DESC:FIELD OF INVENTION
The present invention relates to a texture coating formulation preferably suitable for trowel application based on a select binder and including sand/extender formulation of select dimensions that are key to the thickness and the final attributes of the coating, said coatings being trowel able coatings have advantageous features of low water absorption, exterior durability and efflorescence resistance also extendable to interior application.
BACKGROUND ART
Texture coatings are known to have PVC 75-85% which aids in the formation of the scratch design during trowel application. These coating is found to have a high-water absorption in the range of 40-50% after 7 days of immersion in water. Water absorption of a coating determines the overall durability and the anti-microbial performance of the coatings. The coatings also have high porosity which helps in the transportation of the dissolve salts and hence the resistance to efflorescence is low.
On this reference is invited to Materials (Basel). 2021 Dec; 14(24): 7558 that teaches results of research on the influence of polymer modifiers: styrene-acrylic copolymer, vinyl acetate/ethylene (EVA), vinyl acetate/acrylic copolymer (VAAc), and VA/VeoVa/acrylic terpolymer on the water permeability and adhesion of cement-containing waterproofing mortars in concrete. The content of the polymers in the composition of the mortars was 15, 20 and 26% (m/m) in relation to the weight of the dry ingredients. Using microscopic methods, an attempt was made to analyse the relationship between the microstructure of the mortars and the properties of these polymers. The EVA and the vinyl acetate/acrylic copolymer, which were used in the form of dry powders, had the most favourable effect on water permeability and adhesion to the concrete substrate. They may prove to be useful for the production of one-component cement-containing waterproofing mortars. On the other hand, the VA/VeoVa/acrylic terpolymer modifier had the least favourable effect on the tested properties. For mortars with this modifier, the desired water-permeability parameters were not achieved. Depending on the amount of polymer modifier, the mortars were characterized by differences in water tightness, as established on the basis of changes in porosity and differences in the adhesion of the cement-polymer paste to the surface of aggregate grains. It was determined that the type of polymer and its dispergation properties influence the water permeability of mortars, as well as their adhesion to concrete substrates.
US20090264585A1 teaches copolymers of hydrophobic higher branched vinyl esters, and a polymerization process for polymerization of hydrophobic monomers in the presence of surfactants having low critical micelle concentration.
Mingguang Hu et al. in Advances in Engineering Research, volume 125, Pg 271-274 teaches that in order to get good weather resistance, water repellency, and thermal stability of emulsion lattices, this prior art aimed to prepare Quaternary Co-polymer Emulsion, therefore, a conventional seeded emulsion polymerization is prepared by (NH4)2S2O8-initiation and by core/shell technique of four monomers namely MMA, BA, MAA, and VeoVa-10. As a result, stable Tertiary acrylic emulsion with improved physico-mechanical properties were obtained. The effect of the VeoVa-10 and emulsifier content on the properties of the resulting emulsion lattices and their corresponding films were investigated and achieved enhanced and excellent properties. Characterization of the prepared emulsions was performed using e.g. IR, TEM, SEM, thermal analysis. The VeoVa-10 and emulsifier amount had a great influence on the properties of the resulting lattices and their corresponding films.
Aspects of Water Sensitivity of PVAc Latex Films by Chen, Zhijin 2011 teaches acetoacetoxy ether methacrylate (AAEM)-Vinyl acetate-VeoVa10 terpolymer latex employed as wood adhesive with enhanced water resistance when crosslinked with diamines.
Inspite of the above binders and formulation known in the art there was need to further explore for coating formulations that would have overall enhanced durability in terms of reduced water adsorption and would have reduced porosity to not much facilitate transportation of the dissolve salts to cause higher resistance to efflorescence.

