METHOD FOR MANUFACTURING BISMUTH VANADATE PIGMENT HAVING AN IMPROVED ALKALINE RESISTANCE

Abstract

The present invention is directed to a method for manufacturing a bismuth vanadate pigment having an improved alkaline resistance, the method comprising: i) obtaining a dried bismuth vanadate pigment; ii) encapsulation of the bismuth vanadate pigment using a functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group; iii) final processing of the encapsulated pigment; and v) drying of the pigment.

In addition, the present invention is directed to a bismuth vanadate pigment encapsulated with a functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group.

Claims

1-15. (canceled)

16. A method for manufacturing a bismuth vanadate pigment having an improved alkaline resistance, the method comprising: (a) obtaining a dried bismuth vanadate pigment; (b) encapsulating the bismuth vanadate pigment with a functionalized silane having the formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group to form an encapsulated pigment; (c) final processing of the encapsulated pigment; and (d) drying the pigment.

17. The method of claim 16, wherein R is an alkyl group having more than 10 carbon atoms; and R is a methyl or ethyl group.

18. The method of claim 16, wherein R is an alkyl group having more than 10 carbon atoms and one or more substituents comprising an aryl group and one or more fluorine atoms.

19. The method of claim 16, wherein the functionalized silane is a mix of (a) a functionalized silane of the formula RSi(OR)3 wherein R is an alkyl group having more than 10 carbon atom(s); and R is a methyl or ethyl group, and (b) a functional silane selected from the group consisting of amino-3-propyltriethoxysilane, N-(2-aminoethyl-3-aminopropyl)-trimethoxysilane, phenyltriethoxysilane, hexadecyltrimethoxysilane, propyltrimethoxysilane, methyltriethoxysilane, N-benzyl-N-aminoethyl-3-aminopropyltrimethoxysilane, N-vinylbenzyl-N-aminoethyl-3-aminopropylpolysiloxane, N-(n-butyl)-3-aminopropyltrimethoxysilane, and combinations thereof.

20. The method of claim 16, wherein the method further comprises the step of reslurrying the pigment by adding water to form a dispersion, and stirring said dispersion at a temperature ranging from 10 C. to 100 C., for a time period ranging from 30 minutes to 140 minutes.

21. The method of claim 16, wherein encapsulating comprises adding the functionalized silane in a range from 0.1% to 10% by weight with respect to the pigment.

22. The method of claim 21, wherein the functionalized silane is added in a range from 1% to 3%.

23. The method of claim 16, wherein the method further comprises adding a chelating agent.

24. The method of claim 23, wherein the chelating agent is a polyglycoside, polyacrylate, or modified organosilane with a polyacrylate chain.

25. The method of claim 23, wherein encapsulating comprises adding the chelating agent in a range from 0.1% to 10% by weight with respect to the pigment.

26. The method of claim 25, wherein the chelating agent is added in a range from 2% to 4%.

27. The method of claim 16, wherein encapsulating comprises slurrying the pigment in an aqueous solution of the functionalized silane and optionally a chelating agent.

28. A bismuth vanadate pigment encapsulated with a functionalized silane of the formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group.

29. The bismuth vanadate pigment of claim 28, wherein R is an alkyl group having more than 10 carbon atom(s).

30. The bismuth vanadate pigment of claim 28, wherein R is an alkyl group having more than 10 carbon atoms and one or more substituents comprising an aryl group and one or more fluorine atoms.

31. The bismuth vanadate pigment according to claim 28, wherein the functionalized silane is a mixture of (a) a silane of the formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group, and (b) a silane selected from the group consisting of amino-3-propyltriethoxysilane, N-(2-aminoethyl-3-aminopropyl)-trimethoxysilane, phenyltriethoxysilane, hexadecyltrimethoxysilane, propyltrimethoxysilane, methyltriethoxysilane, N-benzyl-N-aminoethyl-3-aminopropyltrimethoxysilane,N-vinylbenzyl-N-aminoethyl-3-aminopropylpolysiloxane, N-(n-butyl)-3-aminopropyltrimethoxysilane, and combinations thereof.

32. The bismuth vanadate pigment of claim 28, wherein the weight of functionalized silane is 0.1% to 10% by weight of the pigment.

33. The bismuth vanadate pigment of claim 32, wherein the weight of functionalized silane is between 1 and 3% by weight of the pigment.

34. A bismuth vanadate pigment according to claim 28, further encapsulated by a layer of chelating agent.

35. The bismuth vanadate pigment of claim 34, wherein the chelating agent is a polyglycoside, polyacrylate, or modified organsilane with a polyacrylate chain.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0029] FIG. 1 illustrates a flowchart depicting a method for manufacturing a bismuth vanadate pigment pigment having improved alkali resistance, according to an embodiment of the present invention.

