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    11 views11 pages

    US8236885B2

    Uploaded by

    ALEXANDER FRANCO CASTRILLON

    Copyright:

    © All Rights Reserved
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    ‘USOO8236885B2 2) United States Patent (10) Patent No: US 8,236,885 B2 Tarng et al (45) Date of Patent: Aug. 7, 2012 (64) EXTERIOR PAINT FORMULATION {9040.30 832000, Menovck ta 00090 A $000 Jahon : ‘sams A 62000 Fy tal (75) Tnveawors: Ming-Ren Tarng, vine, CA (US), 00.900 A $000 Freyetal Mark Minamyer, Also Viego, CA iueses ® 72000 Farah ea (US); Anh Pham, vine, CA (US), Stan fier 8 a3 Vien Brownell, Rancho Seats Manat CA saueors Br 'Y3001 vere (Gey antic Pham, Anaieen, CA (US, «200824 BL 32001 amar ‘Anil Alesander, Sana Ans, CA (US), 2001 Ath et Deven Sha, Palms, C4 (US): Kim nt Reyna Er Nguyen, Sata Ams, CA US) My Mani al Tinh Pham, Anabein, CA (US), Sidney Gere Maxey, Rancho Santa Margi, CA Naat ws) Hoan be Sans BE (73) Assignee: Behr Process Corporation, Santa Ana, 20020028867 Al cA US) os 8 2eosooisios Al Znnvnoosss7 Al ‘rental (*) Note: Subjectio any disclaimer the term ot his Saunas. At eee Talent is extended or adjisted under 35 20080181399 AL Nata USC. 1540) by O days. Zponoisess9 Al Retna y jonnoaiais? Al Coxe ooswaiow1 Al ow tal (21) Appl. Nos 121620,226 Zonnonsae Al {tan Fanaoesoss Al Fava (22) ‘ied: Nov. 17,2009 anannssase AL aga ta 2ounz02s01 Al Went ( Prior Publication Data Zamneonsons6 AL Tag oionai? Al Tanga US 20100137495.A1 Jun. 3, 2010 FOREIGN PATENT DOCUMENTS, Related US. Applicaton Data ca 2313765 AL * 2001 re oan? Al 12i990 (62) Division of pplication No, 10914439, fled on Aug. Ep Sous At ‘aioe 9, 2004 08 Pat. No, 7.642309 i Bessa BLS ib Desas BL Smt Gh me. i 0835541 BL thst Coek 30 (2006.01) i {ioaar Az 3003 cost 3300 (2006.01) os Ligels Signa (52) USC nn S24MN2; S73; 324490, 524/497, GB Tas alone 524/501; $24/522; $24/523 TW Biot aor (58) Field of Classification Search 524/32, OTHER PUBLICATIONS 124497, 501-503, 523.533; 523384 see appication a7 2h, Me, 522223; ‘id, ms, “Don Skipthe Prion” Fine Homan Feb, Ma See application file for complete search history. nde ‘Wood el, Prins and Unt” PuiPR, vl, 3, No 5 6) References Cited Reni Sa US. PATENT DOCUMENTS * cited by examiner A 911988 tain , SBS A TS Net a Primary Evaminer —Vickey Nerangis naet A Mom Come (04) Attorney, Agent or Firm — Rath Linden LLP Sia A to02 Lovamlonsk eal Shes A too Neel 5,385.90 A 1/1995 Emmons et al on ABSTRACT San0019 A $098 Roulone tal The present invention provides increased sain resisiace Sak A 88 Li 24641 annin blocking alheston, and various other properties. A ss Simpson is composition in sceordanc wit he principle othe present 5,534,385 A 7/1996 Roulstone et al. Poona ™ SURE A Tiss Ronkeeets fnvettion comprises at least two binders, nanoparticle pig- Sesoo0o 241997 Bae ‘ea dd pigmentary titnium dioxide, In one embodiment S088) AL 1BDT Sar otal the preset invention relates to a coating on a sibstate ST41.44 A © 4/1998 Nass etal ‘524/523 wherein the coating has two binders, nanoparticle metal oxide Sango A+ $1908 Ninel we Severe ate cree lmecaea Pigment, and pigmentary titanium dioxide Various aves Soph Oss tee ‘ay be inlued to Formulate pats knows athe a. Soie207 A 111599 Haat einsiad A 121999) Karen 6 Claims, 5 Drawing Sets U.S. Patent Aug. 7, 2012 Sheet 1 of 5 US 8,236,885 B2 ADHESION 10 STAIN DB TANNIN REMOVAL BLOCKING HIDING POWER CORROSION —@— COMMERCIAL SATIN 1 —t#— SUPER EXTERIOR SATIN FIG. 1 U.S. Patent Aug. 7, 2012 Sheet 2 of 5 US 8,236,885 B2 ADHESION 10, STAIN DB TANNIN REMOVAL, BLOCKING HIDING POWER CORROSION —@ COMMERCIAL FLAT 1 cm SUPER EXTERIOR FLAT FIG. 2 U.S. Patent Aug. 7, 2012 Sheet 3 of 5 US 8,236,885 B2 ADHESION 10 STAIN DB TANNIN REMOVAL BLOCKING HIDING POWER CORROSION —@— COMMERCIAL SEMI-GLOSS 1 —W— SUPER EXTERIOR SEMI-GLOSS FIG. 3 > FIG. 4 U.S. Patent Aug, 7, 2012 Sheet 5 of 5 ADHESION HIDING POWER —@— COMMERCIAL STAIN 2 —™— SUPER EXTERIOR SATIN FIG. 5 US 8,236,885 B2 1 EXTERIOR PAINT FORMULATION ‘CROSS REFERENCE TO RELATED PATENT. "APPLICATIONS, “The present application isa divisional