Title of Invention

A PAINT COMPOSITION

Abstract A paint composition comprising a first acrylic binder of about 285 pounds per 100 gallons to about 630 pounds per 100 gallons; a second acrylic binder of about 50 pounds per 100 gallons to about 95 pounds per 100 gallons; a third acrylic binder of less than 180 pounds per gallons; a first metal oxide comprising pigmentary titanium dioxide; and a second metal oxide comprising a nanoparticle- sized metal oxide pigment of about 2 pounds per 100 gallons to about 20 pounds per 100 gallons wherein the paint composition has a PVC of about 4 to about 55 and a pigment to binder ratio of about 0.10 to about 3.0.
Full Text FIELD OF THE INVENTION
[0001] The present invention relates to polymer resins. More particularly, the present
invention relates to paints having a nanoparticle based pigment and a plurality of binders.
BACKGROUND OF THE INVENTION
[0002] Traditionally consumers have had to choose between the superior durability offered by
latex paints and the superior hiding properties of oil-based paint. Conventional latex or emulsion
paints require an underlying primer coat prior to their application to provide an adequate level of
blocking and to prevent bleed-through, such as of tannins. In addition, many conventional latex
paints require a primer coat to provide adequate adhesion and durability for specific applications.
Often, even when a primer is applied, multiple coats of the prior art paints are required to prevent
an alteration of color due to the presence of the primer or bleed through of dyes and pigments
from the underlying substrate. In fact, multiple applications of prior art paint will not prevent
bleed-through on substrates such as cedar since the dyes and pigments, such as tannins contained
in the substrates, are often water soluble and diffuse through each layer of the latex paint.
[0003] Paint 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 organic origin although some pigments are artificially produced. Some pigments
possess little or no bulk and must be fixed on a more solid, but at the same time transparent,
substance or base. "Prime" pigments provide color and opacity (opaque coverage). The most
common prime pigment is titanium dioxide, which is white and is used in latex and oil-based
paints.
[0004] Traditionally, pigments have also added hiding properties to paint. Specialty or
extender pigments may also be used and provide bulk to the paint at a low cost. The extender
pigments are often chosen for their impact on properties like scrub resistance, stain resistance

and chalk resistance. Alum or clay are frequently used for this purpose. These pigments are
added to the paint to provide certain characteristics such as thickness, a certain level of gloss and
durability. They are usually naturally occurring products which originally were in the earth and
were mined and purified for use in paint. Such pigments as calcium carbonate, talc and clay are,
for example, used extensively in paints.
[0005] The binder holds the pigment and also adheres it to a surface, and a binder composition
may have more than one component. In latex paint, the latex resin is the binder. Most
commonly in latex paint, the binder is 100% acrylic, vinyl acrylic (polyvinyl acetate), or
styreneated acrylic. The pigment particles are insoluble and merely form a suspension in the
binder. The binder "binds" the pigment into a tough, continuous film and as noted above helps
the paint adhere to the surface. In addition, it has been found previously that the use of 100%
acrylic binder provides for maximum adhesion when wet and also provides for resistance to
blistering and peeling, resistance to mildew and dirt, and alkali resistance for paint applied over
fresh masonry.
[0006] Liquids carry the pigment and binders, and this liquid is the part of the paint or coatings
product which evaporates. The role of the fluid is to keep the paint in a fluid form for ease of
application. Once applied to the surface it evaporates leaving a 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 paints, the liquid is typically a paint thinner, and in latex paints,
the liquid is typically water. Traditionally, top quality paints have less liquid and more solids
(i.e. pigment & binders) as measured by percent solid.
[0007] Additives are ingredients used 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 include rheology modifiers, surfactants,
defoamers, coalescents, and biocides. Other numerous additives are well-known in the art and
may be utilized as required to formulate a paint having the desired properties.
[0008] Various techniques are known in the art for producing paints having various types of
sheens, i.e. "shine" or gloss. For example, by incrementally increasing pigment levels and/or by
using larger pigment particles, various gloss levels can be achieved including, but not limited to


