Coating system for air purification, and method for producing the same

Abstract

To provide a convenient product for continually reducing a VOC and a toxin from the air environment in a room.SOLUTION: Provided are a coating system for purifying air including a carrier agent, and a diatom frustule titanium dioxide particle dispersion combined with the carrier agent, and a method for producing the same. The coating system may include 70 wt.% to 99.9 wt.% of the carrier agent, and 0.1 wt.% to 30 wt.% of the diatom frustule titanium dioxide particle dispersion. The carrier agent of the coating system may include a cleaning agent or a glazing agent. The diatom frustule titanium dioxide particle dispersion may include a diatom frustule titanium dioxide particle having a particle size of 1 micron to 35 micron combined with water and a dispersion additive. The dispersion may further include a sedimentation-preventive additive, a rheological additive and / or an antifoam agent.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates generally to the field of coatings. More specifically, the present invention relates to an air-purifying coating system having a dispersion of diatom frustule titanium dioxide particles combined with a carrier agent, such as a cleaning agent and / or polishing agent. The present invention also relates to a method for making the air-purifying coating system. The air-purifying coating system can be applied to substrates such as wood, laminate, or synthetic surfaces such as PVC, vinyl, linoleum, or hard surfaces such as concrete, stone, terrazzo, granite, or marble, and reduces toxins such as volatile organic compounds (VOCs) from the surrounding air environment. [Background technology]

[0002] Indoor air quality continues to be a significant area of ​​concern. Indoor air pollutants can come from sources such as carpets, furnaces, furniture, insulation, pets, trash, and fuel from the garage. Current home building techniques are making homes more airtight, but this can trap VOCs inside the home, potentially leading to conditions such as sick building syndrome.

[0003] There are products available that claim to remove VOCs from indoor air. However, many of these available products have drawbacks. For example, many of these products become inactive when loaded with impurities, losing their VOC reduction effectiveness.

[0004] Therefore, there is a need for easy-to-use products that sustainably reduce VOCs and toxins from indoor air environments. Summary of the Invention

[0005] SUMMARY OF THE INVENTION The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present concepts of the invention in a simplified form as a prelude to the more detailed description that is presented below.

[0006] The present invention includes an air purifying coating system. In one embodiment of the present invention, the air purifying coating system includes a carrier agent and a dispersion of diatom frustule titanium dioxide particles combined with the carrier agent. In one embodiment of the present invention, the coating system includes 70% to 99.9% by weight of the carrier agent and 0.1% to 15% by weight of the dispersion of diatom frustule titanium dioxide particles.

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

[0008] In one embodiment of the present invention, the diatom frustule titanium dioxide particle dispersion contains 50% to 75% by weight of water, 20% to 50% by weight of diatom frustule titanium dioxide particles, 1% to 10% by weight of a dispersing additive such as a copolymer of a pigment-affinitive group, and 0.1% to 2% by weight of a rheological additive such as a modified urea resin.

[0009] In one embodiment of the air purifying coating system of the present invention, the carrier agent can be a detergent. The coating system of the present invention can further include 95% to 99.9% by weight of a detergent and 0.1% to 5.0% by weight of a diatom frustule titanium dioxide particle dispersion. In one embodiment of the air purifying coating system of the present invention, the detergent can include an acrylic resin, a surfactant, and a hydrotrope. In another embodiment of the air purifying coating system of the present invention, the detergent can 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 hydrotrope, 0.1% to 3% by weight of an emulsifier such as an alkyl polyethylene glycol ether formed from C10-Guerbet alcohol and ethylene oxide, 0.1% to 1% by weight of a freeze-thaw agent such as a surfactant blend, and 0.1% by weight of a surfactant blend. The composition may contain 0.1% to 1% by weight of a flow additive such as polyether-modified hydroxy-functional polydimethylsiloxane and / or polyether-modified siloxane, 0.1% to 1% by weight of an antifoaming agent such as an antifoaming polysiloxane, 0.1% to 1% by weight of a surface modifier polyether-modified siloxane, 0.1% to 1% by weight of an anti-settling additive such as a modified urea resin, and 0.1% to 0.5% by weight of a biocide such as a blend of benzoisothiazirinone and methylisothiazirinone.

[0010] In one embodiment of the air purifying coating system of the present invention, the carrier agent can be a polishing agent. The coating system of the present invention can further include 70% to 99.9% by weight of a polishing agent and 0.1% to 30% by weight of a diatom frustule titanium dioxide particle dispersion. In one embodiment of the air purifying coating system of the present invention, the polishing agent can include water, a binder, a freeze-thaw agent, a solvent, an antifoaming agent, and a surface modifier. In one embodiment, the binder can be an acrylic copolymer resin. Alternatively, the binder can be a polyurethane resin. In another embodiment of the air purifying coating system of the present invention, the polishing agent may comprise 45% to 95% by weight of water, 3% to 53% by weight of acrylic copolymer and acrylic copolymer, 1% to 5% by weight of solvent, 0.0% to 1% by weight of freeze-thaw additive, 0.1% to 1% by weight of anti-settling additive such as modified urea resin, 0.01% to 1% by weight of flow additive such as polyether modified siloxane and / or fluorinated surfactant, 0.01% to 1% by weight of anti-foaming agent, 0.01% to 0.5% by weight of biocide, 0.1% to 3% by weight of wax additive, and 0.01% to 0.1% by weight of dispersant such as copolymer with pigment affinity group.