OBJECTS OF THE INVENTION
The primary object of the present invention is to provide for texture coating formulation preferably suitable for trowel application based on a select binder including a sand/particle/ extender formulation that would have advantageous features of low water absorption, exterior durability and efflorescence resistance also extendable to interior application.
It is another object of the present invention to provide for said texture coating formulation and a process thereof including the preparation of said binder together with the preparation of sand/ extender formulation based on involvement of extenders of select dimensions key to the thickness and the final attributes of the coating formulation including necessary attributes of reduced water adsorption and anti-efflorescence.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention there is provided texture paint/coating formulation comprising synergistic co-acting combination of select (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler/extender.
Said texture coating formulation provided is suitable for trowel application wherein said silane modified Veova-acrylic tetramer binder emulsion formulation (i) comprises silane modified tetramer of monomers styrene - butyl acrylate - Veova-10 - methacrylic acid with Veova-10 content between 1-10 wt. %, total monomers between 38-50 wt.% and silane content between 0.2-3 wt. % of the total binder emulsion formulation also having polymerizable surfactant in the levels of 0.05-0.5 wt.%.
Preferably said texture coating formulation is provided wherein Veova-10 content only between 1-5 wt.%, silane content only between 0.6-1.0 wt.% and methacrylic acid content between 0.5-2 wt.% of the total binder emulsion formulation with particle size of the binder emulsion in the range of 80-130 nm are key to water absorption and anti-efflorescence performance of the resulting texture coating formulation due to efficient packing together with conventional/ select sand formulation where water absorption is reduced by 50% with 2 times improvement in efflorescence of the resulting coating observed as compared to conventionally known texture paint samples.
According to another preferred aspect of the present invention there is provided said texture coating formulation wherein said binder emulsion formulation is present in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate upon trowel application and is preferably present in the levels of 8-14 wt.% also adapted to reduce water absorption of conventional texture paints when added to it.
Preferably said texture coating formulation is provided wherein said sand formulation (ii) comprises coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30 mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of the total sand formulation.


According to another aspect a sand formulation adapted to reduce water absorption in texture coating formulations is provided comprising coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of the total sand formulation optionally including china clay in amounts of 0-10 wt.%, said sand formulation when incorporated in conventional texture paints could also enable reduction in water absorption.
According to another aspect of the present invention there is provided a process for manufacture of texture coating formulation comprising the steps of providing (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler/extender in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate and blending the same to attain said texture coating formulation.
Preferably said process is provided for manufacture of texture coating formulation wherein said step (i) of providing silane modified Veova-acrylic tetramer binder emulsion is based on the following sub-steps based on seeded emulsion polymerization
(a) Pre-heating demineralized water in a reactor at 78-82 degree C followed by adding anionic surfactant alkyldiphenyloxide Disulfonate for emulsion processing;
(b) dissolving the Initiator Potassium persulfate (PPS) in demineralized water;
(c) dissolving buffer agent Sodium Bicarbonate(SBC) in demineralized water;
(d) preparing a pre-emulsion separately containing anionic surfactant like polymerizable surfactant and non-ionic surfactant like Alcohol ethoxylate (30M), adding Potassium persulfate dissolved in demineralized water followed by adding monomers-Styrene, Butyl acrylate, Veova-10, Methacrylic acid, Vinyl Trimethoxy Silane one by one into the pre-emulsion;
(e) adding 5% pre-emulsion seed into the reactor followed by adding dissolved PPS solution and dissolved SBC solution (b) and (c) into the reactor and post 15 mins rest of pre-emulsion addition is done for 240-260 mins for seeded emulsion polymerization to proceed due to which free monomers are consumed by addition of digestion catalyst, Tertiary butyl hydroperoxide (TBHP) and Sodium formaldehyde sulfoxylate(SFS) by 90 min of continuous addition;
(f) cooling the emulsion down to 40-45 degree C;
(e) adding additives of in-can biocide Nipacide CFF MV, defoamers Tegofoamex K3, followed by adding neutralizer Liquor Ammonia that is followed by filtration giving said binder emulsion formulation of particle size of 80-130 nm preferably 90-105 nm with glass transition temperature of 19-21 degree C and enabling an emulsion film that is bits free, non-tacky and clear with Bluish white appearance.
Preferably in said process for manufacture of texture coating formulation wherein said step (ii) of providing sand formulation comprises adding coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30 mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of to obtain select sand formulation.
According to another preferred aspect of the process for manufacture of texture coating formulation wherein said texture coating formulation by incorporating said binder emulsion and said sand formulation is based on the following sequence of blending steps comprising:
(a) adding Water, defoamer, non-ionic surfactant, dispersing additive and biocide in a blender followed by slow addition of Bentonite organo clay and mixed for 10 mins to form a uniform jelly;
(b) adding neutralizer and then carrying out mixing for 10 mins, adding dispersing agent, non-ionic surfactant and open time enhancer sequentially followed by binder emulsion formulation addition and mixing again for 10 mins, again followed by intermittently adding sand formulation/extenders including Dolomite, Marble powder and optionally China clay followed by adding select levels of binder emulsion formulation to maintain consistency and thereafter adding PU (polyurethane) thickener, coalescent, and demineralized water to obtain therefrom said texture coating formulation of consistency desired of said formulation.

