GB2617407A

GB2617407A - A binder composition for various paints and coatings

Info

Publication number: GB2617407A
Application number: GB2205238.5A
Authority: GB
Inventors: Ross Rhind Harling Stuart
Original assignee: Individual
Current assignee: Individual
Priority date: 2022-04-10
Filing date: 2022-04-10
Publication date: 2023-10-11
Also published as: GB202205238D0

Abstract

A dry powder binder composition comprises proteins, flours, and lecithin derived from natural sources together with starch-based saccharides, plant gums, cellulose fibres, calcium and sodium compounds, and metallic salts. Preferably, the binder composition comprise 3-6 parts casein and dry proteins, 1.5-3 parts calcium minerals, 0.5-1 parts lecithin and plant flours, 0.07-0.75 parts sodium salts, 0.07-0.75 parts other sodium compounds, 0.05-0.5 parts plant gums, saccharides, and adhesives, 0.05-0.5 parts cellulose esters and fibres, and 0.05-0.5 parts metallic compounds. The calcium minerals preferably comprise apatite or carbonate. The sodium salts may be sodium chloride, sodium silicate, or sodium phosphate, whilst other sodium compounds may include sodium carbonate, sodium hexametaphosphate, sodium hydroxide, sodium bentonite, or sodium tetraborate. The metallic compounds may be zinc oxide, copper sulphate, copper chloride, or silicon dioxide. The binder composition may be combined with colourants, mineral fillers, water, solvents, or additives to produce architectural or decorative paints or coatings.

Description

DESCRIPTION

BACKGROUND TO MODERN PAINT AND COATINGS MANUFACTURE: During the last 120-150 years, architectural and decorative paints and coatings have been manufactured to specific formulations and colours by specialist firms in liquid form using mainly fossil-fuel derived and synthetic ingredients and distributed in metal or plastic containers.

According to the latest OECD Coating Industry Emissions report, Decorative paints alone account for 63% of the 5.5 Million tonnes of paint and coatings sold in the EU. The remaining balance of 37% spread in lesser amounts across 9 other industries including Automotive and Marine. At an average specific gravity (weight) per litre, the volume of liquid Decorative paint for, household and professional painter use, sold in the EU is 2.5 Billion litres per annum.

Liquid Paints and Coatings of the modern era typically comprise five main components made from over 10,000 permitted ingredients. Many still derived from fossil-fuel sources and known, in some degree, to be harmful to the climate, environment, and various life forms including humans, pets, other animals and aquatic organisms.

FORMULATION: By %, a typical can or pot of liquid decorative paint or coating contains: 1. Binder 20-25%: a 'glue-like' composition that bonds all other ingredients to a surface.

2. Pigment and Colourants: % varies: to provide colour and a degree of hiding power 3. Fillers or 'extenders 20-25%: to be blended with pigments, and usually consisting of low-cost bulk minerals to add bulk, hiding power and thickness to the paint layer 4. Liquid Solvents 50%-80%: to provide a vehicle or means to transport the paint solids from container to surface and then to evaporate-includes water, a range of petrochemical products, plant oils 5. Additives c.10%: used to provide additional paint property enhancements, such as flow, stability, and to defoam paint liquid. Preservatives and anti-freeze are often included to extend in-can life.

Paint 'quality' is judged by the percentage of solid ingredients, c.40% in premium paints or <30% in budget brands.

PRODUCTION: The typical manufacturing process for such paints and coatings consists of blending a specific combination of all the ingredients in large tanks (500-5000+ litres) using high-shear liquid dispersion mixers which can take 12 hours or more. Such processes have high energy consumption, the materials are heavy, and costly to store and transport.

In addition, modern liquid paints and coatings are often formulated, manufactured, and labelled for pre-determined 'sheens,' colours, textures, and attributes, such as those configured for interior or exterior walls, woodwork, bathrooms, kitchens, and high-traffic areas. These pre-determined product variations means that exceptionally large numbers of finished items need to be distributed, stocked, and sold to purchasers.

This in turn leads to high transportation costs and higher Co2 emissions throughout the supply chain, as well as product and container disposal problems as 10%-12% of products purchased are eventually wasted. Disposal of paint and its containers is classified as trade hazardous waste and costs can vary from £200-£600 per ton at 2022 prices.

