FIRE-RETARDANT ADDITIVE WITH FIBERS FOR WATER-BASED PAINTS

Abstract

The present invention is related to a tire-retardant composition, specifically directed to an additive with natural fiber components which provide fire retardant properties to water-based paints.

Claims

1. A water-based paint additive composition comprising: a) Water; b) Sodium 2,4,5-trichlorophenolate (Dowicide); c) Tamol; d) Titanium dioxide; e) Calcium carbonate Class B-325; f) An aqueous antifoaming agent; g) Rehydrated natural fibers; h) Carbopol; i) Sodium methylparaben; j) Triethanolamine; and k) Methocel; wherein the water-based paint additive composition comprises a solid component, the solid component comprising of at least 99% the rehydrated natural fibers (g).

2. The water-based paint additive according to claim 1, wherein the solid component comprises approximately 30% of the water-based paint additive.

3. The water-based paint additive according to claim 1, wherein the rehydrated natural fibers comprise one or more of hemp, coconut, palm, and rubber fibers.

4. The water-based paint additive according to claim 1, wherein the rehydrated natural fibers consist of hemp, coconut, palm, and rubber fibers.

5. The water-based paint additive according to claim 3, wherein the rehydrated natural fibers are present in the composition in the following quantities (per liter): Hemp: 10 g-1000 g; Coconut: 10 g-1000 g; Palm: 10 g-1000 g; and Rubber: 10 g-1000 g.

6. The water-based paint additive according to claim 1, wherein the water-based paint additive comprises a thermal conductivity of approximately K=0.026-0.029 British thermal units-inch/hour×foot.sup.2×° Fahrenheit.

7. The water-based paint additive according to claim 1, wherein the water-based paint additive comprises a Brookfield viscosity of between 40,000-50,000 centipose (CPS).

8. The water-based paint additive according to claim 1, wherein the water-based paint additive comprises a density of approximately 1.22 grams/centimeter.sup.3.

9. The water-based paint additive according to claim 1, wherein the water-based paint additive comprises an adherence to concrete of at least 96% and an adherence to metals of at least 99%.

10. The water-based paint additive according to claim 1, wherein the water-based paint additive is flame-retardant.

11. The water-based paint additive according to claim 1, wherein the water-based paint additive reduces a temperature change of a surface to which the additive is applied by approximately 400° C. compared to an uncoated surface when exposed to direct heat.

12. The water-based paint additive according to claim 11, wherein the water-based paint additive is mixed with a water-based paint in approximately a 1:2 ratio.

13. A method for manufacturing a water-based paint additive consisting of: A.) mixing water at approximately 50 degrees Celsius (° C.) in a mixing device at a first speed and performing the following steps in order to form a first mixture: i) combining Dowicide, tamol, titanium dioxide, and calcium carbonate Class B-325 with the water without stopping the mixing; ii) adding an aqueous antifoaming agent and viny resin that is then mixed for approximately 3 minutes; iii) adding, at approximately 5 minutes intervals, the rehydrated natural fibers, carbopol, and sodium methylparaben; iv) increasing the mixing speed to a second speed greater than the first speed and adding Triethanolamine that is then mixed for approximately 5 minutes, after which the second speed is decrease to the first speed to form the first mixture; B) adding methocel to the first mixture as a thickening agent, wherein the thickening agent is pre-prepared as follows: v) combining water with the methocel and mixing to form a second mixture such that the methocel is present in a concentration of approximately 5% to approximately 10% by weight, wherein the mixing is first in a clockwise direction, stopping the mixing, and then continuing the mixing of the second mixture in a counterclockwise direction; vi) repeating the mixing of the second mixture of step v for approximately 30 seconds; vii) after step vi, adding the second mixture to the first mixture to form a third mixture; C) adding an additional amount of the aqueous antifoaming agent to the third mixture; viii) continuing the mixing of the third mixture for approximately 40 minutes at the first speed; and ix) letting the third mixture settle for approximately 20 minutes to form the water-based paint additive.

14. The method of claim 13 wherein the rehydrated natural fibers comprise one or more of hemp, coconut, palm, and rubber fibers.

15. The method of claim 13 wherein the rehydrated natural fibers consist of hemp, coconut, palm, and rubber fibers.

16. The method of claim 14 wherein the rehydrated natural fibers are present in the composition in the following quantities (per liter): Hemp: 10 g-1000 g; Coconut: 10 g-1000 g; Palm: 10 g-1000 g; and Rubber: 10 g-1000 g.