flat, satin, and semi-gloss. Pigment volume concentration (PVC) is often associated with the
paint finish, although various finishes may have overlapping ranges of PVC. PVC is the unit
volume of pigments as a percentage of the volume of pigments plus the volume of the binder.
PVC represents the relationship between durability of the coating and the amount of pigment.
[0009] Thus, there is a need for a paint composition and method of making the same to replace
the traditional role of a primer and topcoat system and which is capable of providing a coating
having improved properties such as, tannin blocking, hiding power, stain removal, and corrosion
resistance.
SUMMARY OF THE INVENTION
[0010] The present invention relates generally to a binder composition and a paint system with
superior tannin blocking, stain removal, corrosion resistance, adhesion, and various other
improved properties. The present invention preferably includes a two binder system with an
inorganic nano-particle pigment and with a pigmentary titanium dioxide. In one embodiment, a
paint composition in accordance with the principles of the present invention further includes
additives for formulating paint. In another embodiment, the present invention relates to a coating
on a substrate that provides improved coverage through the use of at least two binders, an
inorganic nano-particle pigment and a pigmentary titanium dioxide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 depicts a multi-axis property graph of the test results of paint of the present
invention having a satin sheen and white base, as compared to commercially available exterior
satin in a white base;
[0012] FIG. 2 depicts a multi-axis property graph of the test results of flat white base paint in
accordance with the principles of the present invention, as compared to a commercially available
exterior flat paint in a white base;
[0013] FIG. 3 illustrates a multi-axis property graph of the test results for semi-gloss white
base paint of the present invention versus a commercially-available, exterior semi-gloss paint in
a white base;


[0014] FIG. 4 illustrates a multi-axis property graph for a fiat white base paint of
the present invention versus a second commercially available exterior flat paint in
a white base; and
[0015] PIG 5 illustrates a multi-axis property graph for a satin white base paint
of the present invention versus a second commercially-available, exterior satin
paint in a white base.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] According to this invention there is provided a paint composition
comprising a first acrylic binder of about 285 pounds per 100 gallons to about
630 pounds per 100 gallons; a second acrylic binder of about 50 pounds per 100
gallons to about 95 pounds per 100 gallons; a third acrylic binder of less than
180 pounds per gallons; a first metal oxide comprising pigmentary titaniumk
dioxide; and a second metal oxide comprising a nanoparticle-sized metal oxide
pigment of about 2 pounds per 100 gallons to about 20 pounds per 100 gallons,
wherein the paint composition has a PVC of about 4 to about 55 and a pigment
to binder ratio of about 0.10 to about 3.0
[0017] The present invention is directed in part to a polymer composition within
a paint system which replaces the traditional role of a primer and a topcoat with
improved properties such as tannin blocking, stain removal, adhesion, and
corrosion resistance. In one embodiment, the present invention relates to a
composition having a first binder, a second binder, inorganic nanoparticle
pigments, and in some cases a third binder. This composition can be used in a
conventionai paint formulation as known in the art. Binders for use in the present
invention include those prepared by conventionally known methods. Suitable
binders include, but are not limited to, 100% acrylic resins and styreneated,


acrylic resins as manufactured. Preferably, the first binder is a 100% acrylic resin
designed to be used as a primer vehicle, and the second binder is a 100% acrylic
resin designed to be used in top coating applications.
[0018] Pigments for use in the present invention may comprise any suitable
pigments known in the art. In one embodiment, the pigments of the present
invention are titanium oxide or zinc oxide but other suitable pigments include
nepheline syenite, bentonite, and calcium carbonate. Preferably, the primary
pigment is titanium dioxide, such as commercially available pigments.
[0019] Metal oxide nanoparticle materials for use in a preferred embodiment of
the invention have an average particle size of about 20-150 nanometers,
although some embodiments can employ average sizes outside this range. In
one preferred embodiment, the nanoparticle material is a zinc oxide material
having an average particle size of about 60 nm.
[0020] A paint can be prepared in accordance with the principles of the present
invention according to a number of known manufacturing methods. Generally,
such methods involve the preparation of a binder or a multiple binder system,
mixing of the additional ingredients, dispersing of the pigments, and adjusting
the density and viscosity to desired levels. A variety of

