Air purification coating system and method for making the same

Abstract

An air purification coating system and a method for manufacturing the same, the air purification coating system having a carrier and a diatom frustule particle dispersion combined with the carrier. The diatom frustule particle dispersion may include diatom frustule zinc oxide particles, diatom frustule titanium dioxide particles, or a combination thereof. The coating system may include 70% to 99.9% by weight of the carrier and 0.1% to 30% by weight of the diatom frustule particle dispersion. The carrier of the coating system may include a cleaning agent or a polishing agent. The diatom frustule particle dispersion may include diatom frustule particles having a particle size of 1 micron to 35 microns combined with water and a dispersing additive. The dispersion may also include an anti-settling additive, a rheology modifier, and / or a defoamer.

Description

Background Art

[0001] The present invention generally relates to the field of coatings. More specifically, the present invention relates to an air purification coating system having a combination of a diatom frustule particle dispersion and a carrier, wherein the carrier (for example) is a cleaning agent and / or a polishing agent. The diatom frustule particle dispersion can be zinc oxide, titanium oxide or a combination thereof. The present invention also relates to a method for manufacturing an air purification coating system. The air purification coating system can be applied to a substrate such as wood, a laminate, or a synthetic surface such as PVC, vinyl, linoleum, or a hard surface such as concrete, stone, terrazzo, granite or marble, and reduces toxins in the surrounding air environment, such as volatile organic compounds (VOCs).

[0002] Indoor air quality has always been an important area of ​​concern. Indoor air pollutants can come from sources such as carpets, furnaces, furniture, insulation, pets, trash, and fuel in the garage. Although current residential construction technology makes homes more airtight, this can trap VOCs inside the home and cause symptoms such as sick home syndrome.

[0003] Products are available that claim to clean VOCs from indoor air. However, many of these commercially available products have drawbacks. For example, many of these products become inactive after becoming filled with impurities and lose their effectiveness in reducing VOCs.

[0004] There is a need for easy-to-use products that can durably reduce VOCs and toxins in indoor air environments. Summary of the invention

[0005] The following is a brief summary of the invention to provide a basic understanding of several aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify important or critical elements of the invention or to describe the scope of the invention; the sole purpose of this summary is to present the concepts of the invention in a simplified form as a preface to the detailed description that is subsequently given.

[0006] The present invention includes an air purification coating system. In one embodiment of the present invention, the air purification coating system comprises a carrier and a diatom frustule particle dispersion combined with the carrier, wherein the dispersion may be a diatom frustule zinc oxide particle dispersion, a diatom frustule titanium oxide particle dispersion, or a combination thereof. In one embodiment of the present invention, the coating system comprises 70 wt % to 99.9 wt % of the carrier and 0.1 wt % to 15 wt % of the diatom frustule particle dispersion.

[0007] In one embodiment of the air purification coating system of the present invention, the diatom frustule particle dispersion may include diatom frustule particles having a particle size of 1 micron to 35 microns. In another embodiment of the present invention, the diatom frustule particle dispersion may include water, diatom frustule particles and a dispersing additive. The diatom frustule particle dispersion may further include an anti-settling additive, a rheological additive and / or a defoaming agent.

[0008] In one embodiment of the present invention, the diatom frustule particle dispersion comprises 50 wt % to 75 wt % of water, 20 wt % to 50 wt % of diatom frustule particles, 1 wt % to 10 wt % of a dispersing additive (such as a copolymer of a pigment-affinity group), and 0.1 wt % to 2 wt % of a rheological additive (such as a modified urea-formaldehyde resin).

[0009] In one embodiment of the air purification coating system of the present invention, the carrier may be a detergent. In addition, the coating system of the present invention may include 95% to 99.9% by weight of a detergent and 0.1% to 5.0% by weight of a diatom frustule particle dispersion. In one embodiment of the air purification coating system of the present invention, the detergent may include an acrylic resin, a surfactant and a hydrotropy. In another embodiment of the air purification coating system of the present invention, the detergent may include 80% to 97% by weight of water, 0.5% to 5% by weight of an acrylic resin (such as an alkali-soluble metal-complexed acrylic copolymer), 0.1% to 1% by weight of a hydrotropy, 0.1% to 3% by weight of an emulsifier (such as a C10-Guerbet alcohol (Guerbet Alcohol) and ethylene oxide), 0.1 wt % to 1 wt % of a freeze-thaw agent (such as a surfactant mixture), 0.1 wt % to 1 wt % of a flow additive (such as a polyether-modified hydroxyl-functional polydimethylsiloxane and / or a polyether-modified siloxane), 0.1 wt % to 1 wt % of a defoamer (such as a foam-breaking polysiloxane), 0.1 wt % to 1 wt % of a polyether-modified siloxane surface modifier, 0.1 wt % to 1 wt % of an anti-settling additive (such as a modified urea-formaldehyde resin), and 0.1 wt % to 0.5 wt % of an antimicrobial agent (such as a mixture of benzisothiazolinone and methylisothiazolinone). The dispersion can be a diatom frustule zinc oxide particle dispersion, a diatom frustule titanium oxide particle dispersion, or a combination thereof.

[0010] In one embodiment of the air purification coating system of the present invention, the carrier may be a polishing agent. In addition, the coating system of the present invention may include 70% to 99.9% by weight of a polishing agent and 0.1% to 30% by weight of a diatom frustule particle dispersion. In one embodiment of the air purification coating system of the present invention, the polishing agent may include water, an adhesive, a freeze-thaw agent, a solvent, a defoamer, and a surface modifier. In one embodiment, the adhesive may be an acrylic copolymer resin. Alternatively, the adhesive may also be a polyurethane resin. In another embodiment of the air purification coating system of the present invention, the polishing agent may include 45 wt % to 95 wt % of water, 3 wt % to 53 wt % of acrylic copolymers and acrylic copolymers, 1 wt % to 5 wt % of solvents, 0.0 wt % to 1 wt % of freeze-thaw additives, 0.1 wt % to 1 wt % of anti-settling additives (such as modified urea-formaldehyde resins), 0.01 wt % to 1 wt % of flow additives (such as polyether-modified siloxanes and / or fluorinated surfactants), 0.01 wt % to 1 wt % of defoamers, 0.01 wt % to 0.5 wt % of antimicrobial agents, 0.1 wt % to 3 wt % of wax additives, and 0.01 wt % to 0.1 wt % of dispersants (such as copolymers of pigment affinity groups). The dispersion may be a diatom shell zinc oxide particle dispersion, a diatom shell titanium oxide particle dispersion, or a combination thereof.