BRIEF DESCRIPTION OF FIGURES
Figure 1: illustrates efflorescence test results for (a) Texture paint 1 with Latex A as per the present invention and (b) commercial sample that shows complete wetting, tested as per Test method C.

DETAILED DESCRIPTION OF THE INVENTION
As discussed hereinbefore, the present invention provides for texture coating formulation preferably suitable for trowel application comprising a select Veova-acrylic binder in select dosage levels, and includes sand formulation having wide sized sandy fillers/extenders of select particle sizes leading to efficient packing when applied as a coating film enabling significantly low water absorption by the film.
The select latex binder of the present invention involved in the coating formulation has a Tg between 5-15 ?C and MFFT between 10-15 ?C, including a silane modified tetramer of styrene-butyl acrylate-Veova-10-methacrylic acid with Veova-10 content only between 1-5% of the total formulation with the total active monomers between 38-50 wt% and silane content between 0.6%-1.0%. The acid content of the copolymer tetramer utilized is between 0.5-2% of the total formulation. The particle size of the latex is between 80-130 nm. All the aspects in the design of the latexes are key for water absorption and anti-efflorescence performance of the texture coating.
Texture coating formulation of the present invention comprises fillers/extenders including Marble powder 18/240Mesh, Dolomite sand 30/80 mesh, Dolomite 240 mesh, Dolomite sand 16/30mesh, Dolomite 3MM, Dolomite 6/8/12 mesh, which fillers synergizes with select silane modified tetramer of styrene-butyl acrylate-Veova-10-methacrylic acid in combination that is critical towards the attainment of most efficient packing of the resultant coating enabling significantly low water absorption by the coating film.
The water absorption is reduced by 50% and 2 times improvement in efflorescence of the coating film is observed.
Examples:-Attainment of Waterproofing texture
Synthesis of Emulsion Latex A
The Veova-Styrene-Acrylic emulsion is synthesized by conventional seeded emulsion polymerization. Pre-heated demineralized water (DMW) is taken into the reactor for processing of emulsion. Anionic surfactant Dowfax 2A1 is added into the reactor. Buffer agent Sodium Bicarbonate (SBC) is dissolved in demineralized water. Initiator Potassium persulfate is dissolved in demineralized water. Pre-emulsion contains anionic surfactant like Adeka SR 2090 and non-ionic surfactant like Atpol 5731. Potassium persulfate (PPS) is dissolved in demineralized water and added into the pre-emulsion vessel. Monomers - Styrene, Butyl acrylate, Veova-10, Methacrylic acid is added one by one into the pre-emulsion vessel.
5% seed is added into the reactor in between 78-82 degree C. Dissolved PPS solution and SBC solution is charged into the reactor. After 15 mins, pre-emulsion addition is done for 240-260 mins. Free monomers are consumed by addition of digestion catalyst, TBHP and SFS by 90 min continuous addition. Emulsion is cooled down to 40-45 degree C. Additives added are In-can biocide Nipacide CFF MV, defoamers Tegofoamex K3, and neutralizer Liquor Ammonia. Properties were checked after filtration of the batch. Particle size was found to be within 80-130 nm preferably around 90-105 nm. Glass transition temperature is tested in DSC instrument found to be 19-21 degree C. Emulsion film is found to be bits free, non-tacky and clear with Bluish white appearance, which is desired, as any alteration of monomer constitution and wt.% range and process pathway leads to particle size variation and presence of bits on film and tackiness of films.