[0011] The present invention also includes a method of making an air purifying coating system. In one embodiment of the present invention, the method includes the steps of providing diatom frustule titanium dioxide particles, combining the diatom frustule titanium dioxide particles with water and a dispersing additive to form a diatom frustule titanium dioxide particle dispersion, providing a carrier agent, and combining the carrier agent with the diatom frustule titanium dioxide particle dispersion to form the air purifying coating system of the present invention.

[0012] In one embodiment of the method of the present invention, the diatom frustule titanium dioxide particles have a particle size of 1 micron to 35 microns. Furthermore, the method of the present invention can further comprise milling the diatom frustule titanium dioxide particles to a particle size of 1 micron to 35 microns. In one embodiment of the present invention, the method can further comprise combining the diatom frustule titanium dioxide particles with a rheological additive and an antifoaming agent to form a dispersion. In one embodiment of the method of the present invention, the method can comprise combining 50% to 75% by weight water, 20% to 50% by weight diatom frustule titanium dioxide particles, and 1% to 10% by weight dispersing additive to form a diatom frustule titanium dioxide particle dispersion.

[0013] The method of the present invention is a method for producing a soluble polymer comprising: 85% by weight to 99.9% by weight of a carrier agent and 0.1% by weight to 15% by weight of a soluble polymer; % by weight of the diatom frustule titanium dioxide particle dispersion. In one embodiment of the method of the present invention, the carrier agent can be a detergent. Further, the method can include combining 95% to 99.9% by weight of the detergent with 0.1% to 5% by weight of the diatom frustule titanium dioxide particle dispersion. In another embodiment of the method of the present invention, the carrier agent can be a polishing agent. Further, the method can include combining 70% to 99.9% by weight of the polishing agent with 0.1% to 10% by weight of the diatom frustule titanium dioxide particle dispersion.

[0014] Additional features of the present invention will be apparent from the following description. Such features will be apparent in part from the description, or may be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention relates to air purifying coating systems and methods for making the same. The air purifying coating systems can be in the form of cleaners and / or polishes applied to substrates and surfaces. When applied to a substrate or surface, the air purifying coating systems preferably reduce indoor air toxins, such as volatile organic compounds. The coating systems can also provide acceptable chemical resistance, gloss levels, scuff resistance, and / or transparency to the surface to which they are applied. The air purifying coating systems of the present invention can include a carrier agent, such as a cleaner, polish, or cleaner / polish agent. The air purifying coating systems can further include a diatom frustule titanium dioxide particle dispersion combined with a carrier agent. The air purifying coating systems of the present invention can be combined with additional components and / or additives depending on the intended use of the coating system.

[0016] Although primarily described herein with respect to use as a surface cleaner and / or polish, it will be apparent that the air purifying coating system of the present invention may have a variety of other applications. Furthermore, while the air purifying coating system of the present invention has been primarily identified as providing advantageous air purifying properties when applied to surfaces and substrates, it may also exhibit additional advantageous properties and characteristics.

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

[0018] As used herein, unless otherwise specified, the term "nanoparticle" has its normal and accustomed meaning in the art, and includes particles ranging from 1 nanometer to 100 nanometers, or 1×10 -9 It refers to particles that are meter-sized.

[0019] As used herein, unless otherwise specified, the term "micron" has its normal and accustomed meaning in the art, which is between 1 micron and 100 microns, or 1 x 10 -6 Refers to particles having a size of a meter.

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

[0021] As used herein, unless otherwise specified, the term "surfactant" refers to a positive or negative surfactant used to stabilize and separate pigment particles in aqueous or organic solvent solutions. Refers to an organic polymer that has an electric charge.

[0022] As used herein, unless otherwise specified, the term "dispersion solution" refers to a solution containing pigment, solvent, antifoam agent, surfactant, and 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 "polish" 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] As used herein, unless otherwise specified, the term "cleaner" refers to a material composed of surfactants, solvents, water, and polymeric resins.

[0026] As used herein, unless otherwise specified, the term "particle size analyzer" refers to a device that measures particle size and particle count in a solution. Values ​​can be calculated in nanometers or micrometers. The unit utilized for testing herein is an Accusizer N3000, although other units can be used without departing from the scope of the present invention.

[0027] As used herein, unless otherwise specified, the term "weatherometer" refers to an apparatus used to simulate exposure to sunlight in a controlled and accelerated manner. The chamber can be controlled to various temperature and humidity conditions. The unit utilized for testing herein is an XE1 with an air-conditioned chamber to maintain STP (standard temperature and pressure) conditions, although other units can be used without departing from the scope of the present invention.

[0028] Reference will now be made in detail to embodiments and examples of the present invention. The specific ingredients and amounts thereof set forth in these examples, as well as other conditions and details, should not be construed as unduly limiting the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, all ranges disclosed herein should be understood to encompass any and all subranges contained therein. In the examples and discussion throughout this specification, all percentages, ratios, and proportions are by weight (mass) unless otherwise specified.