[0011] The present invention also includes a method for making an air purification coating system. In one embodiment of the present invention, the method includes the following steps: providing diatom frustule particles, wherein the particles are diatom frustule zinc oxide particles, diatom frustule titanium oxide particles, or a combination thereof; combining the diatom frustule particles with water and a dispersing additive to form a diatom frustule particle dispersion; providing a carrier; and combining the carrier with the diatom frustule particle dispersion to form the air purification coating system of the present invention.

[0012] In one embodiment of the method of the present invention, the particle size of the diatom frustule particles is 1 micron to 35 microns. In addition, the method of the present invention may also include the step of grinding the diatom frustule particles to a particle size of 1 micron to 35 microns. In one embodiment of the present invention, the method may also include combining the diatom frustule particles with a rheological additive and a defoamer to form a dispersion. In one embodiment of the method of the present invention, the method may include combining 50% to 75% by weight of water, 20% to 50% by weight of diatom frustule particles, and 1% to 10% by weight of a dispersing additive to form a diatom frustule particle dispersion.

[0013] The method of the present invention may include combining 85% to 99.9% by weight of a carrier and 0.1% to 15% by weight of a dispersion of diatom frustule particles. In one embodiment of the method of the present invention, the carrier may be a detergent. In addition, the method may include combining 95% to 99.9% by weight of a detergent with 0.1% to 5% by weight of a dispersion of diatom frustule particles. In another embodiment of the method of the present invention, the carrier may be a polishing agent. In addition, the method may include combining 70% to 99.9% by weight of a polishing agent with 0.1% to 10% by weight of a dispersion of diatom frustule particles. For the detergent or polishing agent, the diatom frustule particles may be diatom frustule zinc oxide particles, diatom frustule titanium oxide particles, or a combination thereof.

[0014] Other features of the present invention will be apparent from the following description. After the summary, these features may be partially apparent from the description, or may be learned through the practice of the present invention. It should be understood that the summary in the foregoing and the detailed description below are only exemplary and illustrative, and are not limitations of the present invention as claimed. DETAILED DESCRIPTION

[0015] The present invention relates to an air purification coating system and a method for making the same. The air purification coating system may be an air purification cleaning and polishing system. For example, the air purification cleaning and polishing system may be in the form of a cleaning agent and / or polishing agent applied to a substrate and a surface. When applied to a substrate or a surface, the air purification coating system preferably reduces indoor air toxins, such as volatile organic compounds. In addition, the coating system may also provide the coated surface with acceptable chemical resistance, gloss, scratch resistance and / or clarity. The air purification coating system of the present invention may include a carrier, such as a cleaning agent, a polishing agent, or a cleaning / polishing agent. The air purification coating system may also include a diatom frustule particle dispersion combined with a carrier, wherein the dispersion may be a diatom frustule zinc oxide particle dispersion, a diatom frustule titanium oxide particle dispersion, or a combination thereof. Depending on the intended use of the coating system, the air purification coating system of the present invention may also be combined with other ingredients and / or additives.

[0016] Although the air cleaning coating system of the present invention is mainly described herein as a surface cleaner and / or polish, it should be clear that the air cleaning coating system of the present invention can have many other uses. In addition, although the air cleaning coating system of the present invention is mainly pointed out to provide beneficial air cleaning properties when applied to surfaces and substrates, it can also exhibit other beneficial properties and performances.

[0017] Unless otherwise stated, the following terms used in the specification and claims have the meanings given below.

[0018] Unless otherwise specified, the term "nanoparticle" as used herein has the ordinary and usual meaning in the art and refers to a particle having a size between 1 nm and 100 nm, or 1×10 -9 Rice grains.

[0019] Unless otherwise specified, the term "micrometer" as used herein has the ordinary and usual meaning in the art and refers to a particle having a size between 1 micrometer and 100 micrometers, or 1×10 -6 Rice grains.

[0020] As used herein, unless otherwise specified, the term "grinding mill" has its ordinary and customary meaning in the art and refers to a machine used to reduce pigment particle size to a repeatable and consistent distribution.

[0021] As used herein, unless otherwise specified, the term "surfactant" refers to an organic polymer with a positive or negative charge that stabilizes and separates pigment particles in solution in water or an organic solvent.

[0022] Unless otherwise specified, the term "dispersion solution" used herein refers to a solution containing a pigment, a solvent, a defoaming agent, a surfactant, and an anti-settling additive.

[0023] As used herein, unless otherwise specified, the term "polymer / resin" refers to organic compounds used in paints, coatings, and polishes to bind pigments and protect surfaces such as wood, concrete, synthetic surfaces, and natural stone.

[0024] As used herein, unless otherwise specified, the term "finish" refers to a coating used to add protection to surfaces such as wood, vinyl, laminate, pvc, linoleum, stone, granite, terrazzo, marble or concrete floors.

[0025] Unless otherwise specified, the term "cleaner" as used herein refers to a material comprising a surfactant, a solvent, water, and a polymeric resin.

[0026] Unless otherwise specified, the term "particle size analyzer" used herein refers to a device for determining the particle size in a solution and counting the particles. The calculated numerical unit can be nanometers or micrometers. The device used for the test herein is an Accusizer N3000, but other devices can be used without departing from the scope of the present invention.