17. The method according to claim 13, wherein the water-based paint additive comprises a thermal conductivity of approximately K=0.026-0.029 British thermal units-inch/hour×foot.sup.2×° Fahrenheit.

18. The method according to claim 13, wherein the water-based paint additive comprises a Brookfield viscosity of between 40,000 and 50,000 centipose (CPS).

19. The method according to claim 13, wherein the water-based paint additive comprises a density of approximately 1.22 grams/centimeter.sup.3.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 is a photograph of a frontal view of the painted sheet

[0044] FIG. 2 is a photograph of rear view of the sheet without paint

[0045] FIG. 3 is a photograph of a frontal view of the additive for water-based paints performance test. The bare metal surface reaches a temperature of 682 degree Celsius when exposed to direct heat.

[0046] FIG. 4 is a photograph of a rear view of the additive for water-based paints performance test. The surface of the same metal coated with the water-based paint additive only reaches a temperature of 156.4° C. when exposed to the same direct heat as demonstrated in FIG. 3.

DETAILED DESCRIPTION

[0047] A specific reference is made to the attached claims, figures and description, which all describe elements of the present invention. While specific embodiments are identified, it is understood that the elements of a described aspect can be combined with other aspects separately identified. Likewise, any expert of the art will have the required understanding of the common processes, components and methods, and this disclosure intends to encompass and describe said common aspects, even if they are not expressly identified in the present description.

[0048] As has been previously mentioned, paint additives are presently used to provide characteristics and/or functions that are aesthetic or functional.

[0049] There are presently some additives intended to be used as flame retardants, in order to decrease the propagation of fire. These additives are manufactured using different chemical active ingredients, such a halogen-free compositions, comprising (meth)acrylate polymers and polyurethanes, wherein the polyurethane is based on polycarbonate polyols and ammonium polyphosphate, among others.

[0050] However, these additives are costly, in most cases require specialized preparation and application, are aggressive towards the environment, and cause mid- and long-term harms in the respiratory system.

[0051] Accordingly, this invention provides a new additive for water-based paints, containing more than 50% (fifty percent) of hydratable natural fibers. It results in a very practical and low-cost product, easy to use (it only needs to be mixed with the pains), does not release remainders harmful to living beings, and does not affect the environment.

[0052] It is an additive that when mixed with water-based acrylic paint, provides flame retardant properties, and is also capable of decreasing the temperature of a whole surface from 550° C. to less than 150° C., and is a thermal insulator.

[0053] The additive comprises: [0054] Water; [0055] Sodium 2,4,5-trichlorophenolate (Dowicide); [0056] Tamol; [0057] Titanium dioxide; [0058] Calcium carbonate Class B-325; [0059] Antifoaming agent (the antifoaming agent can be any agent comprising water-based fatty acids, free of vegetal and mineral oils, and silicone emulsion); [0060] Rehydrated natural fibers (hemp, coconut, palm, rubber); [0061] Carbopol; [0062] Sodium methylparaben; [0063] Triethanolamine; [0064] Methocel; and

[0065] wherein the rehydrated natural fibers comprise one or more of coconut, palm, rubber, cotton, and hemp.

[0066] In some embodiments, the water-based additive comprises a solid component wherein the solid component comprises at least about 90%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, or at least about 99% of the solid component. In some embodiments, the solid component of the water-based additive comprises tamol, titanium dioxide, calcium carbonate Class B-325; an antifoaming agent, rehydrated natural fibers (hemp, coconut, palm, rubber), Carbopol, sodium methylparaben, triethanolamine, and methocel. In some embodiments, the rehydrated fibers comprise at least 99% of the solid component.

[0067] In some embodiments, the solid component comprises about 30% of the water-based additive and water comprises about 70% of the water-based additive or the remainder of the water-based additive.

