COLOR COATING PAINT AND METHOD FOR MANUFACTURING THE SAME

Abstract

Discloses is a water-soluble color coating paint for coating a rubber foam thermal insulation material and a method for manufacturing the same, and specifically, a color coating paint and an insulation color coating paint which have excellent adhesion to a porous rubber foam thermal insulation material, and retain elasticity of the thermal insulation material, as well as very improved photocatalytic performance, and a method for manufacturing the same. The color coating paint may be applied to a surface regardless of the material or condition of the surface to be painted, and may be coated to a soft or porous surface due to elasticity provided therein. The coating film produced by the color coating paint blocks 95% or more of the emission of volatile organic compounds from the surface of the foam rubber thermal insulation material into the atmosphere.

Claims

1. A color coating paint comprising 10 to 40 parts by weight of polyacrylate and a polyurethane mixture, 15 to 40 parts by weight of titanium dioxide, 5 to 10 parts by weight of calcium carbonate, 1 to 5 parts by weight of aluminum hydroxide, 0.5 to 5 parts by weight of a silicone resin, 0.1 to 1 parts by weight of sulfur, 0.5 to 10 parts by weight of a colored pigment, and 40 to 60 parts by weight of water.

2. The color coating paint according to claim 1, wherein the polyacrylate includes poly butyl acrylate or poly n-butyl methacrylate.

3. The color coating paint according to claim 1, wherein the polyurethane includes polyester urethane (AU), polyether urethane (EU) or a urethane resin.

4. The color coating paint according to claim 1, wherein a mixing ratio of the polyacrylate and polyurethane mixture is 1:0.1 to 5.

5. A method for manufacturing a color coating paint comprising: stirring the color coating paint according to claim 1; and stirring a mixture so that particles of the color coating paint have a particle size of 0.3 to 1 μm.

6. A method for manufacturing a color coating paint comprising: stirring the color coating paint according to claim 1 for 1 to 4 hours; and evenly dispersing a mixture.

7. The method for manufacturing a color coating paint according to claim 6, wherein the color coating paint has a viscosity of 50 to 1000 cps.

8. A rubber foam thermal insulation material coated with a color coating paint, comprising: a rubber foam formed in a shape of a tube or sheet; and an ink coating layer formed by coating the color coating paint of claim 1 on a surface of the rubber foam in a predetermined thickness.

9. A color coating paint comprising 10 to 40 parts by weight of polyacrylate and a polyurethane mixture, 10 to 30 parts by weight of titanium dioxide, 5 to 15 parts by weight of filler, 5 to 10 parts by weight of calcium carbonate, 1 to 5 parts by weight of aluminum hydroxide, 0.5 to 5 parts by weight of a silicone resin, 0.1 to 1 parts by weight of sulfur, and 40 to 60 parts by weight of water.

10. The color coating paint according to claim 9, wherein the polyacrylate includes poly butyl acrylate or poly n-butyl methacrylate.

11. The color coating paint according to claim 9, wherein the polyurethane includes polyester urethane (AU), polyether urethane (EU) or a urethane resin.

12. The color coating paint according to claim 9, wherein a mixing ratio of the polyacrylate and polyurethane mixture is 1:0.1 to 5.

13. The color coating paint according to claim 9, wherein the filler includes one or more selected from the group consisting of talc, diatomite, glass bead, silica balloon, zirconia, alumina, ceramic bead, spherical ceramic particles, thermally expandable microcapsule, and capsule type hollow microspheres.

14. A method for manufacturing a color coating paint comprising: stirring the color coating paint according to claim 9; and stirring a mixture so that particles of the color coating paint have a particle size of 0.3 to 1 μm.

15. A method for manufacturing a color coating paint comprising: stirring the color coating paint according to claim 9 for 1 to 4 hours; and evenly dispersing a mixture.

16. The method for manufacturing a color coating paint according to claim 15, wherein the color coating paint has a viscosity of 50 to 1000 cps.