[0027] Unless otherwise specified, the term "weathering tester" as used herein refers to a device for simulating sunlight exposure by a controlled accelerated method. The chamber can be controlled to various temperature and humidity conditions. The device used for the test herein is XE1, which has an air-conditioned chamber to maintain STP (standard temperature and pressure) conditions, but other devices can be used without departing from the scope of the present invention.

[0028] The embodiments and examples of the present invention will be described in more detail below. The specific ingredients and contents thereof listed in these examples, as well as other conditions and details should not be considered to constitute undue restrictions to the present invention. Although the numerical ranges and parameters showing the wide range of the present invention are approximate values, the numerical values ​​shown in the specific examples are recorded as accurately as possible. However, any numerical value inherently contains a certain error, which is the inevitable result of the standard deviation in its respective experimental measurements. In addition, it should be understood that all ranges disclosed herein cover any and all sub-ranges included therein. In the examples and discussions of this specification, unless otherwise stated, all percentages, ratios and ratios are by weight (mass).

[0029] An air purification coating system and a method for making the same are disclosed. As described above, the system may include a carrier, such as a cleaning agent, a polishing agent, or a cleaning / polishing agent, which is combined with a diatom frustule particle dispersion. The diatom frustule particle dispersion may be a diatom frustule zinc oxide particle dispersion, a diatom frustule titanium oxide particle dispersion, or a combination thereof. In one embodiment of the air purification coating system of the present invention, the coating system may include 70 wt % to 99.9 wt % of a carrier and 0.1 wt % to 15.0 wt % of a diatom frustule particle dispersion.

[0030] The diatom frustule particle dispersion comprises diatom frustule particles ("DF particles") combined with a dispersion liquid. The diatom frustule particles may be diatom frustule zinc oxide particles ("DFZnO particles"), diatom frustule titanium oxide particles ("DFTiO2 particles"), or a combination thereof. The DF particles used in the present invention are preferably nanoparticles. The diatom frustule particle dispersion ("DF dispersion") is preferably a stable aqueous dispersion for introduction into a carrier such as a cleaning agent, a polishing agent, and a cleaning / polishing agent.

[0031] Before forming the DF dispersion, the DF particles may be ground to make the pigment more stable and more uniform in solution. The grinding may be performed using a HCP immersion mill from Hockmeyer Corporation, and the media may be zirconia with a size of 0.4 mm.

[0032] DF dispersions may include several ingredients to ensure that the pigment particles are uniformly dispersed and stable in solution. In addition, DF dispersions may also apply sedimentation and defoaming ingredients. In one embodiment of the DF dispersion of the present invention, the dispersion may include about 50% to 75% by weight of water. The DF dispersion may also include about 20% to 50% by weight of DF particles, such as Diatomix 10 micron powder or diatom frustule zinc oxide particle powder (ZnO DPA). In addition, the DF dispersion may include about 1% to 10% by weight of dispersing additives. The DF dispersion may also include about 0.1% to 2% by weight of rheological additives, such as nonionic urethane copolymers. In addition, the DF dispersion may include about 0.01% to 0.2% by weight of defoamers to minimize the foam generated during the mixing process.

[0033] DF dispersion can be prepared by combining water with dispersing additives in a container such as a dissolver. Preferably, dispersing additives are added to water under slow stirring and mixed for about 5 minutes. Then rheological additives can be added under slow stirring and stirred for about 10 minutes until the rheological additives are fully mixed. Then, defoamers can be added according to the foam generation of the dispersion to avoid foaming during mixing. Finally, DF particles such as Diatomix 10 micron powder or diatom shell zinc oxide particle powder (ZnO DPA) are preferably sieved into the batch material under stirring. The dispersion can then be transferred to an immersion grinder, such as an HCP immersion grinder, by the dissolver. The DF dispersion can be subsequently ground until the effective Hegman (Hegman) particle size is preferably greater than 1 micron and less than 100 microns, more preferably greater than 6 microns or less than 20 microns. In one embodiment, the grinding speed is about 2500rpm to 3500rpm.

[0034] The carriers of the present invention, including most cleaning agents, polishes, and cleaning / polishing agents, are generally lower in viscosity and are preparations with less non-volatile matter than the DF particles. Therefore, it is preferred to have the DF particles in the form of a dispersion to facilitate the introduction of the particles into such lower viscosity and less non-volatile matter agents.

[0035] As mentioned above, the carrier of the present invention includes a detergent. When the detergent is introduced into the present invention, an air purification cleaning system is formed. The detergent of the present invention includes both detergents and refresher products, and the detergent of the present invention is generally aqueous. The detergent of the present invention preferably includes an acrylic resin, more preferably an alkali-soluble metal-complexed acrylic copolymer, and its acid value is greater than 25 mg KOH. The detergent of the present invention also preferably includes a surfactant, such as an alkyl polyglycol ether made from C10-Guerbet alcohol and ethylene oxide. Surfactants are generally used for cleaning, degreasing and emulsifying dirt and other types of pollutants. In water-based cleaning systems, freeze-thaw stability is very important for maintaining system performance. Therefore, when a water-based detergent is introduced into the present invention, a surfactant that can provide freeze-thaw stability but does not interfere with system performance can be introduced. The detergent of the present invention can also utilize a hydrotrope to dissolve hydrophobic compounds.

[0036] To ensure that the air purification cleaning system has sufficient surface wetting and surface protection effects, surface wetting materials that can reduce the surface tension of the cleaning agent and provide a uniform layer on the floor material can be used. Functional surface wetting materials can also be used, which can increase the level of surface damage protection.

[0037] When surfactants are used, defoamers are often introduced into the air purification cleaning system of the present invention to limit excessive foaming or foaming. Preferably, such defoamers (such as foam-breaking polysiloxanes) have long-term effectiveness without adverse interactions with surfactants. When DF particles are introduced into a relatively low viscosity cleaning agent, a rheology modifier can be used to prevent the DF particles from hardening at the bottom of the container.

[0038] Glycol ether solvents, such as dipropylene glycol monomethyl ether, propylene glycol butyl ether, tripropylene glycol methyl ether and / or diethylene glycol ethyl ether, may be introduced into the air purification cleaning system to help dissolve grease and / or resin in the system.