additives and diluents which are well known in the art can be mixed with the binders of the
present invention to achieve certain properties in the paint or the coating. The additives may
include, but are not limited to, surfactants, defoamers, rheology modifiers, coalescents, biocides,
mildewcides, surfactants, and other additives well known in the art.
[0021] In one embodiment, a paint in accordance with the principles of the present invention is
manufactured to a VOC (Volatile Organic Compounds) of 150 gr/L, including a 37% solid by
volume, a 51 % solid by weight, a 34 PVC, and a 1.5 pigment/binder ratio.
[0022] The PVC of paint in accordance with the principles of a preferred form of the present
invention may vary between 4-55 by weight. In one embodiment of the present invention the
paint is a "semi-gloss paint", which has a relatively low PVC. In another embodiment of the
present invention, the paint is a "satin paint", which has a relatively high PVC. In another
embodiment of the present invention, the paint is a "flat paint", which has a relatively high PVC
compared to satin paint.
[0023] Table 1 lists the general ranges of the main ingredients of a paint in accordance with the
principles of a preferred embodiment. The total amount of polymer (i.e., binder) is preferably
between about 30-60 gallons per 100 gallons. The total amount of pigment, excluding the TiO2,
is preferably between about 15 and about 150 pounds per 100 gallons. The TiO2 content is
preferably between 0 pounds per gallon and about 360 pounds per 100 gallons. The
preservatives comprise between about 5 and about 8 pounds per 100 gallons. Additional
additives comprise approximately 50 and approximately 200 pounds per 100 gallons. Water
comprises between about 50 and about 200 pounds per 100 gallons. The paint further includes
additional solvent, aside from the water content of between about 30 and about 45 pounds per
100 gallons.

y


[0024] The preferred formulation process consists of two conventional steps: the grind and the
letdown. During the grind, the solvent (water), dispersant, defoamer, zinc oxide, ethylene glycol,
amino alcohol, nepheline syenite, attapulgite clay are mixed together. During the letdown, the
binder, the mildewcide, the rheology modifier, and the biocide, are added to the grind product.
[0025] The following non-limiting examples illustrate main components of the paint
formulations and the paint formulations themselves. Table 2 provides the material ranges for the
components of the paint formulations of Examples 1-4.



Example 1 - Semi-Gloss Finish
[0026] Example 1 was formulated using the basic components of Table 2, with the following
specific components:


Example 2 - Satin Finish
[0027] Example 2 was formulated using the basic components of Table 2, with the following
specific components:


Example 3 - Flat Finish
[0028] Example 3 was formulated using the basic components of Table 2, with the following
specific components:


Example 4 - Flat Finish
[0029] Example 4 was formulated using the basic components of Table 2, with the following
specific components:


Adhesion Tests
[0030] Various adhesion tests were performed to determine the adhesion properties of a paint
in accordance with the principles of the present invention on different substances. The results of
the tests compare a paint of the present invention to a typical, commercially-available paint and
primer system sold for exterior use, and these tests are presented in Table 7.


[0031] In addition, a battery of tests were performed to evaluate the overall performance of a
paint in accordance with the principles of the present invention at various sheens as compared to
paints currently available in the marketplace. As shown in the results in Tables 8 and 9, the paint
prepared in accordance with the principles of the present invention outperformed all of the other
paints in the respective category.

[0032] As seen in Table 9, the satin sheen of the present invention exhibits improved leveling,
roller foam, contrast, and dry adhesion.


[0033] As illustrated in FIGS. 1, 2, 3, 4, and 5, paint prepared in accordance with the principles
of the present invention exhibits improvements in adhesion, tannin blocking, stain removal,
hiding power, and corrosion resistance. FIG. 1 depicts a multi-axis property graph of the test
results of paint of the present invention having a satin sheen and white base, as compared to
commercially-available, exterior satin in a white base. Adhesion, yellowing, stain removal,
hiding power, scrub resistance, corrosion, and tannin blocking were measured. FIG. 2 depicts a
multi-axis property graph of the test results of flat white base paint in accordance with the
principles of the present invention, as compared to a commercially available exterior flat paint in
a white base. FIG. 3 illustrates a multi-axis property graph of the test results for semi-gloss
white base paint of the present invention versus a commercially available exterior semi-gloss
paint in a white base. All properties were improved in formulations in accordance with the
principles of the present invention with the exception of scrub resistance and yellowing, which
showed a reduction. FIG. 4 illustrates a multi-axis property graph for a flat white base paint of

the present invention versus a second commercially-available, exterior flat paint in a white base.
All properties were improved in formulations in accordance with the principles of the present
invention. FIG. 5 illustrates a multi-axis property graph for a satin white base paint of the
present invention verses a second commercially-available, exterior satin paint in a white base.
All properties were improved in formulations in accordance with the principles of the present
invention.
[0034] While several embodiments have been shown and described in this application, it is
understood that changes and modifications can be made to the invention without departing from
the invention's broader aspects.