Paints and Coatings: VOC and Carbon Dioxide Emissions Volatile Organic Compounds: These are permitted ingredients of modern paints and coatings, even when they are described as 'water based' or 'minimal VOC.' Typically they include numerous fossil fuel-based materials from high-carbon petrochemical sources, together with the additives and bactericides, biocides, surfactants, selected from thousands of permitted chemicals, including some toxins such as mercury.

Using the British Coatings Federation standard for the average % of the Volatile Organic Compounds included in Decorative paints marked as 'Minimal' or 'Low' VOC (4.2%), the amount of climate damaging and harmful VOCs released by conventional paints during production, liquid transfer, and evaporation, amounts to millions litres per annum. VOCs commonly included are: * Benzene * Ethylbenzene * Ethylene Glycol * Toluene * Xylene * Hexane * Cyclohexane * 1,2,4-Trimethylbenzene Some permitted ingredients, such as anti-freeze glycols, are included to extend 'in-can' shelf life, thereby reducing customer returns. Many are considered hazardous to the environment and/or human life and the presence of such chemicals has frequently been linked to a range of serious pathological conditions.

Emissions from such products can also continue to evaporate for a considerable period of many weeks after a paint or coating has been applied. Medical research shows this can lead to short and long-term health effects on adults, children, and pets, including headaches, vision problems, lung irritation, asthma attacks and other breathing difficulties.

Co? Carbon Dioxide: Using the Crown Paints Carbon Dioxide calculation method of 2.72 kg of Co2 per litre. (Resource Futures 2021) the Co2 emissions of the 2.5 Billion litres of Decorative paints and coatings annually made and sold in the EU can be calculated as millions of tonnes.

INDUSTRY AND CONSUMER CHANGES: The conventional paint industry has been using fossil-fuel based materials for around a century. In the last decade, many companies have started initiatives to reduce oil dependence, use of toxic ingredients and high Co2 emissions.

Now, motivated by Climate Change, COP26 Targets, together long-term and latest Oil and Energy cost rises, and of course, Consumer awareness and demand, the pace of change is accelerating with a few large paint producers declaring 'Net Zero' objectives somewhere between 2030 and 2050.

Both the public and professional trade painters are now far more aware of the dangers of air pollution and hazardous chemicals to the health of adults, children, the climate, and environment. This means increasing numbers are seeking 'safe,' non-toxic' and 'low-VOC' (Volatile Organic Compounds) paints and coatings. Often however, even paints described in such terms are still legally permitted to contain a % of solvents, biocides, and other ingredients harmful to the atmosphere, the environment, humans, animals, and other life forms, such as fish and aquatic organisms.

ALTERNATIVES TO OIL-DERIVED LIQUID PAINTS AND COATINGS

As a practice of pre-historic and ancient origin, it has long been known that tolerable and very long-lasting decorative paints can be produced from a range of earth minerals and pigments combined with plant gums as well as other animal, plant or naturally occurring materials. These materials were then mixed with water and/or other liquids in the amounts required at time of use and applied to various surfaces.

In addition, research into historical records from the 17th-19th centuries when various forms of home decoration began, shows evidence of 'itinerant' housepainters and signwriters in the UK, Europe, North America, and elsewhere travelling widely by foot or with pannier horse, with various pigments, oils, gums, and brushes, to be mixed with locally dug chalks, clays, or other minerals. These itinerant painters would then combine their 'trade secret' recipes with locally sourced water, solvent liquids and other materials including water, plant extracts as well as animals' milk and blood, to create paints and coatings of assorted colours, 'sheens,' and attributes for a wide and varied range of purposes and surfaces Contemporary versions of such decorative paints for walls and ceilings in dry-powder form, are generically referred to as milk paints, casein paints, casein-lime distempers, calcimines etc. These contemporary dry powder decorative paints typically contain a binder, as well as filler(s), pigments or colourants, and any other ingredients necessary to produce a usable paint, together with an activating chemical. This last being vital because casein and protein-based binders typically remain chemically inactive at a neutral pH. and will not become sufficiently 'glue like.' These dry powder paints are usually mixed with water by the customer or painter and become a decorative paint coating of a pre-specified colour, usually suitable for interior walls and ceilings. Almost all such powdered paint products after drying, have a surface sheen referred to as 'matt' or flat matt with a sheen of <10% as measured with a Glossmeter or by the Firwood method.