[0039] In one embodiment of the present invention, the cleaning agent of the air purification cleaning system comprises about 80% to 97% by weight of water. In addition, the cleaning agent may comprise about 0.5% to 5% by weight of an alkali-soluble metal complex acrylic copolymer to obtain adhesion and resolubility. In addition, the cleaning agent of the present invention may comprise about 0.1% to 1% by weight of a hydrotropy agent, such as sodium cumene sulfonate. The cleaning agent of the present invention may comprise a surfactant to solve the cleaning and emulsification problems of dirt. In one embodiment, the cleaning agent of the present invention may comprise about 0.1% to 3% by weight of an emulsifier. For example, about 0.1% to 1% by weight of an alkyl polyglycol ether may be introduced into the cleaning agent, wherein the alkyl polyglycol ether is prepared from C10-Guerbet alcohol and ethylene oxide. Special additives may also be introduced into the cleaning agent of the air purification cleaning system. For example, freeze-thaw additives can be introduced, for example, about 0.1% to 1% by weight of freeze-thaw agents, such as surfactant mixtures; about 0.01% to 1% by weight of flow additives, such as about 0.1% to 1% by weight of foam-breaking polysiloxanes; about 0.1% to 1% by weight of surface modifiers; about 0.1% to 1% by weight of anti-settling additives; about 0.1% to 0.5% by weight of antimicrobial agents, such as a mixture of benzisothiazolinone and methylisothiazolinone; and solvents for obtaining resin solubility. In one embodiment of the present invention, about 0.1% to 5% by weight of DF dispersions can be introduced into the cleaning agent to form the air purification cleaning system of the present invention.

[0040] Polishing agents can also be used as carriers of the present invention. When polishing agents are introduced into the present invention, an air purification polishing system is formed. Polishing agents can be used to increase the protection of surfaces such as wood, synthetic materials, stone and / or other hard surfaces. For example, polishing agents are used to protect substrates and surfaces from scratches, scrapes, chemical damage and premature damage. Polishing agents can also provide secondary properties such as gloss, coloring, and image depth or clarity. Polishing agents include both polishing agents and brighteners (finishes).

[0041] The polish of the present invention may be a water-based polish and may contain a binder such as a polyurethane and / or acrylic resin. Such a product preferably provides durable scratch resistance, chemical resistance and / or adhesion to different substrates.

[0042] In a water-based polishing system, freeze-thaw stability is very important for maintaining system performance. Therefore, when a water-based polishing agent is introduced into the system of the present invention, a surfactant that can provide freeze-thaw stability but does not interfere with system performance can be introduced. Examples of such products include tributoxyethyl phosphate, butyl hydroxybutyrate, and propylene glycol.

[0043] To ensure that the air cleaning polish system has adequate surface wetting and surface protection, surface wetting materials that can reduce the surface tension of the polish and provide a uniform layer on the floor material can be used. Functional surface wetting materials can also be used, which can increase the level of surface damage protection.

[0044] As with the cleaning system of the present invention, a foam-destroying polysiloxane that can limit excessive foaming or foaming caused by the surfactant is usually introduced into the air cleaning polishing system of the present invention. Preferably, such a defoaming agent has long-term effectiveness without adverse interactions with the surfactant. In addition, when the DF particles are introduced into a polishing agent with a lower viscosity, a rheology modifier can be used to prevent the DF particles from hardening at the bottom of the container.

[0045] A solvent may be introduced into the air clean polishing system to help dissolve the resin in the system. Examples of solvents used in the present invention include glycol ethers such as dipropylene glycol monomethyl ether, propylene glycol butyl ether, tripropylene glycol methyl ether and / or diethylene glycol ethyl ether.

[0046] In one embodiment of the invention, the polishing agent of the air purification polishing system comprises about 40 wt % to 95 wt % of water. In addition, the polishing agent may comprise about 3 wt % to 53 wt % of an adhesive, more preferably comprising 20 wt % to 50 wt % of an adhesive, such as acrylic and carbamate components. The polishing agent of the present invention may comprise about 1 wt % to 9 wt % of a solvent composition, or more preferably comprises 1 wt % to 5 wt % of a solvent. In addition, the polishing agent may also comprise about 0.1 wt % to 1 wt % of an anti-settling agent (such as modified urea-formaldehyde resin), about 0.1 wt % to 1 wt % of a leveling agent (such as polyether-modified siloxane), 0.01 wt % to 0.05 wt % of a fluorinated surfactant and / or about 0.01 wt % to 1.0 wt % of a foam-breaking polysiloxane. The polishing agent may also comprise about 0.1 wt % to 1 wt % of a freeze-thaw agent, such as a surfactant mixture or propylene glycol. The polishing agent may contain about 0.1% to 1.0% by weight of a rheology modifier, such as a nonionic urethane copolymer for leveling. To prevent microbial attack, about 0.01% to 0.5% by weight of an antimicrobial agent, such as a mixture of benzisothiazolinone and methylisothiazolinone, may be introduced into the polishing agent of the present invention. In addition, about 0.1% to 5% by weight of a wax adjuvant, such as a polyethylene mixture, may be introduced into the polishing agent of the present invention to provide damage resistance. The polishing agent may also contain 0.01% to 0.1% by weight of a dispersant, such as a copolymer of a pigment affinity group.