WE CLAIM:
1.A paint composition comprising:
a first acrylic binder of 285 pounds per 100 gallons to 630 pounds per
100 gallons;
a second acrylic binder of 50 pounds per 100 gallons to 95 pounds per
100 gallons;
a third acrylic binder of less than 180 pounds per gallons;
a first metal oxide comprising pigmentary titanium dioxide; and
a second metal oxide comprising a nanoparticle-sized metal oxide
pigment of 2 pounds per 100 gallons to 20 pounds per 100 gallons,
wherein the paint composition has a PVC of 4 to 55 and a pigment to
binder ratio of 0.10 to 3.0.
2.The composition as claimed in claim 1, wherein the nanoparticle-sized
metal oxide pigment comprises zinc oxide.
3.The composition as claimed in claim 1, wherein the nanoparticle-sized
metal oxide pigment comprises particles having an average particle size
of less than 100 nanometers.
4.The composition as claimed in claim 3, wherein the nanoparticle-sized
metal oxide pigment comprises particles having an average particle size
of between 30 nanometers and 65 nanometers.
5.The composition as claimed in claim 1, wherein the first acrylic primer
binder consists essentially of acrylic.

6.The composition as claimed in claim 1, wherein the second acrylic
topcoat binder consists essentially of acrylic.
7.The composition as claimed in claim 1, wherein the first acrylic primer
binder comprises a self-crosslinking polymer.
8.The composition as claimed in claim 1, wherein the ratio of the first
primer binder to the second topcoat binder is 80:20.
9.The composition as claimed in claim 1 further comprising a third
binder.
10.The composition as claimed in claim 1, wherein the ratio of the first
binder to the second binder is 80:20.
11.A process for producing a paint composition comprising the steps of:
dispersing a pigmentary-sized pigment in a solvent to form a dispersion;
mixing the dispersion with grind additives;
adding a first acrylic primer binder and a second topcoat acrylic binder
to the dispersion; and
adding letdown additives to the dispersion, wherein the resulting
composition includes a PVC of 4 to 55 and a percentage of solid by
weight of between 30 and 55.
12.The process as claimed in claim 11, wherein the nanoparticle metal
oxide pigment comprises zinc oxide.

13.The process as claimed in claim 11, wherein the nanoparticle metal
oxide pigment comprises particles having an average particle size of less
than 100 nanometers.
14.The process as claimed in claim 11, wherein the nanoparticle metal
oxide pigment comprises particles having an average particle size of
between 30 nanometers and 65 nanometers.
15.The process as claimed in claim 11, wherein the step of adding the
first acrylic primer binder includes adding a 100% acrylic binder.
16.The composition as claimed in claim 9, wherein the step of adding the
second topcoat acrylic binder includes adding a 100% acrylic binder.
17.The composition as claimed in claim 9, wherein the first acrylic
primer binder comprises a self-crosslinking polymer.
18.The composition as claimed in claim 9, wherein the first acrylic binder
comprises a 100% acrylic binder.
19. The composition as claimed in claim 1, wherein the ratio of the first
binder to the second binder is 80:20.
20.A coated substrate comprising:
a substrate; and
a coating on the substrate having:
a first binder, a second binder, and a third binder;

a pigmentary-sized pigment; and
a nanoparticle-sized pigment.
21.The coated substrate as claimed in claim 20, wherein the nanoparticle
metal oxide pigment comprises zinc oxide.
22.The coated substrate as claimed in claim 20, wherein the nanoparticle
metal oxide pigment comprises particles having an average particle size
of less than 100 nanometers.
23.The coated substrate as claimed in claim 20, wherein the nanoparticle
metal oxide pigment comprises particles having an average particle size
of between 30 nanometers and 65 nanometers.
24.The coated substrate as claimed in claim 20, wherein the first acrylic
primer binder is 100% acrylic.
25.The coated substrate as claimed in claim 20, wherein the second
acrylic topcoat binder is 100% acrylic.
26.The coated substrate as claimed in claim 20, wherein the first acrylic
binder comprises a self-crosslinking polymer.
27.The coated substrate as claimed in claim 20, wherein the first acrylic
binder comprises a 100% acrylic binder intended for use as a primer
vehicle.

28. The coated substrate as claimed in claim 20, wherein the ratio of the
first binder to the second binder is 80:20.
29. The coated substrate as claimed in claim 20 further comprising a
third binder.
30. A paint composition comprising:
a first binder comprised of 100% acrylic primer binder;
a second binder; and
a first metal oxide and a second metal oxide, the second metal oxide
having an average particle size less than 100 nanometers.
31. The composition paint as claimed in claim 30, wherein the second
metal oxide comprises zinc oxide.
32. The composition as claimed in claim 30, wherein the second metal
oxide comprises particles having an average particle size of between 30
nanometers and 65 nanometers.
33. The composition as claimed in claim 30, wherein the first binder
comprises a self-crosslinking polymer.
34. The composition paint as claimed in claim 30, wherein the ratio of
the first binder to the second binder is 80:20.