[0029] An air purifying coating system and method for making the same are disclosed. As described above, the system can include a carrier agent, such as a cleaning agent, a polishing agent, or a cleaning / polishing agent, combined with a diatom frustule titanium dioxide particle dispersion. In one embodiment of the air purifying coating system of the present invention, the coating system can include 70% to 99.9% by weight of the carrier agent and 0.1% to 15.0% by weight of the diatom frustule titanium dioxide particle dispersion.

[0030] The diatom frustule titanium dioxide particle dispersion comprises diatom frustule titanium dioxide particles ("DFTiO2 particles") combined with a dispersing solution. The DFTiO2 particles used in connection with the present invention are preferably nanoparticles. The diatom frustule titanium dioxide particle dispersion ("DFTiO2 dispersion") is preferably a stable aqueous dispersion for incorporation into carrier agents such as detergents, polishes, and detergent / polish agents.

[0031] Before forming the DFTiO2 dispersion, the DFTiO2 particles can be milled to make the pigment more stable and uniform in solution. Milling is performed using a milling agent such as Hockmeyer Corporation. The process can be carried out using an HCP immersion mill, and the media can be 0.4 mm diameter zirconium oxide.

[0032] The DFTiO2 dispersion can contain several ingredients to ensure that the pigment particles are uniformly separated and stabilized in solution. Additionally, the DFTiO2 dispersion can utilize ingredients for settling and defoaming. In one embodiment of the DFTiO2 dispersion of the present invention, the dispersion can contain approximately 50% to 75% water by weight. The DFTiO2 dispersion can also contain approximately 20% to 50% DFTiO2 particles, such as Diatomix 10 micron powder. Additionally, the DFTiO2 dispersion can contain approximately 1% to 10% dispersing additive by weight. The DFTiO2 dispersion can also contain approximately 0.1% to 2% rheological additive, such as a nonionic urethane copolymer. The DFTiO2 dispersion can also contain approximately 0.01% to 0.2% defoamer by weight to minimize foaming during the mixing process.

[0033] The DFTiO2 dispersion can be made by combining water with a dispersing additive in a container such as a dissolver. The dispersing additive is preferably added to the water with moderate agitation and mixed for approximately 5 minutes. The rheological additive is then added with moderate agitation and mixed for approximately 10 minutes until the rheological additive is fully mixed. Depending on the generation of bubbles in the dispersion, an antifoaming agent can then be added to prevent bubbles from forming during the mixing process. Finally, DFTiO2 particles, such as Diatomix's 10 micron powder, are preferably screened and mixed into the batch with agitation. The dispersion can then be transferred from the dissolver to an immersion mill, such as an HCP immersion mill. The DFTiO2 dispersion can then be milled until the effective Hegman particle size is preferably greater than 1 micron and less than 100 microns, or more preferably greater than 6 microns or less than 20 microns. In one embodiment, the milling speed is approximately 2500 rpm to 3500 rpm.

[0034] Most detergents, polishes, and detergent / polish-containing carrier agents of the present invention typically have lower viscosities and are less non-volatile materials than the DFTiO2 particles, and therefore the DFTiO2 particles are preferably in a dispersed form to aid in the incorporation of the particles into such lower viscosity, less non-volatile materials.

[0035] As described above, the carrier agent of the present invention contains a cleaning agent. When a cleaning agent is incorporated into the present invention, an air purification cleaning system is formed. The cleaning agent of the present invention includes both cleaning agents and deodorant products and is typically water-based. The cleaning agent of the present invention preferably contains an acrylic resin, more preferably an alkali-soluble metal-complexed acrylic copolymer having an acid value greater than 25 mg KOH. The cleaning agent of the present invention also preferably contains a surfactant, such as an alkyl polyethylene glycol ether formed from C10-Guerbet alcohol and ethylene oxide. Surfactants are often used for cleaning, degreasing, and emulsifying soil and other types of contaminants. In water-based cleaning systems, freeze-thaw stability is important for maintaining system performance. Therefore, when a water-based cleaning agent is incorporated in connection with the present invention, a surfactant that provides freeze-thaw stability but does not interfere with system performance can be incorporated. The cleaning agent of the present invention can further utilize a hydrotrope to solubilize hydrophobic compounds.

[0036] To ensure adequate surface wetting and protection in air purification systems, surface wetting materials can be used to reduce the surface tension of the sanitizer and provide a uniform layer on the flooring. Functionalized surface wetting materials can also be used, which can add some surface mar protection.

[0037] In conjunction with the use of surfactants, antifoaming agents to limit excessive foaming or foaming are often incorporated into the air purification cleaning systems of the present invention. Such antifoaming agents, such as antifoaming polysiloxanes, preferably have long-term effectiveness without adverse interactions with the surfactant. When incorporating DFTiO2 particles into lower viscosity cleaners, rheology modifiers can be used to prevent the DFTiO2 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 can be incorporated into the air purification and cleaning system to help solubilize greases and / or resins in the system.