A few formulations for such dry-powder paints have been granted patents in various countries over a period of many years and many have been reviewed in the preparation of this application, in particular GB 2443026, US 2636829, WO 9712946, EP2402402, CN101942234, CN102617086, US 1456842.

KNOWN DRAWBACKS TO EXISTING DRY POWDER DECORATING PAINTS: Contemporary dry-powder paints and coatings, as with conventional liquid paints, are manufactured for specific colours and purposes. This means that additional c.70% by weight or more of the finished product must be included and transported to the point of use by the customer or painter, and the colour range is normally limited to that chosen by the dry-powder paint maker.

Although produced in a water mixable form with customer instructions, many of these paints still require a considerable degree of skill in the art to produce satisfactory results by typical customers when compared with the convenience of conventional ready-to-use liquid paints.

For example, the inclusion of an 'active' alkaline substance within the product package can restrict the shelf life of such dry-powder paints as the moisture contained within other filler and colour ingredients inevitably degrades certain activators over time.

As a result, the resulting liquid mix can fail to thicken, be liable to sedimentation or the agglomeration of granules producing a porridge-like and grainy texture. The incorrect mixing of such products with unclean water or at incorrect temperatures, can also produce excessive foaming, resulting in a mousse-like consistency that typical householders cannot apply satisfactorily with normal brushes and rollers.

The lack of suitable primers or undercoats for such dry powder paints and coatings can cause additional problems when applying these paints over certain surfaces including previous coats of acrylic, or petrochemical paints, as well as mixed material substrates such as gypsum, acrylic plasters, and lime mortars. This can result in rejection of the paint entirely or cracking and flaking.

Another salient drawback is that the finished sheen of such paints is often limited to the flat matt appearance previously described. This flat matt sheen means the use of such paints is often restricted solely to interior walls and ceilings, necessitating the use of other more volatile and hazardous liquid paint and coating products within the same location, for example on woodwork and trim, thereby negating benefits of using non-petrochemical dry powder paint products within an interior space.

From detailed investigation, research and experience it is also known that production and consumer resistance issues can also arise from the following factors * Inconsistent mixing of the packaged paint materials and variable thickening times.

* Inconsistent particle sizes leading to powder 'flotation' of smaller particles and different dissolving rates in water and other solvent liquids.

* The effects of exposure of dry-powder paint ingredients to moisture and/or humid atmosphere causing it to clump and become unusable.

* The surface oxidisation of pigments and other colouring components during storage preventing intimate combination with other materials to produce full colour depth.

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* It is known from chemical evidence that proteins from both plant and animal milk sources together with naturally derived polysaccharides, lecithin and cellulose materials have certain characteristics that can be modified or damaged during dry-powder paint manufacturing through the action of heat, pressure, and moisture.

THE NEED FOR THIS INVENTION: Consequently, there is a need for a safe, sustainable, and reliably effective binder composition for paints and coatings that is produced to be compatible with suitable regional or locally sourced fillers (minerals and other materials), as well as with the pigments and colourants favoured within certain geographical areas.

Such a binder composition is also advantageous if it can also be combined, at or close to point of use, with different additives and solvent liquids to produce paints and coatings with a variety of sheens, textures, and attributes.

Such an invention can also significantly reduce Co2 emissions, product miles, unnecessary packaging, and waste, as well as lowering distribution costs and simplifying the means of local production for architectural and decorative paints and coatings at both the household and commercial scale. This is particularly advantageous in industrially remote locations or those where the production and transportation of liquid paints and coatings is exceedingly difficult or has undesirable impacts or costs.

THIS INVENTION: This novel invention is of a lightweight, dry-powder, long-life, sustainable paint and coating binder composition that overcomes many of the negative impacts, limitations, and user drawbacks of both modern liquid as well as dry-powder paints and coatings.

By being specifically developed, produced, and packaged in the way described it provides many benefits, including: * Exceptionally long packaged shelf life of 5-10+ years, compared with liquid paint * Remains inert and inactive until coming into contact with water and other liquids * Compatible with a wide range of mineral fillers and other materials used to bulk and thicken coatings * Compatible with a wide range of pigments, colourants, tints, and dyes to formulate more than 20,000 colours * Can be used without fillers to function as a varnish, glaze, lazure or primer.

* Is packaged in a light weight and small format that can be transported worldwide with no known restrictions This invention also enables regional and local production and usage of a wide range of architectural and decorative paints and coatings, remotely or close to the point of customer need, as the invention does not necessitate the unnecessary transportation of pigments, colourants, or bulk mineral fillers as well as heavy liquid solvents, and wasteful metal or plastic containers.

Composition: This paint and coating binder composition is made from an innovative combination of proteins, flours and lecithin derived from animal and plant sources, with starch-based saccharides, plant gums, cellulose fibres, thickening agents, emulsifiers, anti-caking minerals, an inert activator, and various non-toxic metallic salts.

Production Procedure: It is well recognised that ingredients derived from animal and plant-based sources can be changed and damaged by even the moderate influences of heat, pressure, and moisture. In certain situations, such as food cooking, all these changes are intentional and very desirable.

However, in the case of this invention, all three influences should be avoided as much as is possible. Therefore, an innovative five-stage approach has been adopted to both production and packaging using technologies available in many international locations.

A. To begin, all ingredients are sourced to standardised specifications and stored in moisture proof packs and containers. Whenever required, they are carefully weighed in a batch size appropriate to the mixing equipment available. Preferably the ingredients are then placed in a closed-cover slow-speed mixer until they are well combined and homogenised.

B. Consistently small and tightly integrated composition particles are necessary to ensure rapid dissolving of the binder composition at the point of use. Typically, the next stage is therefore a combined particle reduction and equalisation as it is not possible to obtain all raw materials to the necessary fineness (say, 150-75 micron or 100-200 mesh). Conventional mills and grinders for powders, such as roller, plate, and stone mills, are unsuitable for this product as they are purposely designed to exert considerable pressure and thereby generate heat in the product being crushed. Preferably the reduction machine is a cutter/mixer machine with horizontal and vertical blades capable of short but intensive pulses, as often used in the food preparation industry. Preferably such machines should be large enough to comfortably accommodate the batch size and repeatedly used for short periods (pulsed) so that particles are both mixed and sheared to the necessary size without generating excessive heat. The fineness of the product can then be checked by passing samples through a series of wire sieves of specified mesh sizes (e.g., 50,100 or 200 mesh, equivalent to 300,150 or 75 microns).

C. Water content of samples of the resulting binder powder can then be measured by use of a suitable moisture meter or by the Niro Accurate Standard method. Preferably the desirable binder moisture content to support maximum packaged binder shelf life (e.g., 5-10+years) is found to be between 4%-9%.

D. Should the sample water content exceed these levels, a batch of the binder powder can then be dried by several the typical powder drying methods. Such as within a fan convection oven, preferably those capable of maintaining an accurate and stable low temperatures.

E. Packaging is the final stage for this new dry-powder binder. Vacuum packaging with heat sealing is today a well-known means of reducing the risk of microbial infection and extending shelf life for a wide variety of raw and cooked food products, and we have found the same benefits for this invention. For example, such packaging containers can consist of the readily available plastic and plastic foil pouches, as used for very longshelf-life dried foods. More preferably, the new types of biodegradable paper pouches with a vegetable derived moisture-proof lining can provide long-life storage with low environmental damage. All such packaging methods are advanced improvements on versions of an earlier related binder product that were merely heat-sealed in polyethylene lined block bottom paper bags, but nevertheless found to be usable after 10 years in storage.

MAIN ADVANTAGES OF THIS PRODUCTION FORMAT: 1. Once produced and packaged, this non-hazardous, non-toxic light-weight dry-powder paint and coating binder invention can then be shipped and/or posted worldwide with none of the current restrictions imposed on liquid paints.

2. At only 7.5% of the weight and size of pre-made conventional liquid paint (0.250 kg vs.c.3.4kg. for a 2.5Iitres tin of emulsion paint) this invention produces significant environmental and economic benefits and significant reductions in terms of transportation costs and emissions.

3. Additionally, by deferring the inclusion of filler, pigments or colourants, and any additives to regional or local sources, this binder invention is less than 30% the weight and size of contemporary dry-powder decorative paints.

4. From research, and direct experience with other paint and coating binders of a not dissimilar nature, it is to be expected that the shelf life of this binder invention will be 5-10+ years. This exceeds the typical shelf life of conventional liquid emulsion paints and consequently has additional benefits to distributors, retailers, and customers.

CORE EMBODIMENT OF THIS INVENTION: The main bulk of architectural and decorative paints and coatings are used in the interiors of homes, offices, warehouses, factories as well as shops, entertainment venues, and many other public spaces. Smaller quantities are used on the exteriors of such buildings and for interior and exterior woodwork, fences, etc. This invention is a sustainable, long-life, non-hazardous paint and coating binder product that can be combined with a blend of pigments colourants and fillers at almost any location to produce architectural and decorative paints.

In this embodiment this dry-powder binder is combined in the ratios by weight of 1 part binder to three parts of a locally produced dry-powder filler/pigment blend and six parts of clean tap water, preferably at a temperature of between 30-40° Centigrade.

As an example of this main embodiment, and by following multi-lingual clear instructions provided with each sealed product pack, a reasonably competent individual with no prior knowledge or skill in the art can enact the following: 1. Using household scales, the dry contents of a 250g. pack of this binder invention are to be combined with 750g. of a known quantity of dry pigment of the colour desired blended with a mineral filler material, preferably of a fineness akin to food flours. This mixing can take place by hand or by using kitchen equipment or machines.

2. Next if the total weight of the blended dry components is equal to 1kg. then clean warm (30-40° C.) tap water equal to 1.5kg (or 1.5 litres by volume) should be placed in any suitably large clean pot or bucket.

3. Then by steadily adding the 1kg of the dry powder blend to the clean water and mixing by hand, electric whisk, or a drill attachment, 2.5 litres of wall and ceiling paint will be produced and will be ready to apply in c.10-15 minutes.

4. Alternatively, a known quantity liquid pigment, colourant, tint, or dye can be mixed with the clean warm water previously placed in the pot or bucket and mixed until all colour is evenly dispersed. Then, the dry contents of a 250g binder pack can be mixed with a mineral filler material and mixed in as in step 3.

5. The resulting paint can be applied with normal decorating brushes and rollers by anyone with basic decorating knowledge. The first coat will usually be dry within 2-3 hours and can then be recoated if necessary.

6. Should the previous wall colour be markedly different to the colour desired, then a separate quantity of the mixed liquid paint can be thinned with an additional two parts clean water and applied as a 'misting' or undercoat.

7. Any smaller or larger quantities of the paint can be produced at will using exactly the same ratios of 1 part product: 3 parts filler/pigment blend: 6 parts water.

8. 'Pot-life' of the liquid paint is typically 2-5 days in a covered container, dependent on ambient temperature, conditions, and method of storage.

9. Any remaining liquid paint or dried residues made with this invention in the recommended ways can be composted with garden waste. Note: Caution should be taken to check the toxicity of any pigments or colourants used, and these are usually declared on such a product's MSDS sheet.

With such procedures and conditions, the resulting paint is expected to provide similar performance levels as a premium emulsion paint, under standard paint industry tests. I.e., Coverage of 10-12 square metres per litre, 93%-98% hiding power and wear resistance, after drying and hardening, to level 3.

ADDITIONAL NOVEL EMBODIMENTS OF THIS INVENTION: This paint and coating binder invention can also be used by local producers, trade, and public customers in a multitude of innovative ways, in addition to its core embodiment as an architectural or decorative paint or coating for walls and ceiling.

These various novel embodiments of this invention enable trade and household painters to follow a range of recipes and instructions provided to them, to formulate different varieties of paint and coating products according to need and desire at the point of use, exactly as itinerant painters did in the 17th-19wcenturies.

The benefits of such innovative embodiments are significant reductions in retailer stock holding together with lower supply chain and transportation costs for distributors. For householders there is the opportunity to create a range of paint and coating products at lower costs and wastage by using this invention with simple household equipment and available materials.

These novel embodiments include: 1. As a VARNISH or GLAZE: This binder invention, when mixed alone with specified quantities of an oil-water emulsion and a powder or liquid dye or stain (often brown in colour) is found to serve as a varnish, a near transparent glaze, and a lazure for woods or a variety of other surfaces.

2. As a SEMI-GLOSS WOOD PAINT: This binder invention, when mixed with specified quantities of an oil-water emulsion, a 'whiting' powder filler and appropriate pigment or colourant, is found to serve as a hard-wearing paint for woods and a variety of other surfaces with a Firwood scale reflectivity of up to 40%-50% (semi-gloss).

3. As a PRIMER or UNDERCOAT: This binder invention, when mixed with 50%-75% additional warm water than normal (9-10.5 parts), is found to serve as an adhesive primer or undercoat for paint resistant, loose, or friable surfaces onto which further paints or coatings need to be applied.

4. As a MASONRY PAINT: This binder invention, when mixed with specified amounts of water, a blend of white or coloured pigments, together with a blend of cement powder and mineral filler is found to serve as a weather-resistant exterior paint for masonry, stone, or brick.

S. As an INSULATING COATING: This binder invention, when mixed with specified amounts of water, a pigment/mineral blend, and ceramic or glass microspheres such as those manufactured by 3M is found to increase the insulation 'u' value of the paint coating by 5%-15% depending on number of coats and substrate.

ADVANTAGES OF THIS INVENTION: A. WEIGHT REDUCTION: Leaving filler selection and inclusion to local producers or customers means that filler products with the lowest transportation or environmental impacts can be selected on a regional or local basis. According to the United Nations review of Maritime Transport 2020, shipping of dry bulk minerals doubled in tonnage from 2000-2020.

This innovative paint and coating binder composition is found to be compatible with a wide range of mineral fillers and other 'extenders,' mined from various parts of the world. The most widely used paint fillers are listed below with their principal source locations: Filler Name Principal Extraction Locations BARIUM SULPHATE CHINA, INDIA, NORTH AFRICA CALCIUM CARBONATE (CHALKS) WORLDWIDE CRISTOBALITE NORTH & MID-AMERICA DIATOMACEOUS EARTH USA, SOUTH AMERICA, FRANCE, CHINA DOLOMITE USA, CANADA, SWITZERLAND, SPAIN FELDSPAR ITALY, TURKEY, CHINA CHINA CLAY/KAOLIN UK, USA, FRANCE, GERMANY, CZECH REPUBLIC MICA INDIA, BRAZIL, CHINA, BELGIUM QUARTZ CHINA, JAPAN, RUSSIA, SOUTH AFRICA SILICA USA, SOUTH KOREA MAGNESIUM SILICATE (TALC) USA, CANADA, JAPAN, INDIA, SOUTH KOREA, FINLAND In addition, other regional or local 'waste' products can be used to extend or even replace mineral fillers, such as glass powder, mine slag, ground ceramic waste, ground seashells.

B. COLOUR SELECTION: By leaving colour selection to local producers and customers, paint, and coating colours suitable for regional and geographical tastes and habits can be better accommodated.

This paint and coating binder composition has been successfully combined with an extensive range of naturally occurring and manufactured non-toxic powder and liquid pigments and colourants, organic and inorganic pigments, colours, tinters, stains, dyes, and plant materials, some of pre-historic and very ancient origin. In the modern era, trials with pigments used in an advanced BASF powder pigment dispensing machine, showed that up to 20,000 assorted colours are possible and meet modern lightfast standards.

Preferably such organic and inorganic pigments and colourants should be non-toxic and non-hazardous, including but not restricted to those derived from Oxides, Ochres, Metals, Chlorophylls, Anthocyanins, Carotenoids and Betalains.

C. AVOIDING TOXIC SOLVENTS AND OFFGASSING: A liquid solvent provides the means of transporting paint solids to a surface via brush, roller, spray, or other application method. The liquid solvent chosen can also change the sheen (light reflectivity) drying time, weather resistance and moisture permeability of the paint or coating.

When this invention is mixed with other dry paint ingredients it can then be combined with water and a range of naturally derived non-toxic liquid solvents including in varying proportions but not restricted to: Various Emulsions, certain Alcohols and Ethers, Animal milks and other animal derived materials such as liquid Eggs, Honey, Beeswax emulsion, Plant Extracts, Drying oils (such as Linseed, Safflower, Walnut and Poppy), Creams, Lotions, Waxes and, if not swallowed, Turpentines.

D. ADDITIVES: Additives are produced to provide a range of often desirable enhancements, such as flow and glitter effects to many types of liquid paint. Proprietary additives are increasingly available to trade and household painters through both specialist retailers and general DIY stores.

When this invention is mixed with other ingredients to produce a liquid paint or coating, we have found it compatible with a range of proprietary non-toxic additives, checked according to the product's MSDS sheet. These include additives designed to modify the sheen, texture, water-repellence, moisture permeability, flow, mildew resistance, adhesion, bacteria resistance, insect-repellence, scent, fire-retardance, pollution-absorbance, skid-resistance, insulation properties and other attributes of the paints and coatings produced.

FURTHER ADVANTAGES: Environment: As well as reducing the size and weight of transportation of all other paint and coating products by 70%90%, resulting in major Co2 and Cost savings, this binder composition is made from non-toxic ingredients, which are fully sustainable and include no oil-derived petrochemical products or volatile organic compounds (VOCs).

Skill: It is advantageous that such a range of paints and coatings can be produced by those of little prior skill in small or larger quantities and closest to the point of need.

Stability: In addition, given the high-weight, emissions, and costs of liquid paint transportation and its relatively short 'in-pot' life it is advantageous that such a binder product can be manufactured in lightweight dry-powder forms and has a long-packaged shelf-life.

Packaging and Waste: Furthermore, it is beneficial if liquid and solid residues of this novel binder can be easily disposed of with minimal detrimental impact on the environment, atmosphere, humans, and other life forms.

Product Miles: Furthermore, given the known economic and environmental benefits of minimising 'product miles' by using local materials, it is desirable if this 'glue-like' binder component is formulated to be compatible with a range of locally sourced pigments mineral fillers, 'extenders', and other bulking materials, which are heavy, expensive to transport and typically comprise 50%-70% of dry paint ingredients by weight.

Colour Ranges: It has long been known that geographical locations and cultural norms make significant differences to peoples' perception of colour and its symbolism, and this extends to home decoration. For example, in Northern European latitudes peak sunlight periods are short and windows small to reduce heat loss during cold periods. Therefore white, and light pastel shades are the overwhelming choice for interior colour schemes. However, in China and Japan white symbolises death and mourning. Whilst Belgium favours blues for baby girls, and pinks for boys, a colour which symbolises poverty in South Africa.

Therefore, it is advantageous if this invention can be combined with the pigments and colourants which meet the decorative paint and coating colours preferred by local populations.

Additives: Prior to the manufacture of oil-based paints and coatings with numerous 'pre-determined attributes, skilled painters as late as the 20th century developed their own modifications, formulations, and adaptations to both powder and liquid paints available to them which they kept as 'trade-secrets'. For example, introducing small quantities of oil to caseins and calcimines at the mixing stage enhances its sheen and wear-resistance. Similarly, an oil-water emulsion combination can be used to produce a hard-wearing scrubbable paint suitable for woodwork. Latterly, a small amount of silver-ion additive can enhance the anti-microbial and anti-bacterial properties of the dried paint.

In addition, other materials, such as glass microspheres, ground seashells and cement powder, can be used in conjunction with this invention to create paints and coatings with other known and desirable attributes such as improved insulation, pollutant absorption and exterior weather resistance.

It is advantageous that such additives could be combined to form a paint or coating shortly before or at point of use to avoid sedimentation and separation problems. This approach would also reduce the environmental damage caused by proliferation of pre-determined paint products in the production, supply, and retail chains as well as the cost and wastage for customers and professional painters.

Costs: In the past 5 years the public and trade cost of any paint or coating dependent on oil-derived binder, additives and solvent ingredients has increased by 30% to 50% or more. The cost of shipping bulk mineral fillers over vast distances has also increased sharply. All these price increases are set to continue, and paint and coating product supplies have been increasingly restricted by ingredient shortages and transport delays.

Further, this binder invention for paints and coatings is produced without oil-derived petrochemical ingredients or volatile organic compounds. Therefore, is not subject to the same supply chain price increases and volatility. In addition, the absence of oil-derived ingredients also reduces the economic and political dependence on oil imports from other nations.

SUMMARY OF THIS INVENTION:

This invention is novel, innovative, overcomes many of drawbacks set forth above and creates many potential advantages and benefits for regional and local producers, retailers, customers as well as professional and household painters.

* I have found that Casein, Milk Powders, and other animal protein products combine to produce an adhesive substance that provides long term durability and stability for a paint or coating when the pH of the liquid solvent in which it is mixed is between 9.0 and 11.0.

* I have found that inclusion of a blend of dry-powder Calcium minerals function as a 'dormant' alkali activator when the moisture content of dry materials with which it is combined is maintained at lower than 9%.

* I have also found that inclusion of such dry-powder Calcium minerals acts as an anti-caking agent during the processing of this composition in the production method described.

* I have found that inclusion of Plant Lecithin and Flours function as an emulsifier or combiner of other ingredients and non-aqueous liquids included in the liquid solvent.

* I have found that inclusion of Sodium salts that rapidly dissolve in a liquid solvent functions as a 'catalytic' stimulant to the dormant calcium activator minerals * I have found that inclusion of Sodium compounds has a modifying effect on any excessive pH of hard water and convert any Calcium and Magnesium ions dissolved therein to Sodium ions.

* I have found that inclusion of Plant Gums, Saccharides and Adhesives creates a more immediate adhesive effect than the animal protein ingredients described before, and therefore keep any pigment/mineral blends or other materials in suspension and prevents initial sedimentation when both are combined with a liquid solvent.

* I have found that inclusion of Cellulose esters and fibres have a thickening and gelling effect when the binder and pigment/mineral blends are mixed with the liquid solvent, which also reduces paint 'splatter' or runs.

* I have found that the inclusion of Cellulose esters and fibres deter cracking or splits in the final dried paint film.

* I have found that inclusion of non-toxic Metallic compounds extends the 'pot-life' of the liquid paint or coating made with this dry-powder binder composition.

* I have found that inclusion of non-toxic Metallic salts also deters the growth of various fungi and mildews in the drying and dried paint and coating surface made with this dry-powder binder composition.

Claims

CLAIMSCLAIMS1. A dry-powder binder composition for producing architectural and decorative paints and coatings, comprising a combination of proteins, flours and lecithin derived from animal and plant sources, with starch-based saccharides, plant gums, cellulose fibres, calcium and sodium compounds and metallic salts.
2. As part of Claim 1, a dry-powder binder composition that can be mixed and combined with a range of pigment, colourant and mineral filler blends produced from regional or local sources to produce Architectural and Decorative paints and coatings.
3. As part of Claim 1, a dry-powder binder composition that can be mixed and combined with water and a range of other liquid solvents at or close to the point of use to produce Architectural and Decorative paints and coatings with several different performance attributes, uses and applications.
4. As part of Claim 1, a dry-powder binder composition that can be mixed and combined with a range of additives at or close to the point of use to produce paints and coatings various sheens, performance characteristics and decorative attributes
5. As part of Claim 1, a dry-powder binder composition that comprises between 3 and 6 parts by weight of Casein and other dry proteins produced from animal products, including Milk Powders and Dried egg yolk.
6. As part of Claim 1, a dry-powder binder composition that comprises between 1.5 and 3.0 parts of Calcium Minerals including Calcium Hydroxide, Calcium Apatite, Calcium Carbonate
7. As part of Claim 1, a dry-powder binder composition that comprises between 0.5 and 1.0 parts of Plant Lecithin and plant flours, including those from Soy, Pea, and Rice
8. As part of Claim 1, a dry-powder binder composition that comprises between 0.07 and 0.75 parts of Sodium Salts, including Sodium Chloride, Sodium Silicate, Sodium Phosphate
9. As part of Claim 1, a dry-powder binder composition that comprises between 0.07 and 0.75 parts of Sodium compounds including Sodium Carbonate, Sodium Hexametaphosphate, Sodium Hydroxide, Sodium Bentonite, Sodium Tetraborate
10. As part of Claim 1, a dry-powder binder composition that comprises between 0.05 and 0.5 parts of Plant derived gums, saccharides, and adhesives, including Gum Arabic, Gum Tragacanth, Gum Neem, Sucrose and Dextrin.
11 As part of Claim 1, a dry-powder binder composition that comprises between 0.05 and 0.5 parts of Cellulose esters and fibres
12 As part of Claim 1, a dry-powder binder composition that comprises between 0.05 and 0.5 parts of other metallic compounds including Zinc Oxide, Copper Sulphate, Copper Chloride, Silicon Dioxide.
13 A procedure for mixing, milling, and packaging a dry-powder binder composition for paints and coatings that ensures the minimum weight and maximum shelf-life of such a composition.
14. As part of Claim 13, a moisture testing, drying, and packaging procedure for such a dry powder binder composition that renders dormant the dry-powder binder 'activation' and reduces any degradation.
15. As part of Claim 14, a moisture testing, drying, and packaging procedure for such a dry powder binder composition that ensures minimum weight and package size for storage and transportation./end Claims