[0047] In another embodiment of the present invention, the polishing agent of the air purification polishing system comprises about 40% to 75% by weight of water. In addition, the polishing agent may comprise about 23% to 58% by weight of an adhesive, such as acrylic and carbamate components. The polishing agent of the present invention may comprise about 1% to 5% by weight of a solvent composition, such as glycol ether. In addition, the polishing agent may further comprise about 0.1% to 3% by weight of a freeze-thaw agent (such as a modified phosphate or salt), about 0.1% to 1% by weight of an anti-settling agent (such as a modified urea-formaldehyde resin), about 0.1% to 1% by weight of a leveling agent (such as a polyether-modified siloxane), 0.01% to 0.05% by weight of a fluorinated surfactant and / or about 0.01% to 1.0% by weight of a defoamer (such as a foam-breaking polysiloxane). The polishing agent may further comprise about 0.1% to 1.0% by weight of a rheology modifier, such as a nonionic carbamate copolymer for obtaining leveling. To prevent microbial attack, about 0.01 wt % to 0.5 wt % of an antimicrobial agent, such as a mixture of benzisothiazolinone and methylisothiazolinone, may be introduced into the polish of the present invention. In addition, about 0.1 wt % to 4 wt % of a wax adjuvant, such as a polyethylene mixture, may be introduced into the polish of the present invention to provide damage resistance. The polish may also contain 0.01 wt % to 0.2 wt % of a dispersant, such as a copolymer of a pigment affinity group.

[0048] In another embodiment of the present invention, the polishing agent of the air purification polishing system comprises about 40% to 75% by weight of water. In addition, the polishing agent may comprise about 20% to 50% by weight of acrylic copolymers and about 5% to 30% by weight of polyurethane dispersion polymers. The polishing agent of the present invention may comprise about 1% to 5% by weight of solvent composition, such as glycol ether. In addition, the polishing agent may also comprise about 1% to 7% by weight of matting pigments, about 1% to 5% by weight of rheological additives (such as bentonite), about 0.1% to 1% by weight of leveling agents (such as polyether-modified siloxanes), about 0.01% to 0.05% by weight of fluorinated surfactants and / or about 0.01% to 1.0% by weight of defoamers (such as defoaming polysiloxanes). The polishing agent may comprise about 0.1% to 1.0% by weight of rheological modifiers, such as nonionic urethane copolymers for obtaining leveling. In order to prevent microbial attack, about 0.01 wt % to 0.5 wt % of antimicrobial agents, such as a mixture of benzisothiazolinone and methylisothiazolinone, may be introduced into the polishing agent of the present invention. In addition, for further curing, about 1 wt % to 15 wt % of a cross-linking agent, such as a polyisocyanate polymer, may be included. The polishing agent may also include about 0.01 wt % to 0.1 wt % of a dispersant to further stabilize the DF particles in the DF dispersion. In one embodiment of the present invention, about 0.1 wt % to 10 wt % of a DF dispersion may be introduced into the polishing agent to form an air purification polishing system of the present invention. The DF dispersion may include DFZnO particles, DFTiO2 particles, or a combination thereof.

[0049] Because the vehicle of the present invention is typically a cleaner and / or polish, the coatings of the present invention are typically used primarily for cleaning or polishing a variety of substrates and surfaces, such as wood, concrete, laminate, PVC, vinyl, linoleum, and / or natural stone, in addition to having the secondary benefit of providing a reduced VOC coating system.

[0050] The coating system of the present invention preferably reduces the level of volatile organic compounds in the air. For example, the coating system preferably reduces volatile organic compounds that can lead to poor indoor air quality, such as ketones, amines, alcohols, and aldehydes. In addition to reducing volatile organic compounds in indoor air, the coating system of the present invention also preferably maintains or improves surface cleaning and / or polishing properties, such as surface gloss, chemical resistance, surface clarity, and cleaner / polish leveling. When the coating system is applied to a surface and is exposed to indoor lighting or natural lighting (such as sunlight), the reduction of volatile organic compounds in the surrounding air can be activated.

[0051] The present invention includes a method of forming the air purifying coating system of the present invention. In one embodiment of the present invention, the method includes the steps of providing diatom frustule particles, such as diatom frustule zinc oxide particles, diatom frustule titanium dioxide particles, or a combination thereof; combining the diatom frustule particles with water and a dispersing additive to form a diatom frustule particle dispersion; providing a carrier; and combining the carrier and the diatom frustule particle dispersion to form the air purifying coating system of the present invention.

[0052] In one embodiment of the method of the present invention, the particle size of the diatom frustule particles is 1 micron to 35 microns. In addition, the method of the present invention may also include the step of grinding the diatom frustule particles to a particle size of 1 micron to 35 microns. In one embodiment of the present invention, the method may also include combining the diatom frustule particles with an anti-settling additive, a rheological additive and / or a defoamer to form a dispersion. In one embodiment of the method of the present invention, the method may include combining 50% to 75% by weight of water, 20% to 50% by weight of diatom frustule particles, 0.1% to 5% by weight of an anti-settling additive, 0.1% to 2% by weight of a foam-breaking polysiloxane, and 1% to 10% by weight of a dispersing additive to form a diatom frustule particle dispersion.

[0053] The method of the present invention may include combining 85% to 99.9% by weight of a carrier and 0.1% to 15% by weight of a dispersion of diatom frustule particles. In one embodiment of the method of the present invention, the carrier may be a detergent. In addition, the method may include combining 95% to 99.9% by weight of a detergent and 0.1% to 5% by weight of a dispersion of diatom frustule particles. The dispersion of diatom frustule particles may be a dispersion of diatom frustule zinc oxide particles, a dispersion of diatom frustule titanium dioxide particles, or a combination thereof. In another embodiment of the method of the present invention, the carrier may be a polishing agent. In addition, the method may include combining 90% to 99.9% by weight of a polishing agent and 0.1% to 10% by weight of a dispersion of diatom frustule particles.

[0054] Having generally described this disclosure, further understanding can be obtained by reference to certain specific examples as shown below, which are provided for purposes of illustration only and are not intended to be exhaustive or limiting unless otherwise specified.

[0055] Test & Examples

[0056] The preparation, identification and testing of exemplary compositions of the present disclosure are further described below. The specific materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed as constituting undue limitations on this invention.

[0057] Nanoparticle functional diatom frustule material was obtained from Diatomix Incorporated and tested for use in the present invention. The material was a cream colored powder and had a particle size of about 10 microns. When the material was placed in water, the particle size was measured to be about 15 microns. The measurements were made using an Accusizer N3000. The original Diatomix DPA52 10 micron powder had a particle size distribution of 1 micron to 20 microns. The material did not remain in solution but began to settle rapidly in solution as particles with a very coarse, granular appearance. The material was then ground to make the pigment more stable and uniform in solution.