[0039] In one embodiment of the present invention, the cleaner for the air purification system contains approximately 80% to 97% by weight of water. Furthermore, the cleaner may contain approximately 0.5% to 5% by weight of an alkali-soluble metal-complexed acrylic copolymer for adhesion and resolubility. The cleaner may also contain approximately 0.1% to 1% by weight of a hydrotrope, such as sodium cumene sulfonate. The cleaner may contain a surfactant to address soil cleaning and emulsification. In one embodiment, the cleaner may contain approximately 0.1% to 3% by weight of an emulsifier. For example, approximately 0.1% to 1% by weight of an alkyl polyethylene glycol ether formed from a C10-Guerbet alcohol and ethylene oxide may be incorporated into the cleaner. Special additives may also be incorporated into the cleaner for the air purification system. For example, about 0.1% to 1% by weight of a freeze-thaw additive, such as a surfactant blend, about 0.01% to 1% by weight of a flow additive, about 0.1% to 1% by weight of an antifoaming polysiloxane, about 0.1% to 1% by weight of a surface modifier, about 0.1% to 1% by weight of an anti-settling additive, about 0.1% to 0.5% by weight of a biocide, such as a blend of benzisothiazirinone and methylisothiazirinone, and a solvent for resin solubility can be incorporated. In one embodiment of the present invention, about 0.1% to 5% by weight of the DFTiO dispersion can be incorporated into a purifier to form the air purification and cleaning system of the present invention.

[0040] Polishes can also be used as carrier agents in the present invention. When a polish is incorporated into the present invention, an air-purifying polish system is formed. Polishes can be used to add protection to surfaces such as wood, synthetic materials, stone, and / or other hard surfaces. For example, polishes are used to protect substrates and surfaces from scratches, abrasions, chemical damage, and premature breakage. Polishes can also provide secondary properties such as gloss, color, image depth, or transparency. Polishes include not only polishes but also finishing agents.

[0041] Polishes of the present invention can be water-based and can include binders such as polyurethane and / or acrylic resins. Such products preferably provide scratch resistance, chemical resistance, and / or adhesion to a variety of substrates.

[0042] In water-based polish systems, freeze-thaw stability is important to maintain system performance. Therefore, when water-based polishes are incorporated into the system of the present invention, surfactants that provide freeze-thaw stability but do not interfere with system performance can be incorporated. Examples of such products include tributoxyethyl phosphate, butyl hydroxybutanoate, and propylene glycol.

[0043] To ensure adequate surface wetting and surface protection in air-purifying glazing systems, Surface wetting materials can be used that reduce the surface tension of the cleaner and provide a uniform layer on the flooring. Functionalized surface wetting materials can also be used, which can add some surface mar protection.

[0044] Similar to the cleaning system of the present invention, antifoaming polysiloxanes can be incorporated into the air purifying polish system of the present invention to limit excessive foaming or foaming often caused by surfactants. Preferably, such antifoaming agents have long-term effectiveness without adverse interactions with surfactants. Additionally, when incorporating DFTiO2 particles into lower viscosity polishes, rheology modifiers can be used to prevent the DFTiO2 particles from hardening at the bottom of the container.

[0045] Solvents may be incorporated into the air purifying polish system to aid in solubilizing the resin in the system. Examples of solvents for use in connection with 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 present invention, the polish of the air-purifying polish system contains approximately 40% to 95% by weight of water. Furthermore, the polish may contain approximately 3% to 53% by weight, or more preferably 20% to 50% by weight, of a binder, such as an acrylic component or a urethane component. The polish of the present invention may contain approximately 1% to 9% by weight of a solvent composition, or more preferably 1% to 5% by weight of a solvent. Furthermore, the polish may further contain approximately 0.1% to 1% by weight of an anti-settling agent, such as a modified urea resin; approximately 0.1% to 1% by weight of a flow and leveling agent, such as a polyether-modified siloxane; 0.01% to 0.05% by weight of a fluorinated surfactant; and / or approximately 0.01% to 1.0% by weight of an anti-foaming polysiloxane. The polish may also contain approximately 0.1% to 1% by weight of a surfactant blend or a freeze-thaw agent, such as propylene glycol. The polish 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 a biocide, such as a blend of benzisothiazirinone and methylisothiazirinone, may be incorporated into the polish of the present invention. Additionally, to provide damage resistance, about 0.1% to 5% by weight of a wax additive, such as a polyethylene blend, may be added to the polish of the present invention. The polish may also contain 0.01% to 0.1% by weight of a dispersant, such as a copolymer of pigment-affinic groups.

[0047] In another embodiment of the present invention, the polish of the air-purifying polish system contains approximately 40% to 75% by weight of water. Furthermore, the polish may contain approximately 23% to 58% by weight of a binder, such as an acrylic component and a urethane component. The polish of the present invention may contain approximately 1% to 5% by weight of a solvent composition, such as a glycol ether. The polish may further contain approximately 0.1% to 3% by weight of a freeze-thaw agent, such as a modified phosphate salt; approximately 0.1% to 1% by weight of an anti-settling agent, such as a modified urea resin; approximately 0.1% to 1% by weight of a flow and leveling agent, such as a polyether-modified siloxane; 0.01% to 0.05% by weight of a fluorinated surfactant; and / or approximately 0.01% to 1.0% by weight of an anti-foaming agent, such as an anti-foaming polysiloxane. The polish may further contain approximately 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 a biocide, such as a blend of benzisothiazirinone and methylisothiazirinone, can be incorporated into the polishes of this invention. Additionally, to provide mar resistance, about 0.1% to 4% by weight of a wax additive, such as a polyethylene blend, can be added to the polishes of this invention. The polishes can also contain 0.01% to 0.2% by weight of a dispersant, such as a copolymer of pigment-affinic groups. Cut.