[0030] FIG. 2 illustrates a flowchart depicting a method for manufacturing a bismuth vanadate pigment having improved alkali resistance, according to another embodiment of the present invention.

[0031] FIG. 3 illustrates a flowchart depicting a method for manufacturing a bismuth vanadate pigment having improved alkali resistance, according to yet another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] Reference will now be made in detail to the preferred embodiment of the present invention, examples of which are illustrated in the accompanying drawings. Aspects, advantages and/or other features of the exemplary embodiment of the disclosure will become apparent in view of the following detailed description, which discloses various non-limiting embodiments of the invention. In describing exemplary embodiments, specific terminology is employed for the sake of clarity. However, the embodiments are not intended to be limited to this specific terminology. It is to be understood that each specific portion includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

[0033] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those or ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well known methods, procedures and/or components have not been described in detail so as not to obscure the invention.

[0034] Bismuth vanadate pigments are widely used in the coating industry and offer good resistance and coloristic properties. However, one major disadvantage of using Bismuth vanadate pigments is its low alkaline resistance, a feature necessary in certain water based coating formulations like silicate coatings. This limited alkaline resistance of these pigments leads to partial or even complete discoloration of the pigment and thus the coatings. This occurs because the chemical structure of Bi (Bismuth) based pigments are altered when they are exposed to high alkaline environment, due to the presence of high concentration of ions like Na+, K+, Ca+2, Zn2+, Ba2+ etc., which causes the replacement of bismuth ions to form other vanadate salts, leading to the discoloration.

[0035] This limitation can be seen by performing alkaline resistance tests of coated plates dipped in alkaline aqueous solutions (NaOHKOH) which lead to partial discoloration of the plates, the more the discoloration, the less resistant the pigment is to alkaline media. There is consequently a need to improve the alkaline resistance of the pigment for architectural coatings.

[0036] The present invention provides a method for manufacturing bismuth vanadate pigment having an improved alkaline resistance by treating in-situ obtained bismuth vanadate pigments with functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group preferably having more than 10 carbon atom(s); and R is a methyl or ethyl group. Preferably, R is an alkyl group having more than 10 carbon atom(s); and R is a methyl or ethyl group. More preferably, R is an alkyl group having more than 10 carbon atoms and may have one or more ramifications comprising an aryl group and may contain one or more Fluor atoms.

[0037] Optionally the pigment to be encapsulated may be initially pre-encapsulated by a silica and addition a functionalized silane of the group comprising amino-3-propyltriethoxysilane, N-(2-aminoethyl-3-aminopropyl)-trimethoxysilane, phenyltriethoxysilane, hexadecyltrimethoxysilane, propyltrimethoxysilane, methyltriethoxysilane, N-benzyl-N-aminoethyl-3-aminopropyltrimethoxysilane, N-vinylbenzyl-N-aminoethyl-3-aminopropylpolysiloxane, N-(n-butyl)-3-aminopropyltrimethoxysilane, or any combination of two or more thereof. This pre-encapsulation may optionally take place just before the treatment with the alkyl silane described in the present invention.

[0038] Without being bound by any theory, it is found that this functionalized silane blocks the action of the ions present in the coating formulation thereby improving the alkaline stability while avoiding discoloration of Bi based pigments.

[0039] In addition, in some embodiments, adding chelating agents may even more enhance alkaline resistance. In some embodiments, these chelating agents may be prepared in situ via a polymerization.

[0040] The general process for the preparation of bismuth vanadate pigments is as follows: [0041] Highly pure solutions of raw materials are used from which the pigment is precipitated, followed by heat treatment and stabilization. [0042] The pigment is then separated and purified. [0043] The purified product is dried and optionally calcined to obtain bismuth vanadate pigments.

[0044] Different embodiments of the invention describe the coating of these bismuth vanadate pigments with functionalized silane and optionally chelating agents.