[0058] Subsequently, the ground Diatomix material is used to form a DFTiO2 particle dispersion. In a dissolver, 50% to 75% by weight of water and 1% to 10% by weight of a dispersing additive are mixed under slow stirring to make a dispersion. The water and dispersing additive are mixed for five minutes. Then, under slow stirring, a rheological additive in an amount of 0.1% to 2% by weight is mixed and mixed for 10 minutes until the rheological additive is fully mixed in the dispersion. A defoamer is then added to avoid foaming during the mixing process. Then, under stirring, about 20% to 50% by weight of the ground Diatomix material is sieved into the batch and then transferred from the dissolver to the HCP immersion grinder. The dispersion is ground at a speed of 2500rpm to 3500rpm until the effective Hegman particle size is greater than 6 microns or less than 20 microns.

[0059] Two systems, the Air Purifying Cleaning System and the Air Purifying Polishing System, were tested to determine the air purification capabilities of each system. The testing was conducted by Research Triangle Park Laboratories in Raleigh, North Carolina.

[0060] The first test involves the air purification cleaning system of the present invention. A first control sample containing a cleaning agent and no DFTiO2 particle dispersion is analyzed, and a second active sample containing a cleaning agent and a DFTiO2 particle dispersion is analyzed for comparison. ASTM D6670 "Standard Practice for Full-Scale Chamber Determination of Volatile Organic Emissions from Indoor Materials / Products" is used to test the VOC reduction of the sample by introducing a known concentration of the selected VOC into a 27-liter glass chamber. Two four-foot T8 LED light fixtures are placed outside the chamber, about 6 inches from the chamber. The lamps are placed adjacent to each other and work during the entire test. The sample is applied directly to a glass plate (7 inches x 14 inches), three layers of coating are applied, and then cured. By weighing the glass plate before and after coating, the weight of the three layers of coating is measured to be 0.1 grams. The sample is then placed in a sealed chamber for 30 minutes, with the coated side facing the light. Before the introduction of VOCs, the chamber was sealed and allowed to reach equilibrium. Temperature and relative humidity were monitored throughout the test, and the temperature was measured to be 25°C and the relative humidity was 35% to 45%. At the beginning of each test and before the introduction of VOCs into the chamber, air samples were collected from the chamber to confirm that there were no VOCs in the chamber before the test was performed. Then known amounts of formaldehyde (2.5ppm) and methyl mercaptan (1.0ppm) were introduced into the chamber. Then chamber air samples were collected again at 1 hour, 24 hours, 48 ​​hours and 72 hours, and the specific VOCs introduced were analyzed. Table 1 below shows the VOC air sample test results for the control sample and the active sample at different time stages.

[0061] Table 1

[0062]

[0063] As shown in Table 1 above, the test chamber containing the active sample including the air purification cleaning system of the present invention has a formaldehyde VOC reduction of about 15% and a methyl mercaptan VOC reduction of about 19% at 48 hours compared to the control sample with only a detergent. In addition, the test chamber containing the active sample including the air purification cleaning system of the present invention has a formaldehyde VOC reduction of about 30% and a methyl mercaptan VOC reduction of about 35% at 72 hours compared to the control sample with only a detergent.

[0064] The second test involves the air purification polishing system of the present invention. A first control sample containing a polish and no DFTiO2 particle dispersion was analyzed, and a second active sample containing a polish and a DFTiO2 particle dispersion was analyzed for comparison. The VOC reduction of the sample was tested by introducing a known concentration of the selected VOC into a 27-liter glass chamber using ASTM D6670 "Standard Practice for Full-Scale Chamber Determination of Volatile Organic Emissions from Indoor Materials / Products". Two four-foot T8 LED light fixtures were placed outside the chamber, approximately 6 inches from the chamber. The lights were placed adjacent to each other and operated throughout the test. The sample was applied directly to a glass plate (7 inches x 14 inches), a coating was applied, and then cured. By weighing the glass plate before and after coating, the weight of a coating was measured to be 1.0 grams. The sample was then placed in a sealed chamber for 30 minutes with the coated side facing the light. Before the introduction of VOCs, the chamber was sealed and allowed to reach equilibrium. Temperature and relative humidity were monitored throughout the test, and the temperature was measured to be 25°C and the relative humidity was 35% to 45%. At the beginning of each test and before the introduction of VOCs into the chamber, air samples were collected from the chamber to confirm that there were no VOCs in the chamber before the test. Then known amounts of formaldehyde (5.0ppm) and methyl mercaptan (2.5ppm) were introduced into the chamber. Then chamber air samples were collected again at 24 hours, 48 ​​hours, and 72 hours, and the specific VOCs introduced were analyzed. Table 2 below shows the VOC air sample test results for the control sample and the active sample at different time stages.

[0065] Table 2

[0066]

[0067] As shown in Table 2 above, the test chamber containing the active sample including the air purification polishing system of the present invention had a formaldehyde VOC reduction of about 4.3% and a methyl mercaptan VOC reduction of about 22.5% at 48 hours compared to the control sample with only the polishing agent. In addition, the test chamber containing the active sample including the air purification polishing system of the present invention had a formaldehyde VOC reduction of about 12.5% ​​and a methyl mercaptan VOC reduction of about 37.5% at 72 hours compared to the control sample with only the polishing agent.

[0068] In the second polishing agent for another application, the test was carried out in the same manner as in the previous example. The results are shown in Table 3.

[0069] Table 3

[0070]

[0071] The polish example in Table 3 is similar to the polish of Table 2 except that the non-volatile content, fluorinated surfactant, and additional wax are increased. From the data, formaldehyde is reduced by 19% at 24 hours, and at 48 hours, the formaldehyde is reduced sharply by 58%, and at 72 hours, the formaldehyde reduction is 51% higher than the control system. From the methyl mercaptan data, the following results can be seen: at 24 hours, methyl mercaptan is reduced by 20%, at 48 hours, methyl mercaptan is reduced sharply by 50%, and finally at 72 hours, the methyl mercaptan reduction is 37% higher than the control.

