WO2023187600A1

WO2023187600A1 - Coating system and a process of its preparation

Info

Publication number: WO2023187600A1
Application number: PCT/IB2023/052994
Authority: WO
Inventors: Surya GHOSH; Ganesh DEOKAR; Bhushan Pradhan; Randhirsinh PARMAR
Original assignee: Asian Paints Limited
Priority date: 2022-03-29
Filing date: 2023-03-27
Publication date: 2023-10-05

Abstract

The present disclosure relates to a coating system comprising a base coat and a top coat. The present disclosure further relates to a process for the preparation of a base coat and a top coat. The coating system of the present disclosure is odorless, has odor absorption property, removes toxic chemicals, has thermal insulation property, has air cleaning property for toxic gases, has good acoustic performance and attractive aesthetics. The present disclosure further relates to a process for the preparation of the coating system that is simple, economic and environment friendly.

Description

COATING SYSTEM AND A PROCESS OF ITS PREPARATION

FIELD

The present disclosure relates to a coating system and a process of its preparation. Particularly, the present disclosure relates to a water based odor absorbing coating system and a process of its preparation.

DEFINITIONS

As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.

Acoustic system: The term “acoustic system” refers to the system that prevents the objectionable noise and provides good ambience for the living.

Thermal insulation: The term “thermal insulation” refers to a thermal barrier that provides the ambience with conducive temperature conditions and thus prevents the loss of energy by saving the electricity of air conditioners/coolers.

Aesthetic: The term “aesthetic” refers to an attractive texture finish with possibility of various combinations of colors and finish of the coating system.

BACKGROUND

The background information herein below relates to the present disclosure but is not necessarily prior art.

Coating or paint compositions used for indoor /outdoor applications generally emit odor. This leads to discomfort to the occupiers of the painted spaces, specifically for the indoor environment where odor causing materials are used in the coating or paint composition. Also, there are other sources of odor in residential and office spaces which are due to obnoxious smell causing materials like formaldehyde, hydrogen sulfide, odor causing household materials, microbial growth, and the like. Such problems have been separately addressed by conventional technologies. However, the conventional coating or paint technologies do not provide an efficient solution for the problems together. Moreover, the conventional paint technologies do not provide any solution for the removal of sulphur dioxide and nitrogen oxide odor.

There is, therefore, felt a need to develop a coating system that mitigates the drawback mentioned herein above or at least provides a useful alternative.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

It is an object of the present disclosure to ameliorate one or more problems of the background or to at least provide a useful alternative.

An object of the present disclosure is to provide a coating system.

Another object of the present disclosure is to provide a coating system comprising a base coat and a top coat.

Still another object of the present disclosure is to provide a coating system which, is odorless and has odor absorption property.

Yet another object of the present disclosure is to provide an odor absorbing coating system for indoor air cleaning.

Still another object of the present disclosure is to provide a coating system that improves acoustic performance when applied on the walls or ceilings or other indoor areas.

Yet another object of the present disclosure is to provide a coating system which acts as a thermal barrier for indoor temperature condition.

Still another object of the present disclosure is to provide a simple and an environment friendly process for the preparation of a coating system.

Yet another object of the present disclosure is to provide a process for the preparation of a base coat.

Still another object of the present disclosure is to provide a process for the preparation of a top coat. Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

SUMMARY

The present disclosure relates to a coating system comprising a base coat and a top coat. The base coat comprises at least one odor absorbing material, at least one dispersing agent, a surfactant, a defoamer, a preservative, a thickening agent, a pH stabilizer, a porosity enhancing agent, a negative ion generator, optionally at least one first additive, optionally at least one second additive and water. The top coat comprises at least one odor absorbing material, a rheology modifying agent, a porosity enhancing agent, at least one texturizing agent, a pH stabilizer, a defoamer, a surfactant, at least one dispersing agent, a biocide, a preservative, a thickening agent, a pigment, a negative ion generator, optionally a first binder, optionally a second binder and water.