application of US. patent application Sex. No. 101914439, fled Aug. 9,2004and 's incorporate herein by reference in is entirety. FIELD OF THE INVENTION ‘The present invention relates to polymer resins. More par: ticularly, the present invention relates to paints having asino- particle based pigment and a plurality of binders. BACKGROUND OF TH INVENTION Traditionally consumers have had to choose between the superior durability offered by Tatex paints and the superior hiding properties of oil-based paint, Conventional latex oF ‘emulsion paints require an underlying primer coat prior to their application to provide an adequate level ofblocking and to proven! blecd-through, such as of tannins. In addition, ‘many conventional latex paints require a primer coat to pro- vide adequate adhesion and durability for specific applica- tions. Often, even when a primer i applied, multiple coats of the prior ar paints are required to prevent an alteration of color due tothe presence of the primer or bleed throvgh of ‘dyes and pigments from the underlying substrate. In foc, rnutiple applications of pei ar paint will not prevent bloed- through on substrates sich as colar since the dyes an pig= ments, sich as tannins contained in the substrates, are often ‘water solubleanffise through each layer othe latex paint, ‘aint typically contains four essential ingredients, namely pigment, binder, liquid and additives. Any or all of these Ingredients may be a single component or may comprise multiple items. Pigment provides color to paint and also makes paint opaque, and pigment is usually of mineral or ‘organi origin although some pigments are artificially pro- ‘duced. Some pigments possess litle or no bulk and must be fixed on a more soli, but atthe same time transparent, sub- stance or base. “Prime” pigments provide color and opacity (opaque coverage). The most common prime pigment si nium dioxide, which is white and is used in lex and oil based paints, “Traditionally pigments have also added hiding properties to paint. Specialty or extender pigments may also beused and provide bulk to the paint at Tow cost, The extender pigments ‘are often chosen for their impuet on properties lke serub resistance, stain resistance and chalk resistance. Alum orelay fare frequently used for this purpore. These pigments are added 1 the paint to provide certain characteristics such as thickness, a certain level of gloss and durability. They are ‘asually naturally oourring products which originally were in the earth and were mined and purified for use in paint Such pigmentsscalcium carbonate, tale andclay ar, forexamplo, used extensively in paints The binder bolds the pigment and also adheres it to 3 surface, and a binder composition may have more than one ‘component. In atx paint, te latex resin is the binder. Most ‘commonly in latex paint, the binder is 100% acrylic, vinyl scrylie (polyvinyl acetate), or styrencated acrylic. The pig- ‘ment partiles are insoluble and merely forma sospension ia the binder. The binder “binds” the pigment into a tough, ‘continuous film and as noted above helps the pit adhere 10 the surface, In addition, ithas heen found previowsly thatthe use of 100% acrylic binder provides for maximum adhesion 0 o 2 when wet and also provides for resistance to blistering and peeling, sistance to mildew and dir, and alkali resistance {or paint applied over fresh masonry ‘Liquids carry the pigment and binders, and thsliguidisthe part of the paint or coatings product which evaporates, The role ofthe fs isto koop the paint ina id form for ease of application. Once applied to the surface it evaporates leaving uniform film which then dries to form a protective coating. ‘The liquid used is primarily determined by the solubility of the binder In oil-based and alkyd pains, the liquid istypically a paint thinner, and in latex paints, the liquid is typically ‘water. Traditionally, top quality pats have less Figuid and snore solids (i.e. pigment & binders) as measured by percent solid ‘Additives are ingredients sed at low levels to provide key properties, such as but not limited to: mildew