[0072] The final example is a two-component acrylic-urethane polish coating system. Again, this system also showed a reduction in airborne chemicals. The data is shown in Table 4.

[0073] Table 4

[0074]

[0075] The data in this embodiment are slightly different, and this is because the curing kinetics of this system has slight difference.In the first 48 hours, formaldehyde reduction keeps roughly constant, and this may be the result that the reaction that isocyanate is converted into hydroxyl interferes with this reduction.Along with curing slows down, the 72 hour value of the active system containing DFTiO2 particle differs 21% from the control system.In the time of 48 hours, methyl mercaptan reduced by 25%, and finally in the time of 72 hours, methyl mercaptan reduction amplitude is 28% higher than control.

[0076] Although various embodiments and embodiments of the present invention have been described above, the purpose of giving these descriptions is only for illustration and explanation, rather than limitation. The systems and methods disclosed above may be changed, modified, improved and varied without departing from the spirit and scope of the present invention. In fact, after reading the above description, it will be apparent to those skilled in the relevant art how to implement the present invention with alternative embodiments. Therefore, the present invention should not be limited by any of the above exemplary embodiments.

[0077] In addition, the purpose of the abstract is to enable various patent workers and the public, especially scientists, engineers and practitioners in the field who are not familiar with patent or legal terms or terminology, to quickly determine the nature and essence of the technical disclosure of the present application through a rough review. The abstract is not intended to limit the scope of the present invention in any way.

Claims

1. An air purification coating system, comprising: 70% to 99.9% by weight of a carrier, wherein the carrier is a cleaning agent or a polishing agent; and 0.1 wt % to 30 wt % of a dispersion of diatom frustule particles in combination with the carrier, wherein the dispersion of diatom frustule particles comprises diatom frustule zinc oxide particles, or a combination of diatom frustule zinc oxide particles and diatom frustule titanium dioxide particles, The diatom frustule particle dispersion is a stable aqueous dispersion for introduction into the carrier, and comprises ground diatom frustule particles having a particle size of 1 micron to 35 microns. 2 . The air purification coating system according to claim 1 , wherein the diatom frustule particle dispersion is a diatom frustule zinc oxide particle dispersion.

3. The air purification coating system according to claim 1 or 2, wherein the carrier is a detergent.

4. The air purification coating system of claim 3, wherein the coating system comprises 95 wt% to 99.9 wt% of the cleaning agent and 0.1 wt% to 5.0 wt% of the diatom frustule particle dispersion.

5. The air purification coating system according to claim 3, wherein the cleaning agent comprises water, acrylic resin, surfactant and hydrotrope.

6. The air cleaning coating system according to claim 3, wherein the cleaning agent comprises: 80 to 97% by weight of water; 0.5 to 5 wt% acrylic resin; 0.1 wt % to 1 wt % of a hydrotrope; 0.1 wt % to 3 wt % of an emulsifier; 0.1 wt % to 1 wt % of a freeze-thaw agent; 0.1 wt % to 1 wt % of a flow additive; 0.1 wt % to 1 wt % of a defoaming agent; 0.1 wt % to 1 wt % of a surface modifier; 0.1 wt% to 1 wt% of an anti-settling additive; and 0.1 wt% to 0.5 wt% antimicrobial agent.

7. The air purification coating system of claim 6, wherein the acrylic resin comprises an alkali-soluble metal-complexed acrylic copolymer, the hydrotrope comprises sodium cumene sulfonate, the emulsifier comprises an alkyl polyglycol ether made from C10-Guerbet alcohol and ethylene oxide, the freeze-thaw agent comprises a surfactant mixture, the flow additive comprises a polyether-modified siloxane, the defoamer comprises a polysiloxane, the surface modifier comprises a polyether-modified siloxane, the anti-settling additive comprises a modified urea-formaldehyde resin; and / or the antimicrobial agent comprises a mixture of benzisothiazolinone and methylisothiazolinone.

8. The air purification coating system of claim 6, wherein the acrylic resin comprises an alkali-soluble metal-complexed acrylic copolymer, the hydrotrope comprises sodium cumene sulfonate, the emulsifier comprises ethoxylated fatty alcohol, the freeze-thaw agent comprises butyl hydroxybutyrate, the flow additive comprises polyether-modified siloxane, the defoamer comprises polysiloxane, the surface modifier comprises polyether-modified siloxane, the anti-settling additive comprises modified urea-formaldehyde resin; and / or the antimicrobial agent comprises a mixture of benzisothiazolinone and methylisothiazolinone.

9. The air cleaning coating system according to claim 1 or 2, wherein the carrier is a polishing agent.

10. The air purification coating system of claim 9, wherein the coating system comprises 90.0 wt% to 99.9 wt% of the polishing agent and 0.1 wt% to 10.0 wt% of the diatom frustule particle dispersion.

11. The air cleaning coating system of claim 9, wherein the polish comprises water, a binder, a freeze-thaw agent, and a surface modifier.

12. The air purification coating system of claim 11, wherein the binder comprises at least one of an acrylic resin and a polyurethane resin.

13. The air cleaning coating system according to claim 9, wherein the polish comprises: 45 to 95 wt. % water; 3 to 53 wt% of acrylic copolymers and polyurethane resins; 1 to 5 wt % of a solvent; 0.1 wt % to 1 wt % of a freeze-thaw agent; 0.1 wt% to 1 wt% of an anti-settling additive; 0.1 wt % to 1 wt % of a flow additive; 0.01 wt % to 1 wt % of a defoaming agent; 0.1 to 4 wt % of a wax additive; 0.01 wt % to 0.5 wt % of an antimicrobial agent; and 0.01 wt% to 0.1 wt% of a dispersant.