Table 1-
RC PBW
Demineralized water 10-20
alkyldiphenyloxide Disulfonate (Dowfax 2A1) 0.2-0.5
Sodium bicarbonate 0.1-0.3
Demineralized water 1-3
Potassium per sulfate 0.07-0.15
Demineralized water 2-3

Pre-Emulsion 1
Demineralized water 20-25
Alcohol ethoxylate (30M)- Atpol 5731 0.1-0.5
Polymerizable surfactant-Adeka SR 2090 0.05-0.5
STYRENE 10-30
Butyl acrylate 10-30
Vinyl neodecanoate-veova 10 0-10
Methacrylic acid 0.5-2
Potassium per sulfate 0.1-0.5
Demineralized water 2-5
Vinyl trimethoxysilane 0.2-3.0
Digestion
Tertiary butyl hydroperoxide 0.1-0.3
Demineralized water 0.5
Sodium formaldehyde sulfoxylate 0.1-0.3
Demineralized water 3.62
ADDITIVES
Biocide 0.02
Demineralized water 0.5
Defoamer 0.02
Demineralized water 0.3
Neutraliser 0.7-2%
Total 100

Texture coating/ Paint formulation
A typical texture paint TP-01 with 2 mm thickness is made by mixing the components given in Table 2 below in a blender as described in select sequence to maintain consistency desired of a texture paint formulation. Water, defoamer and biocide are added in the blender followed by slow addition of organo clay. The mixture is mixed for 10 mins and a uniform jelly is prepared. Neutralizer is added and then mixing is carried out for 10 mins, then dispersing agent, non-ionic surfactant and open time enhancer are added sequentially. Mixing is carried out for 10 mins, and extenders (Dolomite, Marble powder and China clay) are added sequentially followed by latex A. Sand is added as per the sequence with the addition of Latex A to maintain the consistency. After addition of all the sand and Latex A, PU thickener is added. Finally coalescent is added and demineralized water is added.
The formulation can be extended to 1mm-3mm.

Table 2
1 Demineralised water 1 – 15
2 Defoamer 0 – 0.5
3 Biocide 0 – 1
4 Bentonite Organo clay 0.1 – 2.5
5 Neutraliser 0 – 1
6 Dispersing Additive 0 – 2
7 Non-Ionic Surfactant 0 – 2
8 Di ethylene glycol 0.1 – 5
9 DOLOMITE 240 # 5 – 30
10 MARBLE POWDER 18/240M 5 – 40
11 CHINA CLAY 0 – 10
12 Latex A 2 – 20
13 DOLOMITE SAND 30/80 10 – 50
14 DOLOMITE SAND 16/30 5 – 20
15 Latex A 2 – 20
16 DOLOMITE SAND 3 MM 1 – 10
17 DOLOMITE SAND 6/8/12 1 – 10
18 Latex A 2 – 20
19 PU Thickener 0 – 5
20 Mineral turpentine oil 0 – 10
22 Water beading additive 0 – 10
23 Demineralised WATER 1 - 15
TOTAL 100

Test Method A: Procedure to determine Water Absorption of Texture Film attained:
1. Take glass plate of Specific shape and size.
(Note: All glass plates should have uniform size and weight.
2. Weigh all glass plates and Record the readings for reference.
3. Apply uniformly texture sample as such on glass plate (in duplicate set) by Trowel without scratch to achieve uniform thickness of Texture as desired (as per spreading capacity of texture).
4. Allow the applied panels to air dry properly for 7 Days at Room Temperature.
5. After 7 days drying, record the weight of glass plates with texture as Initial weight and then dip all plates in container containing water (Fully immerse in water).
6. Remove all panels from container after 3 days and soak the extra water gently from panel surface with Cotton/Muslin cloth.
7. Record the weights of all panels as Final weight after 1 Hr, 2 Hrs, 4 Hrs, 24 Hrs, 48 Hrs, 5 Days and 7 Days, and calculate the percentage of water absorption as mentioned below:

Percentage of Water absorbed by Texture Film =

(Final Weight of Texture Panel – Initial Weight of Texture Panel) X 100
‘-------------------------------------------------------------------------------------------
Initial Weight of texture panel

Test Method B: Procedure to Perform Rilem Test on Texture Film: Water Absorption Under Low Pressure (Pipe Method)
1. Apply the texture system: Primer + Texture (With Topcoat or without topcoat) as per mentioned test method.
2. Allow it to air dry for 7 days then start to perform the test by application of Rilem tube.
3. Record the results after 4Hrs, 24 Hrs and 96 Hrs (4days) with drop in level of water in Rilem tube.
4. Test to be conducted always in comparison with Control Sample.
Test Method C: Procedure to check Efflorescence Resistance of Texture:
Highly porous mortar method of application:
1. Take highly porous concrete mortar bed having dimensions of 150 X 150 X 20 mm.
2. Apply texture system on Mortar bed (application as per covering capacity) : Primer + Texture + Topcoat (2 coat) with Terracotta Shade/Blue Shade (Shades are only for better observations of efflorescence).
3. Allow it to air dry for 7 days. After complete drying, place this mortar bed in 15 % NaCl Solution in water.
4. Note down the observation for any defect like efflorescence, blisters, cracking etc periodically and record it for 15 days to 2 months in comparison with control sample.
The generic binder synthesis was carried as per the procedure in Table 1. The binder prototypes were made, and paint was made as per the Table 2 above. The individual components of the binder are shown in Table 3 varied within the scope of Table 1 ingredients for studying the impact on water resistance. Latex B and Latex C shows the importance of vinyl trimethoxy silane in the formulation especially indicated by Latex C which leads to the desired decrease in water absorption. Comparative binder formulation Latex D and E shows the role of polymerizable surfactant through Latex D. As both the formulations are same, only the surfactant type is different, it can be inferred that the polymerizable surfactant in combination is essential for achieving the low water absorption but is required to be involved at lower amounts due to cost considerations. The introduction of Veova-1 synergistically further decreases the water absorption as shown in Latex A.

Table 3-Water absorption tested for the texture paint as per the method described in method 1 except 3 days curing and 96 hrs of immersion in water. Batch no. describes the Latex formulation used in the paint. Emulsion dosage in the formulation is 12%
Latex % Water absorption Vinyl neodecanoate Vinyl trimethoxysilane Surfactant
Latex B 23.35 2 0.4 Polymerisable ether sulfate surfactant
Latex C 21.73 2 0.6 Polymerisable ether sulfate surfactant
Latex D 16.18 0 1 Polymerisable ether sulfate surfactant
Latex E 20.24 0 1 Sodium Laureuth Sulfate
Latex A 18.69 5 0.6 Polymerisable surfactant

To understand the impact of binder in the formulation, comparison is made of commercial texture paint and the commercial paint with Latex A (Table 4). The water absorption goes down significantly. The texture Paint with the commercial latex shows poor water resistance as compared to the Texture paint 1 as defined by Table 1 involving Latex A.
Table 4- Water absorption of texture paint with Latex A and Commercial latex.
Descriptions 0.5 Hr 1 Hr 2 Hr 4 Hr 24 Hr 48 hr 4 Days 7 Days
Texture Paint 1 with Latex A 1.58 2.08 3.02 3.85 8.73 11.67 14.71 17.47
Createx Scratch Finish Texture 9.32 11.13 13.49 15.45 23.23 30.51 36.08 39.19
Commercial Sample with Latex A 3.75 4.60 5.37 6.74 11.28 14.72 21.38 25.76
Texture Paint 1 with
ACRONAL IN 296D AP
3.98 5.45 7.62 11.33 21.59 29.35 Film Detached Film Detached

The select binder content in the formulation is between 8%-14%. Increase in the binder content will negatively impact the application properties, material loss during application. The formulation also becomes economically unviable. For low water absorption, 12-14% binder emulsion formulation is required. In Table 5 below, water absorption of the texture paint at dosage 10.75% and 12% is measured. At 12% dosage, significant improvement is seen. Rilem testing has not shown the difference as shown in Table 6.

