Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1999-03-23
2001-12-18
Sanders, Kriellion (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S413000, C524S423000, C524S425000, C523S404000, C523S414000
Reexamination Certificate
active
06331585
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a formulation useful in making paints or coatings, and more particularly, to a formulation that may be mixed with a resin and hardener to extend the pot-life of the paint mixture. The invention further relates to paints and coatings made with the inventive formulation.
BACKGROUND OF THE INVENTION
There is a continuing need for paints and coatings that are anti-corrosive, e.g., that are capable of protecting the surfaces to which they are applied from deterioration or degradation. The demand for protective paints and coatings is increasing with a growing awareness of adverse affects caused by environmental factors, such as air pollution, acid rain, or the effects of UV rays from the sun.
Typically, paints applied at construction sites, such as in coating concrete and metal surfaces (aluminum, steel, and zinc), are prepared on-site. These paints are prepared by mixing a hardener with a resin, with the mixing being done at the construction site. The mixing is done on-site because the pot-life of the paints once mixed is relatively short, that is, within a period of about forty minutes, the paint mixture will harden or degrade. This places constraints on workers and often causes a waste of resources, because if the paint mixture is not quickly applied to the surface being coated, it will be wasted. There are additional drawbacks with resin and hardener paint mixtures in use. For example, alcoholic solvents have been needed to make the paints water soluble, which is disadvantageous for environmental reasons, and relatively large percentages of water have been required to adequately dissolve the hardener, resin and other fillers. Thus, there is a continuing need for improved formulations for making paints and coatings having anti-corrosive properties, where the pot-life of the paints once prepared is extended for longer periods of time.
SUMMARY OF THE INVENTION
Summarily, the invention embraces a formulation to be mixed with a resin and a hardener so that when the resin and hardener are combined to form a paint mixture, e.g., at a construction site, the pot-life of the paint mixture is increased, thereby expanding the time period during which the paint mixture may be applied to the surface being coated. The formulation comprises a combination of a defoamer, titanium dioxide (TiO
2
), at least one of barite (BaSO4) or calcite (CaCO
3
), at least one of 1,2-propyleneglycol (propane-1,2-diol) or a corrosive-inhibitor, such as L-4™, and a thickener. Other contemplated ingredients include slate, water, colorants, and dispersion additives.
DETAILED DESCRIPTION OF THE INVENTION
The invention embraces a formulation which is intended to be used as a primer or filler in making paints and coatings. It is anticipated the formulation will be combined with a resin and a hardener to produce a paint mixture useful for coating concrete and metal surfaces, such as aluminum, zinc, stainless steel, and steel. The mixture also may be applied to fiber glass and powder coatings. The formulation is combined with either the resin or the hardener, and the resin and hardener are then mixed together to form the paint mixture. With the inventive formulation, the pot-life of the paint mixture may be extended to up to about eight hours, allowing for a much greater time period during which the paint, after mixing, can be applied to the surface being coated. The inventive formulation may be mixed with the hardener before the paint products are brought to the construction site, and then the hardener with the formulation added to the resin. Conversely, the formulation may be added to the resin, with the hardener added thereafter. A further advantage of this invention is that toxic solvents, e.g., reactive thinners based on fatty alcohols, are avoided.
More particularly, applicant has discovered that a formulation having as its primary components one or more of titanium dioxide, barite, calcite, propylene glycol, LOXANOL™, and a thickener is advantageous to be added with either a resin or a hardener, with the resin and hardener then mixed together to form a paint mixture for coating a surface. The resultant paint mixture has a relatively long pot life, e.g., substantially greater than the pot-life of existing paints and greater than two hours and up to about eight hours, and as applied to certain surfaces (e.g., aluminum and zinc), it has anti-corrosive properties. The term “pot life” is used herein to describe the time period during which the paint mixture effectively may be used once the resin and hardener have been mixed, that is, the time period before the mixture hardens, coagulates, or otherwise degrades.
In one embodiment, the formulation comprises a mixture of a (1) defoamer known as FOAMASTER TCX™ or FOAMASTER 410™ which are available from HENKEL Corp. of Germany (hereinafter “Henkel”); (2) titanium dioxide (TiO
2
); (3) at least one of barite (BaSO4) or calcite (CaCO
3
); (4) at least one of 1,2-propyleneglycol (propane-1,2-3 diol), a corrosive inhibitor, or a retarder, such as LOXANOL DP-6™; and (5) a thickener. The formulation is then added to a resin, and the combined resin-formulation composition is added to a hardener. An advantageous resin to be used with the formulation comprises WATERPOXY 1455,™ which is a tradename for a product available from Henkel comprising a polymer based on epoxyamine adducts. Advantageously, the weight percent of the resin to the formulation comprises about 50-80 parts by weight resin to formulation. The hardener advantageously comprises WATERPOXY- 751,™ also a tradename for a product available from Henkel which comprises an epoxy polymer emulsion.
Both FOAMASTER TCX™ or FOAMASTER 410™ are tradenames of products available from Henkel. It is understood the defoamer known as FOAMASTER TCX™ comprises a mixture of aliphatic hydrocarbons and non-ionic surfactants, and the defoamer known as FOAMASTER 410™ comprises a blend of fatty acid esters, ether alcohols, and non-ionic emulgators. The defoamer should comprise up to about 0.5% by weight of the resin-formulation composition. With regard to the titanium dioxide (TiO
2
), an advantageous source of this ingredient comprises RKB-5,™ a tradename for a product available from BAYER Corp. Titanium dioxide may comprise from about three to up to about thirty-one percent by weight of the resin-formulation composition; exemplary embodiments showing differing values for TiO
2
are set forth below in the examples. The barite (BaSO
4
) or calcite (CaCO
3
) should be added in amounts of about three to fifty parts by weight of the composition. LOXANOL DP-6™ is a tradename for a product available from Henkel, which is believed to comprise a fatty alcohol dispersion, which when used as a retarder should be present in the composition in about 0.5 percent by weight. Another advantageous corrosive-inhibitor that may be used (at approximately 0.2% by weight), comprises a product available from C.H. Erbsloeh Company, 47809 Krefeld, Germany, under the tradename L-4,™ which is based on borate and organic esters of a tertiary alcohol-amine base with synergetic additives. An advantageous thickener comprises a product sold under the tradename NOPCO DSX 1550,™ by Henkel, which comprises a polyurethanepolymer in water and butyldiglycol. The thickener should be present at about 0.1 to 1.0 percent by weight of the resin-formulation composition.
Other contemplated components of the formulation include slate, water, and colorants. A dispersing additive may be added, such as a product commonly known under the tradename DISPONIL AEP 5300,™ available from Henkel, which is believed to comprise an etherphosphate acid ester having greater than 20 percent alkylphenol polyglycolether phosphate. The dispersing additive advantageously is added in small quantities (e.g., about 0.1 parts by weight). The formulation is mixed with the resin. The temperature should be controlled and preferably maintained below 50° C., as the resin may tend to coagulate at higher temperatures. A dissolver, which is known in the field, may be used
Mathews, Collins Shepherd & Gould P.A.
Sanders Kriellion
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