[0068] When contacted with water-based paint and water, it releases natural fiber particles and encapsulated air containing the additive with flame retardant and insulating properties. The manufacturing of the additive is at room temperature, and the components are as follows (per liter): [0069] 1) Water: 70% [0070] 2) Sodium 2,4,5-trichlorophenolate (Dowicide) 50 mg-1000 g [0071] 3) Tamol: 50 mg-1000 g [0072] 4) Titanium dioxide: 100 mg-1000 g [0073] 5) Calcium carbonate Class B-325: 5 mg-1000 g [0074] 6) Antifoaming agent (aqueous): 50 mg-1000 g [0075] 7) Rehydrated natural fibers: [0076] Hemp: 10 g-1000 g, [0077] Coconut: 10 g-1000 g, [0078] Palm: 10 g-1000 g, [0079] Rubber: 10 g-1000 g [0080] 8) Carbopol 5 mg-1000 mg [0081] 9) Sodium methylparaben 5 mg-1000 g [0082] 10) Triethanolamine 5 mg-1000 g [0083] 11) Methocel 50 mg-1000 g

[0084] In some embodiments, a composition may comprise sodium 2,4,5-trichlorophenolate (Dowicide), tamol, antifoaming agent, and Methocel, are each present in a range of about 50 mg, about 100 mg, about 150 mg, about 200 mg, about 250 mg, about 300 mg, about 350 mg, about 400 mg, about 450 mg, about 500 mg, about 550 mg, about 600 mg, about 650 mg, about 700 mg, about 750 mg, about 800 mg, about 850 mg, about 900 mg, about 950 mg, or about 1000 mg, or a range in between any two of the aforementioned integers (for example, about 200 mg to about 800 mg).

[0085] In some embodiments, calcium carbonate Class B-325, Carbopol, sodium methylparaben, and triethanolamine are each present in a range of about 5 mg, about 10 mg, about 15 mg, about 20 mg, about 25 mg, 50 mg, about 100 mg, about 150 mg, about 200 mg, about 250 mg, about 300 mg, about 350 mg, about 400 mg, about 450 mg, about 500 mg, about 550 mg, about 600 mg, about 650 mg, about 700 mg, about 750 mg, about 800 mg, about 850 mg, about 900 mg, about 950 mg, or about 1000 mg, or a range in between any two of the aforementioned integers.

[0086] In some embodiments, the rehydrated natural fibers hemp, coconut, palm, and rubber each may be present in an amount of about 10 mg, about 20 mg, about 30 mg, about 40 mg, 50 mg, about 100 mg, about 150 mg, about 200 mg, about 250 mg, about 300 mg, about 350 mg, about 400 mg, about 450 mg, about 500 mg, about 550 mg, about 600 mg, about 650 mg, about 700 mg, about 750 mg, about 800 mg, about 850 mg, about 900 mg, about 950 mg, or about 1000 mg, or a range in between any two of the aforementioned integers.

[0087] In some embodiments, the titanium dioxide may be present in an amount of about 100 mg, about 150 mg, about 200 mg, about 250 mg, about 300 mg, about 350 mg, about 400 mg, about 450 mg, about 500 mg, about 550 mg, about 600 mg, about 650 mg, about 700 mg, about 750 mg, about 800 mg, about 850 mg, about 900 mg, about 950 mg, or about 1000 mg, or a range in between any two of the aforementioned integers.

[0088] In various embodiments, the amount of the components in the water-based paint additive may differ relative to each other. For example, carbopol may be present in an amount of 300 mg while triethanolamine may be present in an amount of 450 mg, or hemp may be present in an amount of 100 mg and coconut fibers present in an amount of 800 mg, or methocel may be present in an amount of 200 mg and titanium dioxide present in an amount of 500 mg, etc.

[0089] The process is initiated when pouring water at 50° C. in the mixer, the mixing begins at medium speed and the materials are added in the following order, at 1-minute intervals between one material and the next. [0090] Dowicide, tamol, titanium dioxide and calcium carbonate Class B-325 without stopping the mixing, scratching the lower part of the mixer bar with a paddle until the adhered powders are removed, and incorporating them to the mix. [0091] Pour antifoaming agent (aqueous) and vinyl resin, mix 3 minutes, add at 5-minutes intervals rehydrated natural fibers (hemp, coconut, palm, rubber), Carbopol and sodium methylparaben, increase the mixing speed and add Triethanolamine, mix 5 minutes more and decrease the mixing to medium speed and add Methocel,

[0092] Do not add methocel (thickening powder) directly to the tank; the thickener should be prepared as follows: [0093] Pour 3 gallons of water in a container, add 700 grams of the thickener and mix. It should be mixed first clockwise. Then stop the mixing and then mix counterclockwise, repeat these steps for 30 seconds, and then add immediately this mix to the tank. Do not let pass more than 30 seconds to add it, since it can thicken in the container and will not adequately perform its function when adding it to the tank.