17. A rubber foam thermal insulation material coated with a color coating paint, comprising: a rubber foam formed in a shape of a tube or sheet; and an ink coating layer formed by coating the color coating paint of claim 9 on a surface of the rubber foam in a predetermined thickness.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0058] FIG. 1 is a photograph illustrating application of colors and adhesion state of a coating film according to use by mixing various pigments with paints of Examples 1 and 2;

[0059] FIG. 2 are photographs illustrating experiments that, when the thermal insulation material coated with the paint of Example 2 in Experimental Example 1 was folded or bent at to 180°, the coating was maintained over the entire surface without an occurrence of a breakage of the coating film;

[0060] FIG. 3 are photographs illustrating the adhesion state of the coating film when the paints of Examples 1 and 2 were applied to the surface of the rubber foam thermal insulation material and then subjected to a test such as bending;

[0061] FIG. 4 are photographs illustrating results of the surface temperature measurement experiment in Experimental Example 3; and

[0062] FIG. 5 is schematic views illustrating a rubber foam thermal insulation material coated with the color coating paint according to embodiments of the present invention, wherein (a) shows a tube-shaped thermal insulation material and (b) shows a sheet-shaped thermal insulation material.

DETAILED DESCRIPTION OF EMBODIMENTS

[0063] Hereinafter, embodiments of the present invention will be described in detail with reference to examples, and the present invention is not limited to the following examples. For reference, the terms and words used in the present disclosure and claims of the present invention should not be construed as limited to a lexical meaning, and should be understood as appropriate notions by the inventor based on that he/she is able to define terms to describe his/her invention in the best way to be seen by others. In addition, embodiments and drawings described in the present disclosure are example embodiments and do not represent all the technical sprites of the present invention, and it will be understood that various modifications and equivalents may be made to take the place of the embodiments at the time of filling the present application.

[0064] Photocatalysts using titanium dioxide (TiO.sub.2) are representative materials that can reduce the precursors, which are a cause of forming the secondary pollutants, and have properties of decomposing organic materials through a light reaction with ultraviolet rays. There may be techniques for producing a paint containing titanium dioxide that can be used indoors by using photocatalytic properties of the titanium dioxide and can reduce primary and secondary pollutants of fine dust. Studies into water-soluble paints containing titanium dioxide are being actively conducted in the field of photocatalysts having functions of decomposition of nitric oxide and sulfur oxide, antibacterial and virus sterilization functions, and a function of removal of VOCs. There may be possibility of applying the water-soluble paints not only to indoor walls but also to thermal insulation materials of industrial facilities, etc.

[0065] The thermal insulation material is applied to various thermal insulation works such as building equipment construction and industrial equipment construction for thermal insulation, cold reservation, condensation prevention, and freeze protection of pipes, ducts, devices and tanks, and includes glass wool thermal insulation materials, polyethylene (PE) thermal insulation materials, rubber foam thermal insulation materials and the like.

[0066] The rubber foam thermal insulation material is a closed cell elastomer, and is made in a fine independent closed cell structure composed of nitrile butadiene rubber (NBR) and various synthetic mixtures, thereby having excellent thermal insulation and easy workability. This thermal insulation material is used in general building equipment, shipbuilding, refrigeration, and plant fields to prevent moisture from penetrating even if a surface thereof is damaged, and has excellent thermal insulation and cold reservation properties.

[0067] Due to a carbon black component added to reinforce inherent properties and abrasion resistance of rubber, such a rubber foam thermal insulation material is dark black, and is manufactured in a fine closed cell structure to reduce thermal conductivity, thereby having characteristics that the surface thereof is soft.

[0068] As a means for further improving the thermal insulation performance of the rubber foam thermal insulation material, there may be a need to develop a technique capable of forming a coating film on the surface of the thermal insulation material by reducing a water vapor permeability coefficient and increasing airtightness. However, in the existing water-based paint, solid matters are cured after water which plays a role of solvent is dried to form a coating film. At this time, the resulting coating film is mainly used for solid wall painting, but an elasticity of the coating film itself is weak and an adhesive force to an elastic pipe with a soft surface, a wall composed of a foam material, and the thermal insulation material, etc. may be very small, such that there is a technical limitation in which coating may be impossible.

[0069] Due to the limitation that no paint is adhered to soft or porous materials, in order to identify the use of thermal insulation material, in particular, a pipe wrapped with the rubber foam thermal insulation material, colored tapes or bonding thick films may be used with an adhesive, or the rubber foam thermal insulation material using pigments while excluding carbon may be produced. However, all of these methods have a drawback of reducing the durability, elasticity or thermal insulation of the rubber foam thermal insulation materials.