Embodiment 1

[0045] In an embodiment of the present invention discloses a method 100 as illustrated in FIG. 1, for coating of the bismuth vanadate pigments with functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group preferably having more than 10 carbon atom(s); and R is a methyl or ethyl group. The method 100 starts at step 102 and proceeds to step 104, where a dried and optionally calcined bismuth vanadate pigment is obtained from an in-situ pigment preparation process. At step 106, the dried pigment obtained is reslurried. The reslurry of the pigment is prepared by adding an amount of solvent to the dried pigment at a predetermined temperature range and then stirring it to form a homogeneous aqueous dispersion. In one example, the reslurry is prepared by adding water, preferably RO water followed by stirring in a temperature range between 10 C. and 100 C., preferably between 70 C. to 95 C. for a time period ranging between 30 minutes to 140 minutes which is preferably 80 minutes to 110 minutes. In other examples, the pigment may be reslurried in any solvent including, but not limited to municipal water, river water, RO water, glycol based esters, and so on. A pre-encapulation step can also takes place at the end of the step 106 with addition of small amounts of silica or other metal oxides. A person skilled in the art will be able to define the composition of the inner coating, which may be built of a plurality of layers. It may comprise a first layer comprising one or more salts, or one or more oxides, heteropolyacids, organic acids, sulphites, sulfides, sulfates, phosphates, pyrophosphates, polyphosphates, or a combination thereof, selected from the group of alkali-earth metals, metals, non-metals, transition metals or lanthanides, preferably one or more calcium salts or oxides, one or more aluminum salts or oxides, or a combination thereof, and a second layer of silicon dioxide and functionalized or organo modified silane. In addition, the inner coating may comprise a third layer comprising a functionalized silane or an organo modified siloxane or a combination thereof. The method 100 then proceeds to step 108, where the bismuth vanadate pigment is encapsulated by adding the functionalized silane within the slurry obtained at step 106. The step of encapsulation is generally responsible for improving the alkaline resistance of the pigment. Once the pigment is encapsulated, the method 100 proceeds to step 110 where the encapsulated pigment is again separated and purified for its final processing which is followed by drying and packaging of the pigment at step 112.

[0046] Optionally and advantageously, a chelating agents may be added at step 106 such as: [0047] Glycosides and polyglycoside derivatives [0048] Copolymer of modified organosilane with polyacrylate chain [0049] EDTA, their corresponding alkali metal salts and EDTA derivatives [0050] HEDTA and their corresponding alkali metal salts [0051] NTA and their corresponding alkali metal salts [0052] Sorbitan and its derivatives [0053] (Co)polymers of Sodium vinyl sulfonate, sodium styrylsulfonate, (meth)acrylic acid and their corresponding alkali metal salts preferably in combination with non-ionic monomers [0054] Di- to polycarboxylic acids like citric acid, sorbic acid, oxalic acid, succinic acid, itaconic acid, tartaric acid and their corresponding alkali metal salts [0055] Trimercaptotriazine and their corresponding alkali metal salts

[0056] Preferred chelating agents may be polyglycosides, polyacrylate, or modifyied organsilane with polyacrylate chain.

Embodiment 2

[0057] FIG. 2 illustrates an alternative method 200 for coating of the bismuth vanadate pigments with functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group preferably having more than 10 carbon atom(s); and R is a methyl or ethyl group, and in addition coating with chelating agents in which the chelating agent is prepared via an in situ polymerization. The method 200 starts at step 204 where a dried bismuth vanadate pigment is obtained and proceeds to step 206 where the functionalized silane is added and the chelating agent is polymerized. The step of polymerization involves adding an amount of a reactive ionic monomer followed by a polymerization initiator to the pigment slurry and stirring the dispersion in a temperature range between 20 C. to 180 C., for a time period ranging between 30 minutes to 240 minutes, and preferably between 90 minutes to 120 minutes. The step of polymerization process may optionally comprise adding a reactive non-ionic monomer to the dispersion, stirring it in a temperature range between 20 C. to 180 C. and acidifying the pigment slurry to a pH ranging between 0.5 to 4.0, and preferably between 1.5 to 2.5.

[0058] In an embodiment, the monomer may be selected from one or more from the set of monomers comprising [A] one or more functional polymerizable groups selected from an acrylate group or an unsaturated sulfonic group (such as the sodium vinlysulphonate or sodium styrylsulphonate), and [B] one or more nonionic monomers such as, but not limiting to, an alcohol monomer, an epoxide monomer, an organosilane monomer, an organomodified siloxane monomer, a thiol monomer, an amine monomer, an unsaturated carboxylic acid derivatives monomer (such as methacrylate, acrylamide, anhydride monomers), a vinyl monomer, a vinylamine monomer, or any combination thereof

[0059] Preferred chelating agent may be polyglycosides polyacrylate, or modifyied organsilane with polyacrylate chain.

[0060] After the polymerization is performed, the method 200 proceeds to step 208 where the final processing of the encapsulated pigment is performed proceeded by drying at step 210 to obtain a desired encapsulated pigment.

[0061] Final processing is generally dependent upon the type of method used for the synthesis of the pigment. For example, in some embodiments the final processing includes dispersing and milling of the encapsulated pigment. While in some other embodiments, the step of final processing simply includes separation and purification of the encapsulated pigments. The encapsulated pigment with improved alkaline resistance thus obtained is dried and packaged at step 210.