[0094] Add antifoaming agent (aqueous): 50 mg-1000 g Keep mixing for 40 minutes at medium speed, let the mix to settle for 20 minutes and then pour in containers.

[0095] In some embodiments, the water-based paint additive is mixed with a water-based paint in a ratio of about 1:1, about 1:2, about 1:3, about 1:4, about 1:5, about 1:6, about 1:7, about 1:8 about 1:9, or about 1:10. In some embodiments, water-based paint additive is mixed with a water-based paint in a ratio of about 1:2.

[0096] The final product has the following specifications: [0097] 1) Color: White base paint [0098] 2) Toxicity: Non-toxic [0099] 3) Emulsifier: Water [0100] 4) Drying: 60 minutes (according on thickness, temperature, and humidity) [0101] 5) Repainting: 3-4 hours. [0102] 6) Binders: Minerals and organics [0103] 7) Thermal conductivity K=0.026-0.029 Btu-inch/hr ft.sup.2° f [0104] 8) UV ray refraction: 85% [0105] 9) Brookfield viscosity: Cps 40000-50000 (ASTM D-2196) [0106] 10) Water absorption: 0.05% (ASTM D-1653) [0107] 11) Density: 1.22 Gr/cm.sup.3, with a 10% variation. This allows to apply the mix on any surface without altering de design conditions, with a 20 mills (thousandth of an inch) thickness. With a weight of 0.28 km/m (ASTM D-1475) [0108] 12) Minimum recommended thickness 80 mills [0109] 13) Nano active material: Self-extinguishing flammability [0110] 14) Flexibility: 250% [0111] 15) Adherence: 96% on concrete, 99% on metals (ASTM D-1475) [0112] 16) Thermal shock: Does not crack nor loses adherence [0113] 17) Asbestos content: 0% [0114] 18) Fungal growth: 0% [0115] 19) Bacterial growth: 0% [0116] 20) VOCs (g/l): 26.850 (computed according to the formulation) [0117] 21) Impermeability: 90%

[0118] Performance tests of the water-based paint additive are: [0119] 1. A zinc sheet 32-gauge (0.25 mm thick) coated with water-based acrylic paint and additive in a 2:1 ratio and directly exposed to torch flame at 600°, the zinc sheet reaching 523° with peaks of 600° without damaging the sheet (FIG. 1). [0120] 2. There is an incandescent tone in the reverse side; however, the temperature decreases considerably (FIG. 2).

[0121] The results of the performance tests are described in Table 3 below:

TABLE-US-00003 TABLE 3 Performance of various water-based paint additives. Without additive With additive Temperature Temperature Temperature Temperature of direct of direct of direct of direct Yield exposure to exposure to Paint exposure to exposure to Paint Brand Paint type L/M2 flame, front flame, back reaction flame, front flame, back reaction Sayer Vinyl acrylic 5 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands Miahuatlan 5-10 seconds 10-20 minutes before burning Star Colors Vinyl 76 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands 5-10 seconds 10-20 minutes before burning Comex Vinyl 6 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands 5-10 seconds 10-20 minutes before burning Berel Vinyl acrylic 7 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands 5-10 seconds 10-20 minutes before burning Meridian water based 6 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands enamel 5-10 seconds 10-20 minutes before burning Matisse Vinyl acrylic 20 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands 5-10 seconds 10-20 minutes before burning ProCraft Vinyl acrylic 15 550°-600° 550°-600° Burns after 550°-600° 140°-170° Withstands Sherwin 5-10 seconds 10-20 minutes Williams before burning EcoORganic Cactus sap 2 NA NA NA 550°-600° 60°-70° Withstands and water 5-10 minutes EcoPaint DEV — 1 NA NA NA 550°-600° 140°-170° Withstands 1.22 20-30 minutes 6 ro 7 different times

[0122] The results of viscosity, water absorption, density and adherence were obtained according to the corresponding ASTM standards.

Definitions

[0123] The following definitions are included to provide a clear and consistent understanding of the specification and claims. As used herein, the recited terms have the following meanings. All other terms and phrases used in this specification have their ordinary meanings as one of skill in the art would understand.