[0070] One implementation may provide non-toxic and flame-retardant ink which can be adhered to the surface of a rubber foam thermal insulation material. Due to this technique, it may be possible to improve the construction performance by enhancing the elasticity of the rubber foam thermal insulation material, and increase the flame-retardance and anti-moisture permeability of the entire rubber foam thermal insulation material.

[0071] In this regard, the above technique may provide uniform coating on the amorphous surface, but when adding an amount of titanium dioxide powder in a certain amount or more, the coating film is severely peeled off and the coating film is broken, and thereby a photocatalytic effect is significantly reduced.

[0072] In addition, the coating film is broken when the shape changes according to an installation shape of the thermal insulation material after coating and is separated from the surface of the thermal insulation material, and thus, it is difficult to apply the foregoing technique to actual building and industrial equipment constructions.

[0073] Examples of the present disclosure are discussed below.

Example 1: Color Coating Paint

[0074] 25 g of polyacrylate, 5 g of polyurethane, 30 g of titanium dioxide, 2 g of aluminum hydroxide, 10 g of calcium carbonate, 2 g of silica, 3 g of silica sol, 1 g of sulfur, 5 g of colored pigment, and 60 g of water were mixed, and the mixture was stirred at 500 rpm for 2 hours or more to prepare a color coating paint composition.

Example 2: Insulation Color Coating Paint

[0075] 25 g of polyacrylate, 5 g of polyurethane, 25 g of titanium dioxide, 2 g of aluminum hydroxide, 10 g of calcium carbonate, 2 g of silica, 3 g of silica sol, 15 g of spherical ceramic particles, 1 g of sulfur, 5 g of colored pigment, and 60 g of water were mixed, and the mixture was stirred at 500 rpm for 2 hours or more to prepare a color coating paint composition.

Comparative Example 1

[0076] 57 g of water, 20 g of polyacrylate, 7 g of CaCO.sub.3, 10 g of aluminum hydroxide, 0.5 g of silicon, 8 g of titanium dioxide, and 0.5 g of sulfur were mixed, and the mixture was stirred at 500 rpm for 30 minutes to prepare a color coating paint composition.

Comparative Example 2

[0077] 30 g of polyacrylate, 80 g of titanium dioxide, 2 g of aluminum hydroxide, 10 g of calcium carbonate, 2 g of silica, 3 g of silica sol, 1 g of sulfur, 5 g of colored pigment, and 60 g of water were mixed, and the mixture was stirred at 500 rpm for 2 hours or more to prepare a color coating paint composition.

Experimental Example 1: Surface Application Experiment

[0078] Each of the paints of Examples 1 and 2 and Comparative Example 3 (commercially available water-based paint, company N) was applied to a surface of a rubber foam thermal insulation material using a spray in a thickness of 50 μm (increased or decreased depending on the degree of adhesion), followed by naturally curing at 20° C. for 24 hours to prepare a test specimen of embodiments of the present invention.

TABLE-US-00001 TABLE 1 TiO.sub.2 Immediately after content curing Bending at 30° Bending at 90° Bending at 150° Example 1 (21.1%) Excellent coating Coating film Coating film Coating film film adhesion (film maintained maintained maintained thickness: 50 μm) Example 2 (16.4%) Excellent coating Coating film Coating film Coating film film adhesion maintained maintained maintained (50 μm) Comparative .sup. (22%) Film is adhered Coating film Coating film Coating film Example 3 only when partially broken broken broken Thermal increasing the insulation thickness thereof by material 40% or more damaged compared to Examples 1 and 2. Comparative  (7.8%) Adhered (50 μm) Coating film — — Example 1 broken Comparative .sup. (41%) Almost not adhered — — — Example 2

[0079] Existing products may only be used for hard-surface walls, but the color coating paints of Examples 1 and 2 of the present invention have an advantage capable of being applied to the coating film without breakage of the surface thereof in a material having a stretchable surface. FIG. 1 is a photograph illustrating a state when the color coating paint of Example 1 was applied and dried.