[0048] In yet another embodiment of the present invention, the polish of the air-purifying polish system comprises approximately 40% to 75% by weight of water. The polish may further comprise approximately 20% to 50% by weight of an acrylic copolymer and approximately 5% to 30% by weight of a polyurethane dispersion polymer. The polish of the present invention may comprise approximately 1% to 5% by weight of a solvent composition, such as a glycol ether. The polish may further comprise approximately 1% to 7% by weight of a matte pigment, approximately 1% to 5% by weight of a rheological additive, such as bentonite clay, approximately 0.1% to 1% by weight of a flow and leveling agent, such as a polyether-modified siloxane, approximately 0.01% to 0.05% by weight of a fluorinated surfactant, and / or approximately 0.01% to 1.0% by weight of an antifoaming agent, such as an antifoaming polysiloxane. The polish may also comprise approximately 0.1% to 1.0% by weight of a rheological modifier, such as a nonionic urethane copolymer, for leveling. To prevent microbial attack, a biocide, such as a blend of benzisothiazirinone and methylisothiazirinone, can be incorporated into the polish of the present invention. Additionally, a crosslinker, such as a polymeric polyisocyanate, can be included at about 1% to 15% by weight. The polish can also include about 0.01% to 0.1% by weight of a dispersant to further stabilize the DFTiO2 particles in the DFTiO2 dispersion. In one embodiment of the present invention, about 0.1% to 10% by weight of a DFTiO2 dispersion can be incorporated into the polish to form the air purifying polish system of the present invention.

[0049] Because the carrier agents of the present invention are typically cleaners and / or polishes, the coating agents of the present invention are often used primarily to clean or polish a variety of substrates and surfaces, such as wood, concrete, laminate, PVC, vinyl, linoleum, and / or natural stone, with 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 such as ketones, amines, alcohols, and aldehydes, which can lead to poor indoor air quality. In addition to reducing volatile organic compounds from 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 transparency, and cleaner / polish flow and leveling. The reduction of volatile organic compounds in the ambient air can be activated when the coating system is applied to a surface and exposed to natural light, such as indoor lighting or sunlight.

[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 titanium dioxide particles, combining the diatom frustule titanium dioxide particles with water and a dispersing additive to form a diatom frustule titanium dioxide particle dispersion, providing a carrier agent, and combining the carrier agent with the diatom frustule titanium dioxide 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 diatom frustule titanium dioxide particles have a particle size of 1 micron to 35 microns. Furthermore, the method of the present invention can further comprise milling the diatom frustule titanium dioxide particles to a particle size of 1 micron to 35 microns. In one embodiment of the present invention, the method can further comprise combining the diatom frustule titanium dioxide particles with an anti-settling additive, a rheology additive, and / or an anti-foaming agent to form a dispersion. In one embodiment of the method of the present invention, the method comprises combining 50% to 75% by weight of water, 20% to 50% by weight of diatom frustule titanium dioxide particles, and 0.1% to 5% by weight of a sieve containing 100% to 150% water. % of an anti-settling additive, 0.1% to 2% by weight of an anti-foaming polysiloxane, and 1% to 10% by weight of a dispersing additive to form a diatom frustule titanium dioxide particle dispersion.

[0053] The method of the present invention can include combining 85% to 99.9% by weight of a carrier agent with 0.1% to 15% by weight of a diatom frustule titanium dioxide particle dispersion. In one embodiment of the method of the present invention, the carrier agent can be a detergent. Further, the method can include combining 95% to 99.9% by weight of a detergent agent with 0.1% to 5% by weight of a diatom frustule titanium dioxide particle dispersion. In another embodiment of the method of the present invention, the carrier agent can be a polishing agent. Further, the method can include combining 90% to 99.9% by weight of a polishing agent with 0.1% to 10% by weight of a diatom frustule titanium dioxide particle dispersion.

[0054] Having generally described this disclosure, a further understanding can be obtained by reference to the following specific examples, which are provided for illustrative purposes only and are not intended to be exhaustive or limiting unless expressly stated. [Example]

[0055] Tests and Examples The preparation, identification, and testing of example compositions of the present disclosure are further described below. The particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention.

[0056] Nanoparticle-functionalized diatom frustule material was obtained from Diatomix Incorporated and used in connection with the present invention. This material was tested for use in pigment dispersions. The material was a cream-colored powder with a particle size of approximately 10 microns. When this material was placed in water, the particle size measured approximately 15 microns. Measurements were taken using an Accusizer N3000. The particle size distribution ranged from 1 micron to 20 microns for the raw Diatomix DPA52 10 micron powder. This material did not stay in solution and quickly began to take on a very coarse, particulate appearance in solution. The material was then milled to make the pigment more stable and uniform in solution.