A paint composition comprising a first acrylic binder of about 285 pounds per 100
gallons to about 630 pounds per 100 gallons; a second acrylic binder of about 50
pounds per 100 gallons to about 95 pounds per 100 gallons; a third acrylic
binder of less than 180 pounds per gallons; a first metal oxide comprising
pigmentary titanium dioxide; and a second metal oxide comprising a nanoparticle-
sized metal oxide pigment of about 2 pounds per 100 gallons to about 20 pounds
per 100 gallons wherein the paint composition has a PVC of about 4 to about 55
and a pigment to binder ratio of about 0.10 to about 3.0.

Documents:

00352-kolnp-2007 assignment.pdf

00352-kolnp-2007-correspondence-1.1.pdf

00352-kolnp-2007-form-18.pdf

00352-kolnp-2007-pct request.pdf

0352-kolnp-2007 abstract.pdf

0352-kolnp-2007 claims.pdf

0352-kolnp-2007 correspondence others.pdf

0352-kolnp-2007 description(complete).pdf

0352-kolnp-2007 drawings.pdf

0352-kolnp-2007 form-1.pdf

0352-kolnp-2007 form-2.pdf

0352-kolnp-2007 form-3.pdf

0352-kolnp-2007 form-5.pdf

0352-kolnp-2007 international publication.pdf

0352-kolnp-2007 international search authority report.pdf

0352-kolnp-2007 others.pdf

0352-kolnp-2007 pct form.pdf

352-kolnp-2007-assignment.pdf

352-kolnp-2007-correspondence-1.1.pdf

352-KOLNP-2007-CORRESPONDENCE.pdf

352-kolnp-2007-examination report.pdf

352-kolnp-2007-form 18.pdf

352-kolnp-2007-form 26.pdf

352-kolnp-2007-form 3.pdf

352-kolnp-2007-form 5.pdf

352-kolnp-2007-granted-abstract.pdf

352-kolnp-2007-granted-claims.pdf

352-kolnp-2007-granted-description (complete).pdf

352-kolnp-2007-granted-drawings.pdf

352-kolnp-2007-granted-form 1.pdf

352-kolnp-2007-granted-form 2.pdf

352-kolnp-2007-granted-specification.pdf

352-kolnp-2007-others-1.1.pdf

352-KOLNP-2007-OTHERS.pdf

352-kolnp-2007-reply to examination report.pdf

abstract-00352-kolnp-2007.jpg


Patent Number 246934
Indian Patent Application Number 352/KOLNP/2007
PG Journal Number 12/2011
Publication Date 25-Mar-2011
Grant Date 22-Mar-2011
Date of Filing 01-Feb-2007
Name of Patentee BEHR PROCESS CORPORATION
Applicant Address 3400 WEST SEGERSTROM AVENUE, SANTA ANA, CA
Inventors:
# Inventor's Name Inventor's Address
1 TARNG, MING-REN 20 ALCIRA, IRVINE, CA 92614
2 PHAM, ANH 2, AEGEAN IRVINE, CA 92614
3 BROWNELL, STAN 41 VIA PRADO, RANCHO SANTA MARGARITA, CA 92688
4 PHAM, ANNIE 2025 WEST COMPASS LANE, ANAHEIM, CA 92801
5 ALEXANDER, ANIL 3661 BEAR STREET, APT B. SANTA ANA, CA 92704
6 SHAH, DEVEN 5600 ORANGETHORPE AVENUE #914, LA PALMA, CA 90623
7 NGUYEN, KIM L. 402 WEST NOBEL AVENUE APT. C. SANTA ANA, CA 92707
8 PHAM, MY LINH 900 SOUTH BRUCE STREET ANAHEIM, CA 92804
9 MAXEY, SIDNEY 41 VIA PRADO, RANCHO SANTA MARGARITA, CA 92688
10 MINAMYER, MARK 9, LAGUNA MADRE, ALISON VIEGO, CA 92656
PCT International Classification Number C09D 5/00, C09D 4/00
PCT International Application Number PCT/US2005/022676
PCT International Filing date 2005-06-28
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/914,439 2004-08-09 U.S.A.