Hard Dry Over Night Over Night Over Night Over Night Over Night
Matt Matt Matt Matt Matt
Gloss @ 60 º 13 -16 12 -15 12 -15 12 -15 12 -15
Finish Smooth Smooth Smooth Smooth Smooth
Nail Hardness after 24 hrs OK OK OK OK OK
Accelerated In-can stability at 60 ° C (viscosity on F/C 4 at 30 °C)
Initial viscosity 15 sec 15 sec 15 Sec 15 Sec 15 Sec
Viscosity after 5 days 15 sec 15 sec 16 sec 16 sec 16sec
Viscosity after 10 days 16 sec 16 sec 16 sec 16 sec 16 sec
Viscosity after 15 days 17 sec 19 sec 17 sec 17 sec 17 sec
Viscosity after 20 days 21 Sec 20 sec 18 Sec 19 Sec 19 Sec

Inference.
It is evident from table 3 that examples 11 to 15 showed the improved performance, increased in-can stability and no settling. Further, examples 11 to 15 showed better accelerated in-can stability even after 20 days of the storage and no gel was formed. The improved performance and accelerated in-can stability was achieved by optimizing the amounts of the ingredients such as alkyd resin, urea formaldehyde resin, matting agent, trimethylamine (catalyst) and the fluid medium (butyl cellosolve and butanol) of the coating composition (matt) of the present disclosure.
Examples 16-20: Comparative examples
Examples 16 to 20 were prepared in similar way as that of examples 11 to 15 except for the change in the amounts of all the ingredients to evaluate the in-can stability, accelerated stability, and the performance of the one-pack (1K) wood coating composition (matt) in comparison to examples 11 to 15, given in Table 4.
Table 4:
Ingredients Examples (unit-gms)
Example 16 Example 17 Example 18 Example 19 Example 20
Alkyd Resin (first resin) 31.00 29.00 29.00 29.00 25.00
Urea Formaldehyde Resin (second resin) 20.00 19.00 19.00 19.00 16.00
Fume silica powder (Matting Agent) 3.00 3.50 5.00 4.00 4.00
Aerosil 972 (Anti Settling additive) 0.00 0.00 0.00 0.00 0.00
Cellosolve (fluid medium) 5.00 5.00 5.00 6.00 6.00
Butyl Cellosolve (fluid medium) 0.00 0.00 0.00 0.00 0.00
Butyl Acetate (fluid medium) 2.00 2.00 2.00 2.00 3.00
BYK 300 (Orientation additive) 0.05 0.05 0.05 0.05 0.05
Resiflow LF (Flow and leveling additive) 1.00 1.00 1.00 1.00 1.00
Melamine Formaldehide Resin (second resin) 0.70 0.70 0.70 0.70 0.70
Trimethylamine (catalyst) 0.17 0.17 0.17 0.17 0.17
Dodecylbenzene sulfonic acid (catalyst) 1.50 1.50 1.50 1.50 1.50
Toluene (fluid medium) 22.08 25.08 25.08 25.08 29.58
Butanol (fluid medium) 13.50 13.00 11.50 11.50 13.00
Total 100 100 100 100 100
Product parameters
Colour visual Yellowish Yellowish Yellowish Yellowish Yellowish
Clarity Hazy Hazy Hazy Hazy Hazy
HG 7 7 7 7 7
Viscosity on F/C b4 at 30 ° C 16 sec 16 sec 16 sec 15 sec 15 sec
In can stability over night Settling Settling Settling Settling Settling
Performance
Surface dry 10 min 10 min 10 min 10 min 16 min
Tack free 2 hrs 2 hrs 2 hrs 2 hrs 2 hrs 15 min
Hard Dry Over Night Over Night Over Night Over Night Over Night
Matt Matt Matt Matt Matt
Gloss @ 60 º 25- 30 20- 25 8 - 10 17- 20 12 -15
Finish Smooth Smooth Smooth Smooth Smooth
Nail Hardness after 24 hrs OK OK OK OK OK
Accelerated In-can stability at 60 ° C (viscosity on F/C 4 at 30 °C)
Initial viscosity 16 sec 16 sec 16 sec 15 sec 15 sec
Viscosity after 5 days 17 17 17 16 16
Viscosity after 10 days 22 sec 23 sec 24 sec 17 sec 17 sec
Viscosity after 15 days Gelled Gelled Gelled 20 sec 19 sec
Viscosity after 20 days Gelled Gelled

Inference:
It is evident from table 4 that examples 16 to 20 showed poor performance as lower in-can stability was observed in comparison to examples 11 to 15. Further, examples 16 to 20 showed settling and poor accelerated in-can stability even after 5 days, 10 days, 15 days and 20 days of the storage, a gel was formed. This poor improved performance was due to unoptimized or variations (either lower or higher) in the amounts of the ingredients such as alkyd resin, urea formaldehyde resin, matting agent, the amine and the fluid medium (butyl cellosolve and butanol) of the coating composition (matt) of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of the one-pack (1K) wood coating composition that:
• provides surface film at an ambient temperature without applying heat; and
• has higher in-can stability.