Embodiment 3

[0062] In some examples, as illustrated in FIG. 3 a solution of functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group; and R is a methyl or ethyl group is first prepared at step 304. Thereafter, a dried bismuth vanadate pigment obtained is added to the functionalized silane based solution which results in an encapsulation of bismuth vanadate pigments at step 306. Thereafter, final processing of the encapsulated pigment is performed at step 308 proceeded by drying and packaging at step 310 as disclosed in methods 100 and 200.

[0063] Further, chelating agents may be added at step 304.

[0064] In some embodiments, the functionalized silane may be introduced just before the spray drying of the pigment. The spray drying of the pigment is necessary to obtain homogeneity of the encapsulation to ensure the distribution of the chelating agent around the pigment. Optionally, the pigment may be slurried in an aqueous solution of the functionalized silane.

INDUSTRIAL APPLICABILITY

[0065] The present disclosure relates to a bismuth vanadate pigment which is encapsulated using a functionalized silane of the general formula RSi(OR)3 wherein R is an alkyl group preferably having more than 10 carbon atom(s); and R is a methyl or ethyl group.

[0066] These pigments inherit improved alkaline resistance, and in particular in cement and lime coatings, in addition to properties such as high resistance against extreme weather conditions. Further, the pigments offers high heat resistance, weather resistance, acid resistance and SO2 resistance and are outstandingly stable under various light conditions.

[0067] s

[0068] While being lead- and chromate-free, these pigments meet to a high degree demand for optimum outdoor performance while being suitable for most industrial applications. Accordingly, these pigments are advantageous to be used in various industries such as Paint & Coatings Industry, Automotive & Transportation industries, cosmetic industries, or the like. These pigments are particularly recommended for coatings as well for various plastic applications. Further, pigments are ideal for applications such as automotive finishes (OEM and refinish), high-grade industrial paints, manufacture of colored plastic products.

[0069] The bismuth vanadate pigments of the present invention may be used almost everywhere. In particular, logistics and as well in companies in the chemical, painting, cosmetic, packaging, films, cartons and automotive industry as well as aircraft industry requiring highly stable pigment while having excellent resistance to adverse situation.

[0070] Typically bismuth vanadate pigments are first choice pigments for uses in coatings field due to their opacity and the brightness of their shade. The conventional architectural coatings for which water based coatings are applied on high alkaline substrate like cement and plaster, lack bright color. The pigments of the present invention may be used in particular in cement or lime coatings with good resistance properties without observed discoloration with the benefit of its color strength and bright shade. The pigment is also usable in all the other coatings due to its non-modified color strength level. It makes the pigment of the present invention a very universal pigment with very broad applicability.

[0071] The present disclosure further provides a method, generally referred by the numeral 100, for manufacturing bismuth vanadate pigment having improved alkali resistance. The method is generally a simple, cost efficient, time-saving, method for forming a high quality bismuth pigments.

EXAMPLE

[0072] Sample preparation: Blend of cement, sand and pigment is prepared in an automatic L mortar mixer (EN-196-1) with a ratio cement 25/sand 75. Sand and pigment (3% versus the cement amount) are dispersed first and mixed for 20 sec. Then water is added and mixed during 20 sec. Cement is finally added with a continue mixing for a further 30 to 60 sec. [0073] Cement typePortland Cement WhiteBL II/A-L 42.5R or (white cement BL-I 52.5 R) [0074] SandCEN-NORMSAND DIN EN 196-1.

[0075] The above mixture sand/mortar is placed 24 h in mold+5 days curing in high humidity (without contact with water). Test specimen are 4 cm4 cm16 cm bar.

[0076] 2 samples are prepared: [0077] Reference sample cement 6616: with a non-treated BiVa (commercial reference 6616B) [0078] Sample cement 282RDX: Biva prepared in our lab according to the procedure of the example X above

[0079] Results after curing of the Cement and Sand mixture: [0080] External surface: color remains in both cases for both materials (reference sample cement 6616 and sample cement 282RDX) [0081] Internal surface (once we have cut a slice): [0082] Reference cement 6616: color loss [0083] Sample cement 282RDX: color is still OK

[0084] Results after 80 days REAL WEATHERING BARCELONA: [0085] Same results than after curing [0086] External surface: color remains in both cases for both materials (reference sample cement 6616 and sample cement 282RDX). [0087] Internal surface (once we have cut a slice): [0088] Reference cement 6616: color loss [0089] Sample cement 282RDX: color is still OK