resistance, better flow and leveling, and splatter resistance. Common additives used in conventional paint formulations inelude rheology modifiers, surfactant, defoamers,coalescents, and biocides, Other numerous additives are well-known inthe at and may be utilized as required to formulate a paint having the desired propetes ‘Varios techniques are known in the art For producing pints having various types of sheens, i. “shine” oF gloss. For example, by incrementally increasing pigment levels and ‘or by using lager pigment partiles, various gloss levels ean be achieved inluding, but not Kimited to fat, satin, and semi loss. Pigment volunie concentration (PVC) is often asso ated with the paint finish, although various finishes may have ‘overlapping ranges of PVC. PVC is the unit volume of pig- ments a a percentage ofthe volume of pigments plus the volume of the binder. PVC represents the relationship between durability ofthe coating and the amount of pigment. "Thus. there isa need fora paint composition and method of ‘making thesame' replacethe traditional oleofaprimerand {opcoat system and which is capable of providing a coating ‘having improved properties suchas, tannin blocking, hiding power, stan removal, and corrosion resistance, ‘SUMMARY OF THE INVENTION ‘The present invention relates generally toa binder compo- sition and a paint system with superior tannin blocking, stain removal, cofrosion resistance, adhesion, and various other ‘improved properties. ‘The present invention preferably includes two binder system with an inorzanie nano-parte Pigment and with a pigmentary titanium dioxide. In one embodiment, « paint composition in accordance with the prineiples of the present invention further includes adltives Tor formulating paint. In another embodiment, the present invention relates to a coating om a substrate that provides ‘improved coverage through the use of atleast two binders, an ‘organ nano-prtle pigment nds pena ann [BRIEF DESCRIPTION OF THE DRAWINGS. FIG. depicts. a multi-axis property graph of the test results ‘of paint of the present inveation having @ satin sheen and ‘white base, as compared to commercially svailable exterior satin in a white base; FIG. 2depicts amuli-axis property graph ofthe test results ‘of flat white base paint in accordance withthe principles of the present invention, as compared to a commercially ava able exterior flat paint in a white base; US 8,236,885 B2 3 FIG. 3 illustrates 4 multi-axis property graph of the test results for semi-gloss white base paint ofthe present inven- tion versus a commercially-available, exterior semi-gloss paint ina white base; IG, 4 illustrates « multi-axis property graph for a Mat white base paint of the present invention versus a second ‘commercially avilable exterior fat punt ina white base: and FIG. § ilusirates 8 multi-axis property graph fora satin ‘white base paint of the present invention versus a second, ‘commercally-available, exterior satin paint in a white bate. DETAILED DES CRIPTION OF THE PREFERRED EMBODIMENTS, ‘he present invention is directed in part toa polymer com= Position within a pant system which replaces the tational role ofa primer and a topcoat with improved properties sich 48 tannin blocking, sain removal, adhesion, and eorroso resistance, In one embodiment, the present invention relates toa composition having a ist binder, a second binder. nor sani nanoparticle pigments, andin some cases third binder. ‘This composition can be used ina comventional paint formu ton as known in the at ‘Binders for use in the present invention include those pre= pared by conventionally known methods. Suitable binders Include, but are no limited w, 100% acrylic resins and sty- eneated, aerylic resins as manufactured, Preferably. the fst binder is. 100% acryli resin designed to be used as primer vehicle, and the second binder is a 100% acrylic resin designed to be usin top coating spplications. Pigments forusein th present invention may comprise any suitable pigments known in the art. In one embodiment, the pigments ofthe present invention ae titanium oxide or zine ‘oxide bat other suitable pigment include nepheline syenite, bentonite, and calcium carbonate, Preferably, the primary Pigment is ttanium dioxide, such as commercially vailable Pigments. ‘Metal oxide nanoparticle materials for use in a preferred ‘embosiiment a the invention have an average particle size of about 20-150 nanometers, although some embodiments can ‘employ average sizes autside this range. In one preferred ‘embodiment, the nanoparticle material is azine oxide mate rial having an average partite sizeof about 60 nm. ‘A paint can he prepared in acconlance with the principles ‘of the present invention according to number of known, ‘manufacturing methods, Generally such methods involve the preparation ofa binder ora multiple binder system, mixing of the addtional ingredients, dispersing ofthe pigments, and adjusting the density and viscosity to desired levels. A variety ‘of additives and diluents which are well known inthe art aa bbe mixed withthe binders of the present invention toachieve ‘erin properties in the paint or the coating. The aitives may include, but are not limited to, surfactants, defeamers, rheology modifiers, coalescent, biocides, mildeweides, sur facants, and other additives well known in the art In one embodiment, a paint in aevordance with the prin- ciples of the present invention is manufactured to a VOC. (Nolatile Organie Compounds) of 150 gL. inching a 37% solid by volume, s 51% solid by weight a34 PVC, anda 1.5 Pizmeavbinder rato. “The PVC of paint in accordance with the principles of 3 preferred form of the present invention may vary between 4455 by weight. In one embodiment of the presen invention the paint isa “semi-gloss paint”, which has a relatively low PVC. In anther embodiment of the present invention, the paint i a “Satin paint, whieh has a relatively high PVC. 0 o “tat pain satin paint Table | lists the general anges of the main ingricats of 3 pint in aecordance withthe principle of apreferredembodi- ‘meat. The total amount of polymer (i. binder) s preferably ‘between sbout 30.60 gallons per 100 gllons. In one embed ‘meat, the rato ofthe first binder the second binders about 80:20. The first binder is, ia one embodiment, a self crosslinking polymer. The total amount of pigment, exclud- ing the Ti, is preferably between about 15 and about 150 pounds per 100 gallons. The TiO, content is preferably between 0 pounds per gallon and about 360 pounds per 100 sallons. The preservatives comprise between about 5 and faout 8 pounds per 100 gallons, Additional additives com- prise approximately $0 and approximately 200 pounds per 100 gallons. Water comprises between about $0 and about 200 pounds per 100 gallons. The paint further includes addi ‘ional solvent, aside from the Water content of benween about 30 and about 4S pounds per 100 gallons. In one embodiment, the nanoparticle metal oxide pigment particles have an aver age panicle size of less than about 100 nanometers. In & urther embodiment, the nanoparticle metal oxide pigment particles have an average particle size of between about 30 ‘anoaielers and about 6S nanometers, Which has a relatively high PVC compared (0 TABLE L ne on p00 Por esi a0 ‘300 ‘ian Dixie ‘on Eo Preemie So ’ tal « 1398 Ne 4 8 ‘The preferred formulation process consists of wo conven sional step: the grind and the letdowa. During the grind, the solvent (water), dispersant, defoamer, zine oxide, ethylene alyeol, amino alcohol, nepheline syenite attapulgite clay are ‘mixed together: During the letdown, the binder, the miklew- cide, the rheology modifier, and the biocide are added to the arind prod The following noa-limiting examples illustrate main com- ponents of the paint formulations and the paint formulations themselves. Table 2 provides the material ranges forthe com- ponents of the paint formulations of Pxammpes 1-4 TABLE 2 a ae asin Ra Mesa a US 8,236,885 B2 5 6 TABLE 2-continned Example? Rew Mei ane Sain Finish ai Example 2 was formulate using the si components of aw Maw bt Table 2, with he following specie components iw ar o TABLES ei Syne rose » ETE Rheology Modifier 1530, Sos ie Ace ep ner ros00 ve Sa arena ems Sore Act Tot in 1 Socrste Oe am Coden os ie et so 3m noni sa Sete oe wie one o xe mays Fae sutient ea % Photed Co-eser Sica im Crane Pee ono omen one east Ae ar os ae a Semon Seca os ae fo eae Example Example 1 lat Finish, Semi-Gloss Finish Example 3 was formulated using the basic components of Example 1 was formulated using the basic components of Table 2, with the following specific components rae 2 ne lowing cleanness “ TABLES ranLEs Grind “ a aortas _ See a Bey et ae So 7 | oe uesatiemave ae ——— i Couecen gaat tee gy_apehen e “Se 4 oe oe . US 8,236,885 B2 8 TABLE 6 continsed toe poet Weak Fa Fini — sample 4 wos formulated wing the bese componensof Ome 2 “Table 2. with the following specific components Ite fag ee te Np Skit oat u TABLES can Pa Anouk Weighs CMe om Novbathievna a Ethylene Glyeol 0 Sa La Adhesion Tests Sense cat te oes Core Dap oe Various sesion tests were perfomied to detemine the Nowhettet owe ou adhesion properties of pata corance wit he pir ines O1 Beton ole Sips of ie present imention on eile subsiances Th Note ene ste Satay reutlsof tho tts compares ptt of te pes invention o ate a 2 pial, commercially -valable paint and primer system Sol for exer us, an tose tess are presen ab 7 TABLE? Pim fommlaino AsnlisExton Asli Eo eee oe ey er eer es on cenghipen SBS MB SBSD Ietoet —ceapeayea «SBS «SBSD ee ee ee Sutewivigt cunaiayee 0 sts sn ssn sbuszelveel ceniddyiet 888383 Sax cine wp koe sloaybicke owenidh yer = samt dete oye 8081] Sdn su Soa “Re gpg ey heh poet een US 8,236,885 B2 9 In addition, a battery of tests were performed to evaluate the overall performance of a paint in accordance with the Principles ofthe present invention t various shcens as com pared to paints Currently available in the marketplace. AS shown in the results in Tables & and 9, the paint prepared in focordance with the prineiples ofthe present invention ott Performed ull o te oer points in the respective category. TABLES. = ; Super senor sees Sea ale Se ihe satin shen ofthe present invention ‘exhibits improved leveling, roller foam, contrast, and dry ahesion, TABL Heat Stability 3 3 3 3 mete PE : : Eitgee ft i i ihe 5 Yacrspts : SUSTENRa r e As illustrated in FIGS. 1, 2,3, 4, and 8, paint prepared in ‘acconiance with the principies ofthe present invention exhib- its improvements in adhesion, tannin blocking, sain removal, hiding power, and corrosion resistance. FIG. 1 depicts & multi-axis property graph ofthe test results of paint of the present invention having a satin sheen and white base, as ‘compared fo commercially-avalable, exterior satin ina white base. Adhesion, yellowing, stain removal, hiding. power, 0 o sured. FIG, 2 depets res of lat white base paint in accordance with the prin- ciples of the preset invention, as compared fo a commer. cially available exterior flat paint in a white base. FIG. 3 itlustates a multi-axis propery graph of the test results for semi-gloss white base pint ofthe present invention versus commercially available exterior semi-gloss paint in-a white ‘ase. All properties were improved in omnulatios in accor dance with the principles of the present invention with the ‘exception of semth resistance and yellowing, which showed a ‘edition, FIG. 4 illustrates a mnul-axis propery graph fora flat white base paint ofthe present invention versus a second commercially available, exterior fla paint ina white base. All ruperties were improved i formulations in accordance wilh the principles ofthe present invention. FIG. § illustrates ‘multi-axis property’ graph for a satin white base pat ofthe present invention verses a second commercally-xvailable, Exterior satin paint in a while bose. All properties were Smprovedin formulations naccondance withthe peiniplesot the present invention. ‘While’ several embodiments have been shown and deseribed inthis application, its understood that changes and ‘mexificaions ean be made tothe invention without departing from the invention’s broader aspects ‘What is claimed is 1. process for producing apsint composition comprising the steps of

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