and
a process for the preparation of the one-pack (1K) wood coating composition that:
• 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. ,CLAIMS:WE CLAIM:
1. A one-pack (1K) wood coating composition comprising:
a. a first resin in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the composition
b. a second resin in an amount in the range of 10 mass% to 30 mass% with respect to the total mass of the composition;
c. a catalyst in an amount in the range of 1.5 mass% to 3 mass% with respect to the total mass of the composition;
d. a fluid medium in an amount in the range of 35 mass% to 55 mass% with respect to the total mass of the composition;
e. an additive in an amount in the range of 0.01 mass% to 2 mass% with respect to the total mass of the composition; and
f. a matting agent in an amount in the range of 0 mass% to 6 mass% with respect to the total mass of the composition.
2. The composition as claimed in claim 1, wherein said first resin is alkyd resin.
3. The composition as claimed in claim 2, wherein said alkyd resin is a reaction product of:
• at least one oil in an amount in the range of 30 mass% to 40 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin.
4. The composition as claimed in claim 3, wherein said oil is at least one selected from the group consisting of linseed oil, soybean oil, dehydrated castor oil, cottonseed oil, castor oil, and coconut oil.
5. The composition as claimed in claim 3, wherein said polyol is at least one selected from the group consisting of ethylene glycol, pentaerythritol, glycerin, diethylene glycol, monoethylene glycol, and trimethylolpropane.
6. The composition as claimed in claim 3, wherein said polybasic acid is at least one selected from the group consisting of adipic acid, succinic acid, phthalic anhydride, maleic anhydride, and dimethyl terephthalate.
7. The composition as claimed in claim 1, wherein said second resin is selected from the group consisting of urea formaldehyde resin and melamine formaldehyde resin.
8. The composition as claimed in claim 7, wherein said urea formaldehyde resin is selected from the group consisting of butylated urea formaldehyde resin and iso-butylated urea formaldehyde resin.
9. The composition as claimed in claim 1, wherein said catalyst is selected from the group consisting of dodecyl benzene sulphonic acid (DDBSA) and triethyl amine.
10. The composition as claimed in claim 1, wherein said fluid medium is at least one selected from the group consisting of ethyl acetate, methoxypropyl acetate, cellulose acetate, C9 solvent, xylene, para-xylene, cellosolve, butyl cellosolve, butyl acetate, toluene, and butanol.
11. The composition as claimed in claim 1, wherein a mass ratio of said first resin to said second resin is in the range of 2:1 to 4:3.
12. The composition as claimed in claim 1, wherein said additive is at least one selected from the group consisting of anti-settling additive, orientation additive, flow additive, and anti-crater additive.
13. The composition as claimed in claim 12, wherein
• said anti-settling additive is hydrophobic fumed silica (aerosil 972);
• said orientation additive is polyether-modified polydimethylsiloxane (BYK 300);
• said flow additive is modified acrylic polymer (resiflow LF or modaflow); and
• said anti-crater additive is selected from the group consisting of polyether modified dimethylpolysiloxane copolymer (BYK- 331) and polyether-modified polydimethylsiloxane (BYK- 333).
14. The composition as claimed in claim 1, wherein said matting agent is selected from the group consisting of fume silica powder, amorphous silica (Syloid ED 50 or Syloid 906), and wax-treated precipitated silica (ACEMATT OK 412).