[0124] The singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a compound” includes a plurality of such compounds, so that a compound X includes a plurality of compounds X. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as “solely,” “only,” and the like, in connection with any element described herein, and/or the recitation of claim elements or use of “negative” limitations.

[0125] The term “and/or” means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrases “one or more” and “at least one” are readily understood by one of skill in the art, particularly when read in context of its usage. For example, the phrase can mean one, two, three, four, five, six, ten, 100, or any upper limit approximately 10, 100, or 1000 times higher than a recited lower limit. For example, one or more substituents on a phenyl ring refers to one to five substituents on the ring.

[0126] As will be understood by the skilled artisan, all numbers, including those expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth, are approximations and are understood as being optionally modified in all instances by the term “about.” These values can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the descriptions herein. It is also understood that such values inherently contain variability necessarily resulting from the standard deviations found in their respective testing measurements. When values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value without the modifier “about” also forms a further aspect.

[0127] The terms “about” and “approximately” are used interchangeably. Both terms can refer to a variation of ±5%, ±10%, ±20%, or ±25% of the value specified. For example, “about 50” percent can in some embodiments carry a variation from 45 to 55 percent, or as otherwise defined by a particular claim. For integer ranges, the term “about” can include one or two integers greater than and/or less than a recited integer at each end of the range. Unless indicated otherwise herein, the terms “about” and “approximately” are intended to include values, e.g., weight percentages, proximate to the recited range that are equivalent in terms of the functionality of the individual ingredient, composition, or embodiment. The terms “about” and “approximately” can also modify the endpoints of a recited range as discussed above in this paragraph.

[0128] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. It is therefore understood that each unit between two particular units are also disclosed. For example, if 10 to 15 is disclosed, then 11, 12, 13, and 14 are also disclosed, individually, and as part of a range. A recited range (e.g., weight percentages or carbon groups) includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art, all language such as “up to”, “at least”, “greater than”, “less than”, “more than”, “or more”, and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub-ranges as discussed above. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio. Accordingly, specific values recited for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for radicals and substituents. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0129] The term “substantially” as used herein, is a broad term and is used in its ordinary sense, including, without limitation, being largely but not necessarily wholly that which is specified. For example, the term could refer to a numerical value that may not be 100% the full numerical value. The full numerical value may be less by about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 15%, or about 20%.

[0130] This disclosure provides ranges, limits, and deviations to variables such as volume, mass, percentages, ratios, etc. It is understood that a range, such as “number 1” to “number 2”, implies a continuous range of numbers that includes the whole numbers and fractional numbers. For example, 1 to 10 means 1, 2, 3, 4, 5, . . . 9, 10. It also means 1.0, 1.1, 1.2. 1.3, . . . , 9.8, 9.9, 10.0, and also means 1.01, 1.02, 1.03, and so on. If the variable disclosed is a number less than “number 10”, it implies a continuous range that includes whole numbers and fractional numbers less than number 10, as discussed above. Similarly, if the variable disclosed is a number greater than “number 10”, it implies a continuous range that includes whole numbers and fractional numbers greater than number 10. These ranges can be modified by the term “about”, whose meaning has been described above.

[0131] One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the invention encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Additionally, for all purposes, the invention encompasses not only the main group, but also the main group absent one or more of the group members. The invention therefore envisages the explicit exclusion of any one or more of members of a recited group. Accordingly, provisos may apply to any of the disclosed categories or embodiments whereby any one or more of the recited elements, species, or embodiments, may be excluded from such categories or embodiments, for example, for use in an explicit negative limitation.

[0132] Wherever the term “comprising” is used herein, options are contemplated wherein the terms “consisting of” or “consisting essentially of” are used instead. As used herein, “comprising” is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the aspect element. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the aspect. In each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The disclosure illustratively described herein may be suitably practiced in the absence of any element or elements, limitation, or limitations not specifically disclosed herein.

[0133] Thickening agents are used to thicken the fluid, suspend dispersions of additives in the fluid, and improve the stability of dispersion as a function of temperature and shear history. For example, Carbopol is a synthetic polymer of acrylic acid. Also known as carbomers, they are used as emulsion stabilizers or thickening agents in various aqueous products. They are typically homopolymers of acrylic acid, crosslinked with an allyl ether pentaerythritol, allyl ether of sucrose, or allyl ether of propylene. For carbomers generally, see: www.pharmacopeia.cn/v29240/usp29nf24s0_m13027.html.