[0057] The milled Diatomix material was then used to form a DFTiO dispersion. This dispersion was made by combining 50% to 75% by weight of water with 1% to 10% by weight of a dispersing additive in a dissolver with moderate agitation. The water and dispersing additive were mixed for 5 minutes. A rheological additive in an amount of 0.1% to 2% by weight was then mixed for 10 minutes with moderate agitation until the rheological additive was fully mixed into the dispersion. An antifoaming agent was then added to prevent foaming during the mixing process. Approximately 20% to 50% by weight of the milled Diatomix material was then screened and mixed into a batch with agitation, then transferred from the dissolver to an HCP immersion mill. This dispersion was milled at a speed of 2500 rpm to 3500 rpm until the effective Hegman particle size was greater than 6 microns or less than 20 microns.

[0058] Both the air purification purifying system and the air purification glazing system were tested to determine the air purification capabilities of each. Such testing was conducted by Research Triangle Park Laboratories in Raleigh, North Carolina.

[0059] The first test was directed to the air purification cleaning system of the present invention. For comparison purposes, a first control sample containing the purifier but no DFTiO2 dispersion was analyzed, and a second active sample containing the purifier and DFTiO2 dispersion was analyzed. The results were in accordance with ASTM D6670, "Standard Practice for Full-Scale Chamber Determination of Volatile Organic Emissions from Indoor Air." Using "Products / Products" select a volume of known concentration in a 27-liter glass chamber. Samples were tested for VOC reduction by introducing VOCs. Two 4-foot T8 LED light fixtures were placed outside the chamber, approximately 6 inches from the chamber. The lights were positioned adjacent to each other and operated for the entire test period. Samples were applied directly to a glass plate (7 inches x 14 inches) by applying and curing three coating layers. The glass plate was weighed before and after application, resulting in a weight of 0.1 grams for the three coating layers. The sample was then placed in a sealable chamber with the coated side facing the light for 30 minutes. The chamber was sealed and allowed to equilibrate before the VOCs were introduced. Temperature and relative humidity were monitored throughout the test and measured at 25°C and 35% to 45% relative humidity. At the start of each test and before introducing VOCs into the chamber, air samples were collected from the chamber to verify that the chamber was free of VOCs before the test was conducted. Known amounts of formaldehyde (2.5 ppm) and methyl mercaptan (1.0 ppm) were then introduced into the chamber. Air samples of the chamber were then collected again and analyzed for the specific VOCs introduced at 1 hour, 24 hours, 48 ​​hours, and 72 hours. The results of the VOC air sample testing of the control and active samples at various time periods are shown in Table 1 below.

[0060] [Table 1]

[0061] As shown in Table 1, the test chambers with the active samples containing the air purification cleaning system of the present invention had about 15% less formaldehyde VOC and about 19% less methyl mercaptan VOC at 48 hours compared to the control samples containing only the cleaning agent. Additionally, the test chambers with the active samples containing the air purification cleaning system of the present invention had about 30% less formaldehyde VOC and about 35% less methyl mercaptan VOC at 72 hours compared to the control samples containing only the cleaning agent.

[0062] The second test involved the air purifying polish system of the present invention. For comparison purposes, a first control sample containing the polish and no DFTiO2 dispersion was analyzed, and a second active sample containing the polish and DFTiO2 dispersion was analyzed. Using ASTM D6670, "Standard Practice for Full-Scale Chamber Determination of Volatile Organic Emissions from Indoor Materials / Products," a 27 liter glass chamber was filled with a selection of known concentrations. Samples were tested for VOC reduction by introducing selected VOCs. Two LED light fixtures were placed outside the chamber, approximately 6 inches from the chamber. The lights were positioned next to each other and operated for the entire test period. Samples were applied directly to a glass plate (7" x 14") by applying and curing one coating layer. The glass plate was weighed before and after application, resulting in a weight of 1.0 gram per coating layer. The sample was then placed in a sealable chamber with the coated side facing the light for 30 minutes. The chamber was sealed and allowed to equilibrate before the VOCs were introduced. Temperature and relative humidity were monitored throughout the test and measured at 25°C and 35% to 45% relative humidity. At the beginning of each test and before introducing the VOCs into the chamber, air samples were collected from the chamber to verify the absence of VOCs before the test was conducted. Known amounts of formaldehyde (5.0 ppm) and methyl mercaptan (2.5 ppm) were then introduced into the chamber. Air samples were then collected again from the chamber. The test samples were analyzed for the specific VOCs introduced at 24, 48, and 72 hour periods. The results of the VOC air sample testing of the control and active samples at various time periods are shown in Table 2 below.

[0063] [Table 2]

[0064] As shown in Table 2, the test chambers with the active samples containing one of the air purifying polish systems of the present invention had about 4.3% less formaldehyde VOC and about 22.5% less methyl mercaptan VOC at 48 hours compared to the control samples containing only the polish. Additionally, the test chambers with the active samples containing the air purifying polish systems of the present invention had about 12.5% ​​less formaldehyde VOC and about 37.5% less methyl mercaptan VOC at 72 hours compared to the control samples containing only the polish.

[0065] A second polish for another application was tested similarly to the previous example, and the results are shown in Table 3.

[0066] [Table 3]

[0067] The polish example in Table 3 is similar to the example in Table 2, except that it contains additional increases in nonvolatile content, fluorinated surfactant, and additional wax. The data shows formaldehyde reduction of 19% at 24 hours, rapidly decreasing to 58% at 48 hours, and 51% more reduction than the control system at 72 hours. The methyl mercaptan data shows 20% at 24 hours, rapidly decreasing to 50% at 48 hours, and ultimately resulting in a 37% more reduction than the control at 72 hours.

[0068] Finally, a two-component acrylic-urethane gloss coating system is presented. Again, this system demonstrates a reduction in airborne chemicals. This data is presented in Table 4.

[0069] [Table 4]

[0070] In this example, the data differ slightly because the systems cure with slightly different reaction kinetics. Formaldehyde reduction remained fairly constant for the first 48 hours, likely due to the reaction of isocyanate with hydroxyl hindering reduction. As cure slowed, the 72-hour value decreased by 21% from the control to the activated system containing DFTiO2. Methyl mercaptan reduction was 25% at 48 hours, ultimately reaching 28% more reduction than the control at 72 hours.

[0071] While various embodiments and examples of the present invention have been described above, these descriptions have been given for purposes of illustration and description, and not for purposes of limitation. Variations, changes, modifications, and departures from the disclosed systems and methods may be employed without departing from the spirit and scope of the invention. Indeed, after reading the foregoing description, it will be apparent to one skilled in the relevant art(s) how to implement the invention in alternative embodiments. Therefore, the present invention should not be limited by any of the exemplary embodiments described above.

[0072] Furthermore, the purpose of the abstract is to enable the various patent offices and the public, particularly scientists, engineers, and practitioners in the art who may not be familiar with patent or legal terminology or language, to quickly determine, from a cursory inspection, the nature and substance of the application's technical disclosure. The abstract is not intended to limit the scope of the invention in any way.

Claims

1. A carrier agent; a dispersion of diatom frustule titanium dioxide particles in combination with the carrier agent; air purification coating system, including

2. 10. The air purifying coating system of claim 1, comprising 70% to 99.9% by weight of a carrier agent and 0.1% to 30% by weight of the diatom frustule titanium dioxide particle dispersion.

3. 3. The air purifying coating system of claim 1, wherein the carrier agent is a cleaning agent.

4. 4. The air purifying coating system of claim 3, comprising 95% to 99.9% by weight of the cleaning agent and 0.1% to 5.0% by weight of the diatom frustule titanium dioxide particle dispersion.

5. The air purifying coating system of claim 3 , wherein the cleaning agent comprises water, an acrylic resin, a surfactant, and a hydrotrope.

6. The detergent is 80% to 97% by weight of water; 0.5% to 5% by weight of an acrylic resin; 0.1% to 1% by weight of a hydrotrope; 0.1% to 3% by weight 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 an antifoaming agent; 0.1 wt % to 1 wt % of a surface modifier; 0.1 wt. % to 1 wt. % of an anti-settling additive; 0.1% to 0.5% by weight of a biocide; 4. The air purifying coating system of claim 3, comprising:

7. 7. The air purifying 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 polyethylene glycol ether formed from C10-Guerbet alcohol and ethylene oxide, the freeze-thaw agent comprises a surfactant blend, the flow additive comprises a polyether-modified siloxane, the antifoam agent comprises a polysiloxane, the surface modifier comprises a polyether-modified siloxane, the anti-settling additive comprises a modified urea resin, and / or the biocide comprises a blend of benzoisothiazirinone and methylisothiazirinone.

8. 7. The air purifying 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 ethoxylated fatty alcohol, the freeze-thaw agent comprises butyl hydroxybutanoate, the flow additive comprises a polyether-modified siloxane, the antifoam agent comprises a polysiloxane, the surface modifier comprises a polyether-modified siloxane, the anti-settling additive comprises a modified urea resin, and / or the biocide comprises a blend of benzoisothiazirinone and methylisothiazirinone.

9. 3. The air purifying coating system of claim 1, wherein the carrier agent is a polishing agent.

10. 10. The air purifying coating system of claim 9, comprising 70% to 99.9% by weight of a polishing agent and 0.1% to 30% by weight of the diatom frustule titanium dioxide particle dispersion.

11. 10. The air purifying coating system of claim 9, comprising 90.0% to 99.9% by weight of a polishing agent and 0.1% to 10.0% by weight of the diatom frustule titanium dioxide particle dispersion.

12. 10. The air purifying coating system of claim 9, wherein the polishing agent comprises water, a binder, a freeze-thaw agent, and a surface modifier.

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

14. The polishing agent is 45% to 95% by weight of water; 3% to 53% by weight of an acrylic copolymer and a polyurethane resin; 1% to 5% by weight 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 an antifoaming agent; 0.1 wt % to 4 wt % of a wax additive; 0.01% to 0.5% by weight of a biocide; and 0.01 wt % to 0.1 wt % of a dispersant; 10. The air purifying coating system of claim 9, comprising:

15. 15. The air purifying coating system of claim 14, wherein the solvent comprises a glycol ether, the freeze-thaw agent comprises a surfactant blend, the anti-settling additive comprises a modified urea resin, the flow additive comprises a polyether-modified siloxane, the defoamer comprises a polysiloxane, the wax additive comprises a polyethylene blend, the biocide comprises benzisothiazirinone and methylisothiazirinone, and / or the dispersant comprises a copolymer of pigment-affinic groups.