Table-5 Water absorption showing select dosage of the Latex A in the texture paint formulation.
Description 0.5 Hr 1 Hr 2 Hrs 4 Hrs 24 Hrs 48 Hrs 4 Days
Texture Paint with Latex A (Dosage -10.75%) 2.10 2.90 3.60 5.75 11.73 14.60 19.20
Texture Paint with Latex A (Dosage -12%) 1.49 1.79 2.15 4.34 5.55 8.02 10.66
Createx Scratch Finish Texture 5.72 6.54 7.81 11.50 18.05 23.27 29.94

Table-6 Rilem testing showing select dosage of Latex A in texture paint formulation
Description 30 Min 1 Hr 2 Hr 4 Hr 24 Hr 48 Hr 72 hr
Texture Paint with Latex A (Dosage -10.75%) 0.05 0.1 0.1 0.15 0.5 1 1.5
Texture Paint with Latex A (Dosage -12%) 0.05 0.1 0.1 0.15 0.55 1 1.5
Createx Scratch Finish Texture 0.05 0.1 0.3 0.5 1.6 4.8 > 5 mL

The sand/filler formulation used as per the formulation of Table 8 is unique and impactful as can be seen in water absorption results of Table 9 below. Any change of the formulation causes loss of impact. Table 9 further shows that the texture paint 1 of the present invention involving the select binder A but with the conventional sand formulation as shown in Table 7 shows significant improvement in water absorption decrease as compared to the standard sample (Commercial texture paint sample) that can be attributed to the present select latex binder A, however, after 48 hrs the film detached. Moreover, the present texture paint A with latex binder A together with unique sand formulation of Table 8 shows further improvement in water absorption test, as compared to texture paint A of the present invention with sand formulation of Table 7. It can be also inferred from the results of Table 9 that commercial sample with present unique sand formulation significantly improves water absorption test by decreasing water absorption.

Table-7 Sand formulation of the commercial texture paints
Description Qty.
MARBLE POWDER 18/240M 5 – 45
DOLOMITE SAND 30/80 10 – 60
DOLOMITE SAND 3 MM 1 – 10
DOLOMITE SAND 6/8/12 1 – 10

Table-8 Unique Sand formulation of the Texture paint 1
Description Qty.
DOLOMITE 240 MESH 5 – 30
MARBLE POWDER 18/240MESH 5 – 40
Kaolin Clay (Hydrous Aluminium Silicate)
0 – 10
DOLOMITE SAND 30/80 10 – 50
DOLOMITE SAND 16/30 5 – 20
DOLOMITE SAND 3 MM 1 – 10
DOLOMITE SAND 6/8/12 1 – 10

This sand formulation specified in select wt.% ranges is unique in being key to water absorption and anti-efflorescence performance of the resulting texture coating formulation due to allowing efficient packing based on said select sand formulation where water absorption could be much reduced as exemplified. Any changes in the type of material and wt.% ranges destroys such stated packing.

Table-9 Water absorption table to demonstrate the sand composition impact on the formulation
Extender combination 30 Min 1 Hr 2 Hrs 4 Hrs 24 Hrs 48 Hrs
Createx Scratch Finish Texture with Sand formulation of Table 8 1.90 2.46 3.09 4.14 9.07 14.18
Texture Paint 1 with sand formulation as in Table 7 2.79 3.68 4.59 6.07 13.68 17.83
Createx Scratch Finish Texture 9.32 11.13 13.49 15.45 23.23 30.51

It is thus possible by way of the present advancement to provide for texture coating formulation preferably suitable for trowel application comprising a select Veova-acrylic binder in select dosage levels, and includes sand formulation having wide sized sandy fillers/extenders of select particle sizes leading to efficient packing when applied as a coating film enabling significantly low water absorption by the film.
,CLAIMS:We Claim:
1. Texture paint/coating formulation comprising synergistic co-acting combination of select (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler/extender.
2. The texture coating formulation as claimed in claim 1 suitable for trowel application wherein said silane modified Veova-acrylic tetramer binder emulsion formulation (i) comprises silane modified tetramer of monomers styrene - butyl acrylate - Veova-10 - methacrylic acid with Veova-10 content between 1-10 wt. %, total monomers between 38-50 wt.% and silane content between 0.2-3 wt. % of the total binder emulsion formulation also having polymerizable surfactant in the levels of 0.05-0.5 wt.%.
3. The texture coating formulation as claimed in claims 1 or 2 wherein Veova-10 content only between 1-5 wt.%, silane content only between 0.6-1.0 wt.% and methacrylic acid content between 0.5-2 wt.% of the total binder emulsion formulation with particle size of the binder emulsion in the range of 80-130 nm are key to water absorption and anti-efflorescence performance of the resulting texture coating formulation due to efficient packing together with conventional/ select sand formulation where water absorption is reduced by 50% with 2 times improvement in efflorescence of the resulting coating observed as compared to conventionally known texture paint samples.
4. The texture coating formulation as claimed in claims 1-3 wherein said binder emulsion formulation is present in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate upon trowel application and is preferably present in the levels of 8-14 wt.% also adapted to reduce water absorption of conventional texture paints when added to it.
5. The texture coating formulation as claimed in claims 1-4 wherein said sand formulation (ii) comprises coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30 mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of the total sand formulation.