15. The composition as claimed in claim 1, wherein said coating composition in the presence of said matting agent is characterized by having:
• a gloss value in the range of 10 to 16 at 60º; and
• a viscosity in the range of 13 seconds to 30 seconds.
16. The composition as claimed in claim 1, wherein said coating composition in the absence of said matting agent is characterized by having:
• a gloss value in the range of 80 to 90 at 60°; and
• a viscosity in the range of 15 seconds to 45 seconds.
17. A process for the preparation of a one-pack (1K) wood coating composition, said process comprises the following steps:
a. mixing a first resin and a second resin for a first predetermined speed for a first predetermined time period to obtain a mixture;
b. adding at least one additive, and optionally at least one matting agent into said mixture under stirring for a second predetermined speed for a second predetermined time period to obtain a homogeneous mixture; and
c. adding at least one fluid medium and at least one catalyst into said homogeneous mixture under stirring for a third predetermined speed for a third predetermined time period to obtain said one-pack (1K) wood coating composition.
18. The process as claimed in claim 17, wherein said first resin is alkyd resin.
19. The process as claimed in claim 18, wherein said alkyd resin is a reaction product of:
• at least one oil in an amount in the range of 30 mass% to 40 mass% with respect to the total mass of the alkyd resin;
• at least one polyol in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin; and
• at least one polybasic acid in an amount in the range of 20 mass% to 40 mass% with respect to the total mass of the alkyd resin.
20. The process as claimed in claim 19, wherein said oil is at least one selected from the group consisting of linseed oil, soybean oil, dehydrated castor oil, cottonseed oil, castor oil, and coconut oil.
21. The process as claimed in claim 19, wherein said polyol is at least one selected from the group consisting of ethylene glycol, pentaerythritol, glycerin, diethylene glycol, monoethylene glycol, and trimethylolpropane.
22. The process as claimed in claim 19, wherein said polybasic acid is at least one selected from the group consisting of adipic acid, succinic acid, phthalic anhydride, maleic anhydride, and dimethyl terephthalate.
23. The process as claimed in claim 17, wherein said second resin is selected from the group consisting of urea formaldehyde resin and melamine formaldehyde resin.
24. The process as claimed in claim 23, wherein said urea formaldehyde resin is selected from the group consisting of butylated urea formaldehyde resin and iso-butylated urea formaldehyde resin.
25. The process as claimed in claim 17, wherein
• said first predetermined speed is in the range of 400 rpm to 800 rpm; and
• said first predetermined time period is in the range of 5 minutes to 30 minutes.
26. The process as claimed in claim 17, wherein said additive is at least one selected from the group consisting of anti-settling additive, orientation additive, flow additive, and anti-crater additive.
27. The process as claimed in claim 26, wherein
• said anti-settling additive is hydrophobic fumed silica (aerosil 972);
• said orientation additive is polyether-modified polydimethylsiloxane (BYK 300);
• said flow additive is modified acrylic polymer (resiflow LF or modaflow); and
• said anti-crater additive is selected from the group consisting of polyether modified dimethylpolysiloxane copolymer (BYK- 331) and polyether-modified polydimethylsiloxane (BYK- 333).
28. The process as claimed in claim 17, wherein said catalyst is selected from the group consisting of dodecyl benzene sulphonic acid (DDBSA) and triethyl amine.
29. The process as claimed in claim 17, wherein said matting agent is selected from the group consisting of fume silica powder, amorphous silica (Syloid ED 50 or Syloid 906), and wax-treated precipitated silica (ACEMATT OK 412).
30. The process as claimed in claim 17, wherein
• said second predetermined speed is in the range of 500 rpm to 1000 rpm; and
• said second predetermined time period is in the range of 20 minutes to 60 minutes.
31. The process as claimed in claim 17, wherein said fluid medium is at least one selected from the group consisting of ethyl acetate, methoxypropyl acetate, cellulose acetate, C9 solvent, xylene, para-xylene, cellosolve, butyl cellosolve, butyl acetate, toluene, and butanol.
32. The process as claimed in claim 17, wherein
• said third predetermined speed is in the range of 500 rpm to 1000 rpm; and
• said third predetermined time period is in the range of 5 minutes to 40 minutes.
Dated this 17th day of January, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant