US20140037890A1 - Coating composition comprising submicron calcium carbonate-comprising particles, process to prepare same and use of submicron calcium carbonate-comprising particles in coating compositions - Google Patents

Coating composition comprising submicron calcium carbonate-comprising particles, process to prepare same and use of submicron calcium carbonate-comprising particles in coating compositions Download PDF

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US20140037890A1
US20140037890A1 US13/980,386 US201213980386A US2014037890A1 US 20140037890 A1 US20140037890 A1 US 20140037890A1 US 201213980386 A US201213980386 A US 201213980386A US 2014037890 A1 US2014037890 A1 US 2014037890A1
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calcium carbonate
glossing
less
composition according
opacifying
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Joseph McJunkins
Charles Freeman
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Omya International AG
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Omya International AG
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Assigned to OMYA INTERNATIONAL AG reassignment OMYA INTERNATIONAL AG CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: OMYA DEVELOPMENT AG
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/66—Additives characterised by particle size
    • C09D7/67—Particle size smaller than 100 nm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • C09D7/1216—
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    • A61K8/02—Cosmetics or similar toiletry preparations characterised by special physical form
    • A61K8/0241—Containing particulates characterized by their shape and/or structure
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    • A61K8/18—Cosmetics or similar toiletry preparations characterised by the composition
    • A61K8/19—Cosmetics or similar toiletry preparations characterised by the composition containing inorganic ingredients
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F11/00—Compounds of calcium, strontium, or barium
    • C01F11/18—Carbonates
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
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    • C08L75/04—Polyurethanes
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    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
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    • C09C1/021—Calcium carbonates
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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    • C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
    • C09C3/04—Physical treatment, e.g. grinding, treatment with ultrasonic vibrations
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • C09D175/04—Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • C09D175/06—Polyurethanes from polyesters
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/02—Emulsion paints including aerosols
    • C09D5/024—Emulsion paints including aerosols characterised by the additives
    • C09D5/028—Pigments; Filters
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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Definitions

  • the present invention relates to coating compositions comprising submicron natural ground calcium carbonate-comprising particles (hereafter SMGCC).
  • SMGCC submicron natural ground calcium carbonate-comprising particles
  • the invention further relates to a process for preparing coating compositions containing SMGCC, and to the use of SMGCC in coating compositions.
  • the coating composition(s), depending upon their composition, may be used to form either clear coatings, or else they may be formulated as glossing and opacifying coating compositions.
  • provisional patent application No. 61/400,648 filed Jul. 30, 2010 and entitled “Coating Composition Comprising Submicron Calcium Carbonate Comprising Particles, Process to Prepare Same and Use of Submicron Calcium Carbonate-Containing Particles in Coating Compositions” are specifically incorporated herein by reference.
  • FIGS. 1A and 1B are photomicrographs of Omya XC-6600-34 CaCO 3 ;
  • FIG. 2 is a series of particle size distribution curves containing data for a series of samples whose D 98 value is ⁇ 0.3 ⁇ m.
  • the values for D 90 , D 50 and D 20 for these samples can be determined by comparing the x and y-axis.
  • the aqueous nanoparticle dispersion of this invention can be used to make coatings and films for porous and non-porous substrates, such as papers, non-woven materials, textiles, leather, wood, concrete, masonry, metals, house wrap and other building materials, fibreglass, polymeric articles, personal protective equipment (such as hazardous material protective apparel, including face masks, medical drapes and gowns and firemen's turnout gear) and the like.
  • Applications include papers and non-woven materials, fibrous materials, films, sheets, composites and other articles, inks and decorative and industrial coatings, flock and other adhesives and personal care products such as skin care, hair care and nail care products, livestock and seed applications, and the like.
  • Any fibrous material can be coated, impregnated or otherwise treated with the compositions according to the invention by methods well known to those skilled in the art, including carpets as well as textiles used in clothing, upholstery, tents, awnings, airbags and the like.
  • Suitable textiles include fabrics, yarns and blends, whether woven, non-woven or knitted and whether natural, synthetic or regenerated. Examples of suitable textiles include cellulose acetate, acrylics, wool, cotton, jute, linen, polyesters, polyamides, regenerated cellulose (i.e., rayon) and the like.
  • compositions may be dispersed in a variety of binders including, but not limited to, vinyl-acrylic, styrene-acrylic, acrylic dispersions, solution acrylics, alkyds (e.g., SOYA, TOFA, sunflower, etc.), polyurethanes dispersed in either water or solvent, etc., hereinafter referred to as “binder media”.
  • binders including, but not limited to, vinyl-acrylic, styrene-acrylic, acrylic dispersions, solution acrylics, alkyds (e.g., SOYA, TOFA, sunflower, etc.), polyurethanes dispersed in either water or solvent, etc., hereinafter referred to as “binder media”.
  • compositions according to the invention can be used as adhesives or to augment or supplement adhesive types well known to those skilled in the art.
  • particularly desirable properties can be obtained by varying the type and amount of the aqueous nanoparticles used, along with choosing a complementary binder medium from one or more of those listed above, or by incorporating other binder media that would be well known to those of ordinary skill in this art.
  • coatings containing the compositions according to the invention may optionally be formulated as substantially transparent coatings, i.e., typically referred to as ‘clear coats’, or alternately as coatings that serve a glossing and opacifying function.
  • the D 98 particle size of the substantially dispersed nanoparticles contained in the coating composition is ⁇ 350 nm, preferably ⁇ 300 nm and the D 50 is ⁇ 200 nm, preferably ⁇ 150 nm, the coatings obtained will be essentially transparent, provided of course that they are free or essentially free of additional components which would comprise their transparency properties.
  • one useful binder medium for forming, e.g., clear coatings according to the invention are polymers containing ester groups such as, for example, polyesters, polyester-based polyurethanes, polyester-based polyureas and polyester-based polyamides. These various binders, however, have less than desirable water-resistance properties due to the hydrolysis group contained therein.
  • the water resistant properties of such polyester-based polyurethanes can be remarkably enhanced, without affecting the transparency properties of these materials to any significant degree, by combining with the polymer binder a substantially dispersed nano-particle proton scavenger, such as natural ground calcium carbonate-comprising particles.
  • the resultant coating composition therefore, which again is described only for exemplifying (and not limiting) the invention, thus constitutes a hydrolytically stable polyurethane nanocomposite comprising a solid polyester-polyurethane polymer binder containing proton-scavenger nanoparticles in a substantially dispersed form.
  • a colloidally stable aqueous dispersion comprising water, a polyester-polyurethane polymer binder and substantially dispersed proton scavenger nanoparticles such as SMGCC.
  • the term “substantially dispersed” means that the nanoparticles are properly dispersed in the aqueous medium in order to prevent settling or syneresis of the nanoparticles. This is usually achieved via the addition of well-known dispersants comprising homo- or copolymer chains. If necessary, the chains may be partially or completely neutralized by cations such as sodium, lithium, magnesium, calcium, potassium or ammonium.
  • Coatings having the composition of the exemplary formulation described above therefore, constitute polyurethane compositions which, e.g., have improved hydrolytic stability over prior art polyurethane compositions.
  • polyurethane is used generically to describe polymers including oligomers (e.g., prepolymers) which contain the urethane group, i.e., —O—C( ⁇ O)—NH— regardless of how they are made.
  • these polyurethanes can contain additional groups such as urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynurate, uretdione, alcohol, amine, hydrazide, siloxane, silane, ketone, olefin, etc., in addition to the urethane groups.
  • This invention includes, as noted herein the use of substantially dispersed nanoparticles (referring to the primary crystallites or particles of the proton scavenger and or the aggregates of the proton scavenger) of proton scavenger nanoparticles to enhance the water-resistant (hydrolytic stability) of thermoplastic polyurethanes containing polyester segments within the polyurethane polymer or prepolymer.
  • Thermoplastic polyurethanes are made with the same components as waterborne polyester polyurethanes (polyurethane dispersions in water) immediately below but typically the thermoplastic polyurethanes have substantially less or no water-dispersibility enhancing compound(s).
  • the hydrolytically stable polyurethane is a thermoplastic polyurethane.
  • thermoplastic polyurethanes are well known and described for example in U.S. Pat. No. 6,777,466 B2 and J. K. Backus et al., “Polyurethanes,” in: Encyclopedia of Polymer Science and Engineering. Vol. 13, H F. Mark et al., Ed, pp. 243-303 (1988), the entire disclosure of which is incorporated herein by reference.
  • the invention in one embodiment relates to polyester polyurethanes which are derived from aqueous dispersions and which, when dried and cured, produce solid polyester segment containing polyurethane products which are tough and, depending on the other ingredients present (e.g., absence of TiO 2 or other pigment), can be a transparent.
  • polyester polyurethanes to degrade through hydrolysis can be essentially completely eliminated by incorporating into the polymer a substantially dispersed nanoparticle (referring to the aggregate and/or the ultimate particles/crystallite) proton scavenger.
  • Certain materials are known to react with, bind to, or otherwise capture protons, i.e., hydrogen ions, when exposed thereto in solid, liquid and/or gaseous media.
  • Calcium carbonate is a good example as are the other alkali and earth-alkali metal carbonates, i.e., Li 2 CO 3 , BeCO 3 , MgCO 3 , SrCO 3 , BaCO 3 , and RaCO 3 .
  • Other examples of carbonates which will scavenge protons include carbonates of Fe(II), Fe(III), Mn(II), Zn, Ag, Hg(I), Hg(II), Cu(II), Pb(II), Bi(III).
  • Calcium carbonate has the formula CaCO 3 . It is a common substance found in rock in all parts of the world, and is the main component of shells of marine organisms, snails, pearls, and eggshells. Calcium carbonate is found naturally as the following minerals and rocks: aragonite, calcite, vaterite or ( ⁇ -CaCO3), chalk, limestone, marble, travertine. The vast majority of calcium carbonate used in industry is extracted by mining or quarrying. Pure calcium carbonate (e.g., for food or pharmaceutical use), can be produced from a pure quarried source (usually marble).
  • Ground calcium carbonate (GCC) is produced through mechanical grinding of naturally occurring calcium carbonate rocks: marble, limestone and chalk. GCC in pigment formulations provides good rheology and high brightness at low cost.
  • PCC precipitated calcium carbonate
  • This process produces very pure calcium carbonate crystals.
  • the crystals can be tailored to a variety of different shapes and sizes, depending on the specific reaction process used.
  • the three main shapes of PCC crystals are aragonite, rhombohedral, and scalenohedral. Within each crystal type, the PCC process can control mean particle size, size distribution, and surface area.
  • Precipitated calcium carbonate is used as a mineral pigment throughout the world for paper production. It is valued for its high brightness and light scattering characteristics in paper filling and coating applications.
  • organic compounds which will scavenge protons include 1,8-bis-(dimethylamino)naphthalene, 1,8-bis(hexamethyltriaminophosphazenyl)naphthalene and 2,6-di-tert-butylpyridine.
  • these proton scavengers materials form will substantially reduce or even completely eliminate the susceptibility of polyester polyurethanes to degrade though hydrolysis without introducing any significant haze into the polymer, but only if they are incorporated into the polymer in a substantially dispersed nanoparticle and/or high surface area form.
  • nanoparticles are typically obtained commercially in powder or dispersion form, both aqueous and organic.
  • the individual/primary (crystallites for CaCO 3 ) particles in these products may be in the nano size range, these particles usually combine into larger agglomerates in which the nanoparticles are relatively closely-packed with one another usually in three dimensions. Therefore, when these nanoparticle powders and dispersions are used to make nanoparticle-containing polymers, the nanoparticles remain in the form of these larger agglomerates. In other words, the nanoparticles are not substantially dispersed in the polymer mass.
  • proton scavenger nanoparticles will substantially reduce or even completely eliminate the susceptibility of polyester polyurethanes to degrade though hydrolysis, but only if they are incorporated into the polymer mass ultimately formed in a substantially dispersed and/or high surface area form.
  • FIGS. 1A and 1B An example of substantially dispersed (but loosely aggregated having a high surface area (e.g. 41 m 2 /g) arrangement is shown in FIGS. 1A and 1B .
  • the primary nano crystallites of Omya XC-6600-34 from Omya form flocks of various shape and dimensions with a substantial portion of the surface exposed to the matrix they are in. From this perspective, the most effective form of flocculation is a trains or chains of particles.
  • Such an arrangement into relatively large floc particles can introduce some haze to the nanocomposites, but will still be effective in retarding ester hydrolysis because large portion of the nanoparticles surfaces is exposed to the matrix.
  • the D 50 is less than 1 micron, more desirably less than 500 nm, more desirably less than 100 nm, and preferably less than 50 nm.
  • the D 90 is less than 1 micron, more desirably less than 500 nm, more desirably less than 100 nm, and preferably less than 50 nm.
  • the nitrogen BET surface area is greater than 20 m 2 /g; more desirably greater than 30 m 2 /g; still more desirably greater than 35 m 2 /g and preferably about 40 or more m 2 /g.
  • the particle size of the proton scavenger nanoparticles when in the substantially dispersed form desired by this invention can vary widely, and essentially any particle size in the nanoparticle size range can be used.
  • nano particles and substantially dispersed nanoparticles are defined as particles which have at least one of the three dimensions of less than about 250 nm (D 90 ) but will normally be less than about 150 nm.
  • the mean particle size will be about 100 nm or less (D 90 ), 75 nm or less, or even 50 nm or less.
  • the particle size may even be as low as 25 nm or less, 10 nm or less, or even 5 nm or less.
  • the mean particle size, D 50 , of these substantially dispersed nanoparticles may be as large as 250 nm (nanometers) but will normally be less than 100 nm.
  • Substantially dispersed nanoparticles having a mean particle size of about 75 nm or less, more typically 50 nm or less, or even 40 nm or less are interesting.
  • the mean particle size will be 30 nm or less, 25 nm or less, or even 10 nm or less.
  • the particle size may even be as low as 5 nm or less, 2 nm or less, or even 1 nm or less.
  • Particle size is usually characterized by particle size distribution, since all particles in a batch of particles do not have an identical particle size.
  • the nanoparticle batch have a D 90 of less than 250 nm (i.e., 90% of volume of the particles in the batch have equivalent diameters less than 250 nm).
  • Nanoparticle batches with D 90 ′s of 150 nm or less, 100 nm or less, more typically 75 nm or less, or even 50 nm or less, 25 nm or less, 10 nm or less, or even 5 nm or less are especially interesting.
  • nanoparticle batches having D 90 's of about 100 nm or less, and especially 75 nm or less, or even 50 nm or less, since nanoparticles of this size when substantially dispersed in a polymer matrix become essentially transparent to the naked eye.
  • aqueous nanoparticle/polyester-polyurethane dispersions of this invention can be used to make coatings and films for porous and non-porous substrates such as papers, non-woven materials, textiles, leather, wood, concrete, masonry, metals, house wrap and other building materials, fiberglass, polymeric articles, personal protective equipment (such as hazardous material protective apparel, including face masks, medical drapes and gowns, and firemen's turnout gear), and the like.
  • porous and non-porous substrates such as papers, non-woven materials, textiles, leather, wood, concrete, masonry, metals, house wrap and other building materials, fiberglass, polymeric articles, personal protective equipment (such as hazardous material protective apparel, including face masks, medical drapes and gowns, and firemen's turnout gear), and the like.
  • Applications include papers and non-wovens, fibrous materials, films, sheets, composites, and other articles, inks and printing binders, flock and other adhesives, and personal care products such as skin care, hair care, and nail care products, livestock and seed applications, and the like.
  • Any fibrous material can be coated, impregnated or otherwise treated with the compositions of this invention by methods well known to those skilled in the art, including carpets as well as textiles used in clothing, upholstery, tents, awnings, air bags, and the like.
  • Suitable textiles include fabrics, yarns, and blends, whether woven, non-woven, or knitted, and whether natural, synthetic, or regenerated. Examples of suitable textiles include cellulose acetate, acrylics, wool, cotton, jute, linen, polyesters, polyamides, regenerated cellulose (Rayon), and the like.
  • compositions of this invention can also be used to produce articles made of stand-alone films and objects such as personal protective equipment.
  • protective items include gloves and condoms.
  • compositions of this invention can be used as adhesives or to augment or supplement adhesive types well known to those skilled in the art.
  • particular adhesive properties can be achieved by varying type and amount of isocyanates, type, amount, and molecular weight of polyols, and the amount of poly(alkylene oxide) side chain units.
  • the D 90 particle size of the substantially dispersed nanoparticles used is ⁇ 75 nm, preferably ⁇ 50 nm or even ⁇ 40 nm, the polyurethanes obtained will be essentially transparent, provided of course that they are free or essentially free of other materials which would compromise their transparency properties.
  • the principles of the present invention can be applied to other technologies for manufacturing aqueous polyurethane dispersions.
  • this invention can be applied to the technique for manufacturing breathable polyurethane dispersions (i.e. dispersions which form layers of breathable polyurethanes) described in U.S. Pat. No. 6,897,281, as well as to the technique for manufacturing core-shell polyurethane dispersions described in U.S. Published Patent Application No. 20050004306.
  • breathable polyurethane dispersions i.e. dispersions which form layers of breathable polyurethanes
  • Polyurethanes based on polyester macroglycols are known to be susceptible to hydrolysis.
  • the hydrolytic stability of the improved product is attributed to the presence of a proton scavenger in highly dispersed form having significant surface area (increasing the probability that the proton scavenger will be able to scavenge protonic species before the cause hydrolytic chain scission in the polyester portion of the polyurethane).
  • the polyurethane can be in the form of a film, coating or shaped article.
  • the proton scavenger is preferably an inorganic carbonate salt such as calcium carbonate. If the aggregates of the proton scavenger are small relative to the wavelength of light the polyurethane composition will be substantially transparent to visible light.
  • the proton scavenger e.g. calcium carbonate
  • the proton scavenger e.g. calcium carbonate
  • it will have high surface area (e.g. >40 m 2 /g) will be effective at scavenging protons.
  • the samples made with Bayhydrol 110 were prepared using a Speed Mixer Model # DAC 150.1 FVZ-K. They were dispersed for 1 min at 2500 rpm.
  • titanium dioxide In the context of paint applications, titanium dioxide (TiO 2 ) is commonly used, particularly in its rutile form, for providing significant opacity or hiding power. Titanium dioxide pigments marketed for use in paint formulation are well known to present a narrow particle size distribution along with a median particle diameter of between 0.2 and 0.6 ⁇ m, depending on the material and the mean particle size measurement method. Zinc sulphide and zinc oxide are similarly employed.
  • Titanium dioxide suffers however from being relatively high in cost, resulting in a continuing desire to find lower-cost TiO 2 partial replacement pigments that do not translate in a reduction of optical and other coating composition properties.
  • GB1404564 describes ultrafine natural calcium carbonate filled paints and pigments, wherein said natural calcium carbonate has a particle diameter of from 0.5 to 4 ⁇ m and is employed to partially replace titanium dioxide.
  • Imerys has commercialised Polcarb, said to be suitable for glossing paint formulations, which has a mean particle size of 0.9 ⁇ m.
  • such natural calcium carbonate products do not allow the replacement of a part of TiO 2 in glossing paint formulation having a pigment volume concentration below the critical pigment volume concentration without loss of gloss or opacity.
  • the pigment volume concentration is understood to refer to the fraction, quoted in %, of pigment volume relative to the total volume of the pigment plus the other components of the formulation, i.e., it accounts for the pigment volume relative to the total formulation volume.
  • the critical pigment volume concentration is defined as the pigment volume concentration whereupon the resin component of the coating formulation is no longer sufficient to entirely coat all of the pigment particles in a coating. It is well known that above the CPVC, formulations generally provide a matt finish. By contrast glossy paint formulations implement a PVC that is below the CPVC.
  • U.S. Pat. No. 5,171,631 discloses a coating composition for developing hiding on a suitable substrate, the coating composition having a pigment volume concentration (PVC) up to a critical pigment volume concentration (CPVC) and a pigment system comprising about 70-98% by volume of titanium dioxide and about 2-30% by volume of an aluminium trihydrate (ATH) spacer/extender pigment having a medium particle size of about 0.2 microns.
  • FIG. 1 of U.S. Pat. No. 5,171,631 shows a D 98 /D 50 ratio value of approximately 2.7, which corresponds to a relatively narrow particle size distribution.
  • FIG. 2 of U.S. Pat. No. 5,171,631 shows that the ATH-TiO 2 -comprising paint formulations generally fail to achieve the same opacity values as the control paint formulation comprising TiO 2 alone.
  • Natural ground calcium carbonate as opposed to its synthetic counterpart, precipitated calcium carbonate (PCC), generally suffers from a broad particle size distribution and irregular particle shapes. Indeed, as natural ground calcium carbonate is prepared by the grinding down of mined calcite, marble, chalk or limestone-containing stones, it is difficult to ensure that these stones are ultimately fractioned to form fine particles having a very uniform particle size.
  • PCC is formed by a process of building crystals around nucleation sites. Control of nucleation and particle size development, particularly in the size domain under a few micrometers, during PCC precipitation has, over the years, become a well studied science and PCC particles having small and very uniform particle sizes and shapes are now widely available. As in U.S. Pat. No.
  • the small and narrowly distributed PCC particles help space the individual TiO 2 particles and maximize their hiding power.”
  • Specialty Minerals advertises Albafil PCC, a fine, 0.7 micron prismatic calcite, and a range of ultrafine or nano PCCs, namely Calofort S PCC, Calofort U PCC, Ultra-Pflex PCC and Multifex MM PCC, each having a median diameter of 0.07 micron.
  • a ground natural calcium carbonate that is finer than ground natural calcium carbonate products previously offered in this domain, may be used to form an aqueous nanoparticle dispersion in one or more of the binder systems described above for use in forming a variety of (1) clear-coat coating compositions (see the discussion above), as well as serving as (2) a TiO 2 replacement or complementary pigment in the formation of glossing and opacifying coating compositions, even in the case when this ground natural calcium carbonate features a relatively broad particle size distribution and/or a median diameter that is different from that of TiO 2 .
  • clear-coat coating compositions see the discussion above
  • TiO 2 replacement or complementary pigment in the formation of glossing and opacifying coating compositions
  • the ground natural calcium carbonate employed in the present invention not only more fully maintains the gloss and opacity of the paint formulation when used to replace part of the formulation TiO 2 at constant PVC, it may even lead to a gloss and/or opacity improvement.
  • One embodiment of a glossing and opacifying coating composition according to the invention is a composition having a PVC of from 5% up to the CPVC and characterised in that comprises at least one ground natural calcium carbonate having a median diameter (d50 (Mal)) of between 0.05 and 0.3 (hereafter submicron ground natural calcium carbonate, SMGCC), and at least one pigment having a refractive index of greater than or equal to 2.5.
  • d50 mean diameter
  • SMGCC submicron ground natural calcium carbonate
  • CPVC was determined according to the measurement method given in the examples section below.
  • the median diameter (d50 (Mal)) and d98 (Mal) were measured according to the measurement method provided in the examples section below.
  • Another object of the present invention resides in a process to prepare a glossing and opacifying coating composition having a PVC of from 5% up to the CPVC, characterised in that:
  • At least one ground natural calcium carbonate (SMGCC) having a D 50 (Mal) of between 0.05 and 0.3 ⁇ m is provided;
  • At least one pigment having a refractive index of greater than or equal to 2.5 is provided;
  • step d) the SMGCC of step a) is mixed with the pigment of step b) and the resin of step c).
  • a third object of producing the glossing and opacifying coatings according to the present invention lies in the use of at least one ground natural calcium carbonate having a d50 (Mal) of between 0.05 and 0.3 ⁇ m, in a coating composition comprising at least one pigment having a refractive index of greater than or equal to 2.5, characterised in that for a coating composition having a constant PVC in the range of from 5% up to the CPVC, the gloss and/or opacity of the composition is equal to or greater than the gloss and/or opacity of the same composition implementing the pigment having a refractive index of greater than or equal to 2.5 in place of the ground natural calcium carbonate having a d50 of between 0.05 and 0.3 ⁇ m.
  • the gloss of a coating composition applied to a substrate was measured according to the measurement method provided in the examples section below.
  • the opacity of a coating composition applied to a substrate was measured according to the measurement method provided in the examples section below.
  • a first embodiment of such a glossing and opacifying coating comprises a coating composition having a PVC of from 5% up to the CPVC and characterised in that comprises at least one ground natural calcium carbonate having a median diameter (D 50 (Mal)) of between 0.05 and 0.3 ⁇ m (hereafter submicron ground natural calcium carbonate, SMGCC), and at least one pigment having a refractive index of greater than or equal to 2.5.
  • the coating composition has a PVC of from 15 to 25%.
  • the SMGCC has a median diameter (D 50 (Mal)) of between 0.1 and 0.3 ⁇ m.
  • the SMGCC has a D 98 /D 50 (Mal) of greater than 3.
  • this ground natural calcium carbonate may, in an optional embodiment, have a particle size distribution that is broad and dissimilar to the particle size distribution said pigment having a refractive index of greater than or equal to 2.5 employed in the composition. Indeed, even a bi- or multimodal SMGCC particle size distribution may be envisioned.
  • said SMGCC has a D 98 of less than or equal to 1 ⁇ m, more preferably of less than or equal to 0.8 ⁇ m, even more preferably of less than or equal to 0.6 ⁇ m, and even more preferably of less than or equal to 0.4 ⁇ m.
  • the SMGCC has a refraction index of approximately 1.5 to 1.7.
  • the pigment having a refractive index of greater than or equal to 2.5 is selected from one or more of the following: titanium dioxide and/or zinc sulphide and/or zinc oxide.
  • the pigment having a refractive index of greater than or equal to 2.5 is titanium dioxide.
  • the titanium dioxide:SMGCC weight ratio is of 70:30 to 98:2, and it is even more preferred that the titanium dioxide:SMGCC weight ratio is of 85:15 to 90:10.
  • the pigment contributing to the PVC of the composition is a mixture of at least one pigment having a refractive index of greater than or equal to 2.5, SMGCC and one or more of the following: clay, talc, magnesium carbonate, PCC, barium sulphate, mica and bentonite.
  • clay talc
  • magnesium carbonate e.g., magnesium carbonate
  • PCC e.g., calcium carbonate
  • This coating composition is characterised in that when all of said SMGCC is replaced by said pigment having a refractive index of greater than or equal to 2.5 while maintaining a constant PVC value in the range of from 15% up to the CPVC, the gloss of the SMGCC-comprising composition is within 10% of the gloss of the composition wherein the SMGCC is fully replaced by said pigment having a refractive index of greater than or equal to 2.5.
  • the gloss of the SMGCC-comprising composition is within 5%, and more preferably within 3%, of the gloss of the composition having only said pigment having a refractive index of greater than or equal to 2.5.
  • the SMGCC may have a median diameter (D 50 (Mal)) that is equivalent to the median diameter (D 50 (Mal)) of said pigment having a refractive index of greater than or equal to 2.5, though this embodiment is not excluded from the present invention.
  • the median diameter (D 50 (Mal)) of SMGCC may differ from the median diameter (D 50 (Mal)) of said pigment having a refractive index of greater than or equal to 2.5 by up to approximately 0.4 ⁇ m.
  • said SMGCC may feature a broad and even non-uniform particle size distribution relative to the distribution of the pigment having a refractive index of greater than or equal to 2.5 is, though again this does not exclude the case where the particle size distributions of SMGCC and the pigment having a refractive index of greater than or equal to 2.5 is are similar in breadth.
  • the gloss of the SMGCC-comprising composition may be increased by at least 1% relative to the gloss of the composition wherein the SMGCC is fully replaced by the pigment having a refractive index of greater than or equal to 2.5.
  • the gloss of the SMGCC-comprising composition is preferably increased by at least 5% relative to the gloss of the composition wherein the SMGCC is fully replaced by the pigment having a refractive index of greater than or equal to 2.5.
  • said SMGCC is dispersed with one or more dispersants.
  • Conventional dispersants known to the skilled person can be used.
  • the dispersant can be anionic, cationic or non-ionic.
  • a preferred dispersant is polyacrylic acid.
  • compositions according to the present invention may be applied to a variety of substrates as discussed above, including but not limited to, concrete, wood, paper, metal and board.
  • the coating composition is applied to a substrate in an amount so as to form a layer having a thickness of between 100 and 400 um.
  • a glossing and opacifying coating composition according to the invention preferably provides a gloss measured at 60° of greater than 70%. Furthermore, following application to a substrate, the coating composition preferably provides an opacity (contrast ratio) of greater than 97%.
  • the present coating compositions may further include one or more of the following: optical brightener, resin (such as a latex or acrylate-based binder, preferably in the form of an aqueous emulsion), defoamer, thickener, solvent, glycol ethers and dispersant.
  • resin such as a latex or acrylate-based binder, preferably in the form of an aqueous emulsion
  • defoamer e.g., ethylene glycol ether, ethylene glycol ethers and dispersant.
  • the coating composition has a Brookfield viscosity of from 200 to 500 mPa ⁇ s, as measured according to the measurement method provided in the examples below.
  • At least one ground natural calcium carbonate (SMGCC) having a D 50 of between 0.05 and 0.3 ⁇ m is provided;
  • step c) the SMGCC of step a) is mixed with the resin of step b).
  • the SMGCC of step a) may be provided in the form of an aqueous suspension, an aqueous dispersion or as a dry powder.
  • the SMGCC of step a) is provided in the form of an aqueous suspension or dispersion.
  • the resin is preferably a latex and/or acrylate-based binder, said acrylate-based binder preferably being in the form of an aqueous emulsion.
  • Another object of the present invention lies in the use of at least one ground natural calcium carbonate having a D 50 (Mal) of between 0.05 and 0.3 ⁇ m, in a glossing/opacifying coating composition, characterised in that for a coating composition having a constant PVC in the range of from 15% up to the CPVC, the gloss and/or opacity of the composition is equal to or greater than the gloss and/or opacity of the same composition implementing TiO 2 in place of said ground natural calcium carbonate having a d50 of between 0.05 and 0.3 ⁇ m.
  • Another object of the present invention is the production of a paint comprising the glossing/opacifying coating composition of the invention.
  • the weight of the solid material in a suspension or dispersion is determined by weighing the solid material obtained by evaporating the aqueous phase of suspension and drying the obtained material to a constant weight.
  • Weight median grain diameter (d 50 (Sedi)) and grain diameter mass distribution of a particulate material are determined via the sedimentation method, i.e. an analysis of sedimentation behavior in a gravimetric field. The measurement is made with a SedigraphTM 5100.
  • the method and the instrument are known to the skilled person and are commonly used to determine grain size of fillers and pigments.
  • the measurement is carried out in an aqueous solution of 0.1% by weight of Na 4 P 2 O 7 .
  • the samples were dispersed using a high-speed stirrer and ultrasonic means.
  • Weight median grain diameter (d 50 (Mal) was evaluated using a Malvern Mastersizer 2000 (Frauenhofer).
  • the d 98 (Mal) value indicates a diameter value such that 98% by weight of the particles have a diameter of less than this value.
  • BET specific surface area values were determined using nitrogen and the BET method according to ISO 9277.
  • Gloss values are measured at the listed angles according to DIN 67 530 on painted surfaces prepared with a coater gap of 150 and 300 ⁇ m on contrast cards.
  • Contrast ratio values are determined according to ISO 6504/3 at a spreading rate of 7.5 m 2 /l.
  • Brookfield-viscosities are measured with a Brookfield DV-II Viscometer equipped with a LV-3 spindle at a speed of 100 rpm and room temperature (20 ⁇ 3° C.).
  • the pigment volume concentration is calculated as described in Section 6.2.3 of the book entitled “Fuellstoff' by Detlef Gysau (Hannover: Vincentz Network 2005).
  • the critical pigment volume concentration is a well known concentration widely used in the paint industry. It is generally considered to represent the point at which there is just enough resin to wet the pigment particles, and changes to the PVC near to the CPVC can result in abrupt changes to coating properties, such as porosity and gloss.
  • the CPVC and its measurement method according to ISO 4618 are discussed in Section 6.2.4 of the book entitled “Fuellstoff” by Detlef Gysau (Hannover: Vincentz Network 2005).
  • SMGCC dispersions used in the following examples are natural ground calcium carbonate (marble from Vermont) having the median particle size d 50 and particle size characteristics given in the table below.
  • the titanium dioxide employed in the examples herebelow consists of 95% by weight of pure rutile TiO 2 , with the remaining weight being accounted for in a surface treatment of alumina, zirconia and an organic surface treatment agent.
  • This pigment features a d50 (Mal) of approximately 0.55 ⁇ m and is provided in the form of an aqueous paste having a 75% solids content. By scanning electron microscope imaging, the particles appear to be in the range of 0.2 to 0.25 ⁇ m.
  • the refractive index of TiO 2 is 2.7.
  • the following example illustrates a comparative paint composition and paint compositions according to the invention.
  • the formulated paints were applied to a contrast card in the necessary amounts in order to measure both gloss and opacity.

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