14. The air purification coating system of claim 13, wherein the solvent comprises a glycol ether, the freeze-thaw agent comprises a surfactant mixture, the anti-settling additive comprises a modified urea-formaldehyde resin, the flow additive comprises a polyether-modified siloxane, the defoamer comprises a polysiloxane, the wax adjuvant comprises a polyethylene mixture, the biocide comprises benzisothiazolinone and methylisothiazolinone, and / or the dispersant comprises a copolymer of a pigment affinity group.

15. The air purification coating system of claim 13, wherein the solvent comprises glycol ether, the freeze-thaw agent comprises propylene glycol, the anti-settling additive comprises a modified urea-formaldehyde resin, the flow additive comprises a polyether-modified siloxane, the defoamer comprises a polysiloxane, the wax adjuvant comprises a polyethylene mixture, the antimicrobial agent comprises benzisothiazolinone and methylisothiazolinone, and / or the dispersant comprises a copolymer of a pigment affinity group.

16. The air cleaning coating system of claim 9, wherein the polish comprises: 40 to 75 wt. % water; 23 to 58 wt% acrylic copolymer; 1 to 5 wt % of a solvent; 0.1 wt % to 3 wt % of a freeze-thaw agent; 0.1 wt% to 1 wt% of an anti-settling additive; 0.1 wt % to 1 wt % of a flow additive; 0.1 to 4 wt % of a wax additive; 0.01 to 0.05 wt % of a fluorinated surfactant; 0.01 wt % to 1 wt % of a defoaming agent; 0.01 wt % to 0.5 wt % of an antimicrobial agent; and 0.01 wt% to 0.2 wt% of a dispersant.

17. The air purification coating system of claim 16, wherein the solvent comprises a glycol ether, the freeze-thaw agent comprises a modified phosphate ester or salt, the anti-settling additive comprises a modified urea-formaldehyde resin, the flow additive comprises a polyether-modified siloxane, the wax additive comprises a polyethylene mixture, the defoamer comprises a polysiloxane, the biocide comprises benzisothiazolinone and methylisothiazolinone, and / or the dispersant comprises a copolymer of a pigment affinity group.

18. The air cleaning coating system of claim 9, wherein the polish comprises: 40 to 75 wt. % water; 20 to 50 wt% of an acrylic copolymer; 5 to 30 wt% of a polyurethane dispersion polymer; 1 to 5 wt % of a solvent; 1 to 7 wt % of matting pigments; 1 to 5 wt % of a rheological additive; 0.1 wt % to 1 wt % of a flow additive; 0.01 wt % to 1 wt % of a defoaming agent; 0.01 wt % to 0.5 wt % of an antimicrobial agent; and 1 wt % to 15 wt % of a crosslinking agent.

19. The air purification coating system of claim 18, wherein the solvent comprises a glycol ether, the rheological additive comprises bentonite, the flow additive comprises a polyether-modified siloxane, the defoamer comprises a polysiloxane, the biocide comprises benzisothiazolinone and methylisothiazolinone, and / or the crosslinker comprises a polyisocyanate polymer.

20. The air purification coating system of claim 1, wherein the particle size of the ground diatom frustule particles is further greater than 6 microns or less than 20 microns.

21. The air purification coating system of claim 2, wherein the diatom frustule zinc oxide particle dispersion comprises water, diatom frustule zinc oxide particles, a dispersing additive, a rheological additive, and a defoaming agent.

22. The air purification coating system of claim 21, wherein the diatom frustule zinc oxide particle dispersion comprises 50 wt% to 75 wt% water, 20 wt% to 50 wt% diatom frustule zinc oxide particles, 1 wt% to 10 wt% dispersing additives, and 0.1 wt% to 2 wt% rheological additives.

23. The air purification coating system of claim 1, wherein the diatom frustule particle dispersion is a combination of diatom frustule zinc oxide particles and diatom frustule titanium dioxide particle dispersions.

24. A method for manufacturing an air purification coating system, comprising the following steps: forming a dispersion of diatom frustule particles, wherein the diatom frustule particles are diatom frustule zinc oxide particles, or a combination of diatom frustule zinc oxide particles and diatom frustule titanium dioxide particles, and wherein the dispersion is a stable aqueous dispersion for introduction into a carrier and comprises ground diatom frustule particles having a particle size of 1 micrometer to 35 micrometers; providing a carrier, wherein the carrier is a cleaning agent or a polishing agent; as well as The vehicle and the dispersion are combined to form the air cleaning coating system.

25. The method of claim 24, wherein the diatom frustule particles are diatom frustule zinc oxide particles.

26. The method of claim 24 or 25, wherein the ground diatom frustule particles further have a particle size greater than 6 microns or less than 20 microns.

27. The method according to claim 24 or 25, further comprising the step of grinding the diatom frustule particles to a particle size of 1 micron to 35 microns.

28. The method of claim 24 or 25, wherein the step of combining the carrier and the dispersion comprises combining 70 wt% to 99.9 wt% of the carrier and 0.1 wt% to 30 wt% of the dispersion.

29. The method of claim 24 or 25, wherein the carrier is a detergent.

30. The method of claim 29, wherein the step of combining the carrier and the dispersion comprises combining 95 wt% to 99.9 wt% of the detergent and 0.1 wt% to 5 wt% of the dispersion.

31. The method of claim 24 or 25, wherein the carrier is a polishing agent.

32. The method of claim 31, wherein the step of combining the vehicle and the dispersion comprises combining 70 wt% to 99.9 wt% of the polishing agent and 0.1 wt% to 30 wt% of the dispersion.

33. The method of claim 24 or 25, wherein the dispersion comprises 50 to 75 weight percent water, 20 to 50 weight percent diatom frustule particles, 0.1 to 5 weight percent anti-settling additive, 0.1 to 2 weight percent cell-breaking polysiloxane additive, and 1 to 10 weight percent dispersing additive.

34. The method of claim 24, wherein the diatom frustule particles are a combination of diatom frustule zinc oxide particles and diatom frustule titanium oxide particles.

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