16. 15. The air purifying coating system of claim 14, wherein the solvent comprises a glycol ether, the freeze-thaw agent comprises propylene glycol, the anti-settling additive comprises a modified urea resin, the flow additive comprises a polyether-modified siloxane, the anti-foam agent comprises a polysiloxane, the wax additive comprises a polyethylene blend, the biocide comprises benzisothiazirinone and methylisothiazirinone, and / or the dispersant comprises a copolymer of pigment-affinic groups.

17. The polishing agent is 40% to 75% by weight of water; 23% to 58% by weight of an acrylic copolymer; 1% to 5% by weight 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 wt % to 4 wt % of a wax additive; 0.01% to 0.05% by weight of a fluorinated surfactant; 0.01 wt % to 1 wt % of an antifoaming agent; 0.01% to 0.5% by weight of a biocide; and 0.01 wt % to 0.2 wt % of a dispersant; 10. The air purifying coating system of claim 9, comprising:

18. 15. The air purifying coating system of claim 14, wherein the solvent comprises a glycol ether, the freeze-thaw agent comprises a modified phosphate, the anti-settling additive comprises a modified urea resin, the flow additive comprises a polyether-modified siloxane, the wax additive comprises a polyethylene blend, the defoamer comprises a polysiloxane, the biocide comprises benzisothiazirinone and methylisothiazirinone, and / or the dispersant comprises a copolymer of pigment-affinic groups.

19. The polishing agent is 40% to 75% by weight of water; 20% to 50% by weight of an acrylic copolymer; 5% to 30% by weight of a polyurethane dispersion polymer; 1% to 5% by weight of a solvent; 1% to 7% by weight of a matte pigment; 1 wt. % to 5 wt. % of a rheological additive; 0.1 wt % to 1 wt % of a flow additive; 0.01 wt % to 1 wt % of an antifoaming agent; 0.01% to 0.5% by weight of a biocide; and 1% to 15% by weight of a crosslinker; 10. The air purifying coating system of claim 9, comprising:

20. 20. The air purifying coating system of claim 19, wherein the solvent comprises a glycol ether, the rheology additive comprises a bentonite clay, the flow additive comprises a polyether-modified siloxane, the antifoam agent comprises a polysiloxane, the biocide comprises benzisothiazirinone and methylisothiazirinone, and / or the crosslinker comprises a polyisocyanate polymer.

21. 3. The air purifying coating system of claim 1, wherein the diatom frustule titanium dioxide particle dispersion comprises diatom frustule titanium dioxide particles having a particle dispersion comprising diatom frustule titanium dioxide particles having a particle size of 1 micron to 35 microns.

22. 3. The air purifying coating system of claim 1, wherein the diatom frustule titanium dioxide particle dispersion comprises water, diatom frustule titanium dioxide particles, a dispersing additive, a rheological additive, and an antifoaming agent.

23. 23. The air purifying coating system of claim 22, wherein the diatom frustule titanium dioxide particle dispersion comprises 50% to 75% by weight water, 20% to 50% by weight diatom frustule titanium dioxide particles, 1% to 10% by weight dispersing additive, and 0.1% to 2% by weight rheological additive.

24. Providing diatom frustule titanium dioxide particles; combining the diatom frustule titanium dioxide particles with water, an anti-settling additive, an anti-foaming polysiloxane, and a dispersing additive to form a diatom frustule titanium dioxide particle dispersion; providing a carrier agent; combining the carrier agent with the diatom frustule titanium dioxide particle dispersion to form an air purifying coating system; A method for manufacturing an air purification coating system, comprising:

25. 25. The method of claim 24, wherein the diatom frustule titanium dioxide particles have a particle size between 1 micron and 35 microns.

26. 25. The method of claim 24, further comprising milling the diatom frustule titanium dioxide particles to a particle size of 1 micron to 35 microns.

27. 25. The method of claim 24, wherein the step of combining the carrier agent and the diatom frustule titanium dioxide particle dispersion comprises 70% to 99.9% by weight of the carrier agent and 0.1% to 30% by weight of the diatom frustule titanium dioxide particle dispersion.

28. 25. The method of claim 24, wherein the carrier agent is a detergent.

29. 30. The method of claim 28, wherein the step of combining the carrier agent and the diatom frustule titanium dioxide particle dispersion comprises 95% to 99.9% by weight of a detergent agent and 0.1% to 5% by weight of a diatom frustule titanium dioxide particle dispersion.

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

31. 31. The method of claim 30, wherein the step of combining the carrier agent and the diatom frustule titanium dioxide particle dispersion comprises 70% to 99.9% by weight of a polishing agent and 0.1% to 30% by weight of a diatom frustule titanium dioxide particle dispersion.

32. 25. The method of claim 24, wherein the step of combining the diatom frustule titanium dioxide particles with water, an anti-settling additive, an anti-foaming polysiloxane, and a dispersing additive comprises 50% to 75% by weight water, 20% to 50% by weight diatom frustule titanium dioxide particles, 0.1% to 5% by weight anti-settling additive, 0.1% to 2% by weight anti-foaming polysiloxane additive, and 1% to 10% by weight dispersing additive.

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