6. Sand formulation adapted to reduce water absorption in texture coating formulations comprising coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of the total sand formulation optionally including china clay in amounts of 0-10 wt.%, said sand formulation when incorporated in conventional texture paints could also enable reduction in water absorption.
7. A process for manufacture of texture coating formulation as claimed in claims 1-5 comprising the steps of providing (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler/extender in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate and blending the same to attain said texture coating formulation.
8. The process for manufacture of texture coating formulation as claimed in claim 7 wherein said step (i) of providing silane modified Veova-acrylic tetramer binder emulsion is based on the following sub-steps based on seeded emulsion polymerization
(a) Pre-heating demineralized water in a reactor at 78-82 degree C followed by adding anionic surfactant alkyldiphenyloxide Disulfonate for emulsion processing;
(b) dissolving the Initiator Potassium persulfate (PPS) in demineralized water;
(c) dissolving buffer agent Sodium Bicarbonate(SBC) in demineralized water;
(d) preparing a pre-emulsion separately containing anionic surfactant like polymerizable surfactant and non-ionic surfactant like Alcohol ethoxylate (30M), adding Potassium persulfate dissolved in demineralized water followed by adding monomers-Styrene, Butyl acrylate, Veova-10, Methacrylic acid, Vinyl Trimethoxy Silane one by one into the pre-emulsion;
(e) adding 5% pre-emulsion seed into the reactor followed by adding dissolved PPS solution and dissolved SBC solution (b) and (c) into the reactor and post 15 mins rest of pre-emulsion addition is done for 240-260 mins for seeded emulsion polymerization to proceed due to which free monomers are consumed by addition of digestion catalyst, Tertiary butyl hydroperoxide (TBHP) and Sodium formaldehyde sulfoxylate(SFS) by 90 min of continuous addition;
(f) cooling the emulsion down to 40-45 degree C;
(e) adding additives of in-can biocide Nipacide CFF MV, defoamers Tegofoamex K3, followed by adding neutralizer Liquor Ammonia that is followed by filtration giving said binder emulsion formulation of particle size of 80-130 nm preferably 90-105 nm with glass transition temperature of 19-21 degree C and enabling an emulsion film that is bits free, non-tacky and clear with Bluish white appearance.
9. The process for manufacture of texture coating formulation as claimed in claim 7 or 8 wherein said step (ii) of providing sand formulation comprises adding coarser dolomite, dolomite sand and marble powder as filler/extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10–50 wt.% Dolomite Sand 30/80 mesh, 5-20 wt.% Dolomite Sand 16/30 mesh, 1–10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6/8/12 mesh, and 5–40 wt.% marble powder 18/240Mesh of to obtain select sand formulation.
10. The process for manufacture of texture coating formulation as claimed in claims 7-9 wherein said texture coating formulation by incorporating said binder emulsion and said sand formulation based on the following sequence of blending steps comprising:
(a) adding Water, defoamer, non-ionic surfactant, dispersing additive and biocide in a blender followed by slow addition of Bentonite organo clay and mixed for 10 mins to form a uniform jelly;
(b) adding neutralizer and then carrying out mixing for 10 mins, adding dispersing agent, non-ionic surfactant and open time enhancer sequentially followed by binder emulsion formulation addition and mixing again for 10 mins, again followed by intermittently adding sand formulation/extenders including Dolomite, Marble powder and optionally China clay followed by adding select levels of binder emulsion formulation to maintain consistency and thereafter adding PU (polyurethane) thickener, coalescent, and demineralized water to obtain therefrom said texture coating formulation of consistency desired of said formulation.

Dated this the 22nd day of November, 2023 Anjan Sen
Anjan Sen and Associates
(Applicants Agent & Advocate)
IN/PA-199