[0080] The color coating paint may be applied to the surface of foam thermal insulation materials such as a rubber foam thermal insulation material with high elasticity. As shown in FIG. 2, the color coating paint of Example 2 does not break at the surface of the coating film even when bending at about 150 to 180° or more, and retains excellent elasticity, such that the surface of the coating film is not cracked even when repeatedly bending.

[0081] FIG. 3 are photographs illustrating experimental results of Experimental Example 1. In commercially available general high-functional acrylic water-based paints (N company, white semi-gloss), the coating film of the surface is easily broken when the elastic thermal insulation material is bent and expanded by air pressure even after completely drying, thereby resulting in a deterioration of the photocatalytic function due to titanium dioxide. Whereas, the color coating paint according to Example 1 of the present invention maintains the coating film on the surface even when applying the paint in a lower thickness, and bending 10 times or more and expanding by air injection.

Experimental Example 2: Thermal Insulation Effect Experiment

[0082] The uncoated rubber foam thermal insulation material (thermal conductivity: 0.035 W/m.Math.k) and the rubber foam thermal insulation material coated with the paint of Example 2 were exposed to direct sunlight under conditions including an ambient temperature of 19.1 to 19.4° C. and a humidity of 35 to 36% for 60 minutes.

[0083] Results of measuring an increase in the temperature by direct sunlight on the surface of each rubber foam thermal insulation material is shown in photographs of FIG. 3. When comparing the experimental results, the surface temperature of the uncoated rubber foam thermal insulation material is 38.7° C., and the surface temperature of the rubber foam thermal insulation material coated with the paint of Example 2 is 16° C., such that it can be seen that a heat shielding effect is excellent.

[0084] Assuming that areas of the rubber foam thermal insulation materials are the same as each other, it can be seen that the thermal conductivity transmitted to the pipe is reduced due to a decrease in the surface temperature, such that the thermal insulation effect of the thermal insulation material may be further increased. The reason is that, when adding spherical ceramic particles to the water-soluble color coating paint containing titanium dioxide, air in a vacuum state inside the spherical ceramic particles plays a role of a heat insulation material when applying it to the outer wall and the thermal insulation material, and thereby reducing the thermal conductivity on the surface of the thermal insulation material.

Experimental Example 3: Changes in Physical Properties of Rubber Foam Thermal Insulation Material During Coating

[0085] As a result of the test, the rubber foam thermal insulation material coated with the color coating paint showed the following improvements in main performances.

TABLE-US-00002 TABLE 2 General Coating rubber foam of KS foam Example Test item Unit standard Standard material 1 Test method Water vapor ng/m.sup.2 .Math. 6 or less 6 or less 5 1.1 KSM 6962 permeability s .Math. Pa coefficient Dimensional Horizontal % Horizontal 5 or less −1.0 0 KSM 6962 safety direction 7 or less [(40 ± 2)° C., Longitudinal % Longitudinal 5 or less −1.2 0 KSM 6962 48 h] direction 7 or less TVOCs emission mg/m.sup.2 .Math. h 4.0 or less 0.151 0.061 Indoor air quality process test standards (Notified by the Minister of Environment) Toluene emission mg/m.sup.2 .Math. h 0.08 or Less than Not Indoor air quality less 0.001 detected process test standards (Notified by the Minister of Environment)

[0086] When water vapor permeates the foamed thermal insulation material, the thermal conductivity is rapidly increased to cause a great reduction in the thermal insulation performance. In order to maintain the thermal insulation performance of the foamed thermal insulation material, the most important water vapor permeability coefficient was lowered by 78%. In terms of dimensional stability, the larger+/−values, the greater a deformation of the thermal insulation material according to the external temperature, and expansion as well as contraction of the thermal insulation material did not occur according to the external temperature. TVOCs were reduced by 60% or more, and toluene was not detected at all, which proved effective in improving the indoor air quality. This is because a considerable amount of TVOCs are emitted from the rubber foam thermal insulation material itself, but such an emission may be prevented by the coating.

DESCRIPTION OF REFERENCE NUMERALS

[0087] M: Rubber foam thermal insulation material [0088] R: Rubber foam [0089] C: Ink coating layer