Further, the present disclosure relates to a process for the preparation of a base coat. The process comprises the step of mixing predetermined amounts of water, a first odor absorbing material, at least one dispersing agent, a preservative, a first portion of a surfactant, a first portion of a defoamer and optionally at least one first additive selected from the group consisting of a first binder, a biocide, a plasticizer, and a rheology modifying agent under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture. Predetermined amounts of a thickening agent and a pH stabilizer are added to the first mixture at a second predetermined stirring speed for a second predetermined time period to obtain a second mixture. Further, predetermined amounts of at least one second odor absorbing material, a porosity enhancing agent, a negative ion generator, optionally a second portion of the surfactant and optionally a second portion of the defoamer and optionally at least one second additive selected from the group consisting of a second binder, at least one texturizing agent, a plast retarder and a co-solvent are added to the second mixture at a third predetermined stirring speed for a third predetermined time period to obtain the base coat.

Furthermore, the present disclosure also relates to a process for the preparation of a top coat. The process comprises the step of mixing predetermined amounts of water, a first odor absorbing material, a dispersing agent, a first portion of a surfactant, a first portion of a defoamer, a biocide, a preservative, a rheology modifying agent and optionally a first binder under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a first mixture. Predetermined amounts of a thickening agent and a pH stabilizer are added to the first mixture at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a second mixture. Predetermined amounts of a pigment, at least one second odor absorbing material, a porosity enhancing agent, at least one texturizing agent, a second portion of the defoamer, a second portion of the surfactant, a negative ion generator and optionally, a second binder are added to the second mixture at a sixth predetermined stirring speed for a sixth predetermined time period to obtain the top coat.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

The present disclosure will now be described with the help of the accompanying drawing, in which:

Figure 1 illustrates optical micrograph of (A) a base coat (Bl) showing surface porosity, SEM image of (B) a base coat (Bl) showing porosity and fibers and optical micrograph of (C) a top coat (Tl) showing surface porosity;

Figure 2 illustrates images of (A) a basecoat Bl, (B) a topcoat (white) (Tl), (C) a colored textured topcoat (T3), (D) a basecoat with gypsum (B3) and (E) a base coat (B3) with gypsum and coated with topcoat (T4) in accordance with the present disclosure.

Figure 3 illustrates image of acrylic air tight chambers with test panels coated with basecoat (Bl) and topcoat (Tl) for cigarette smoke reduction test;

Figure 4 illustrates graphical representation for the quantitative odor absorption performance of the panels coated with the coating system (base coat (B2) and top coat (T2)) in accordance with the present disclosure, for (A) the reduction of H₂S gas, (B) the reduction of ammonia, (C) the reduction of nitric oxide (NO) gas, (D) the reduction of SO₂. (E) the reduction of nitrogen dioxide (NO₂), (F) the reduction of H₂S in panels after 6 months of coating with the coating system (B2 and T2) and (G) the reduction of H₂S in comparison with various commercially available products for odor absorption;

Figure 5 illustrates images of thermal insulation performance of (A) a base coat (Bl) in accordance with the present disclosure and (B) control (commercial wall putty and flat paint); Figure 6 illustrates (A) image of a panel/mould applied with only a base coat Bl in accordance with the present disclosure and (B) a panel/mould applied with a coating system (Bl and Tl) in accordance with the present disclosure; and (C) the graphical representation of sound transmission loss with the panel coated with the base coat (Bl) and the panel coated with the coating system (Bl and Tl) in accordance with the present disclosure; and

Figure 7 illustrates graphical representation for the quantitative odor absorption performance of the panels coated with gypsum + base coat (B3) + top coat (T4) and control for (A) the reduction of H₂S gas, and (B) the reduction of nitrogen dioxide (NO₂) gas.

DETAILED DESCRIPTION

The present disclosure relates to a coating system and a process for its preparation. Particularly, the present disclosure relates to a water based odor absorbing coating system and a process of its preparation thereof.

Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.

The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.

The present disclosure provides a coating system that has odor absorption property, thermal insulation, acoustic performance, and aesthetic performance; and a process for preparation thereof. Particularly, the present disclosure provides a coating system comprising a base coat and a top coat and a process for the preparation of a base coat and a top coat.

In a first aspect, the present disclosure provides a coating system. Particularly, the present disclosure provides a water based odor absorbing coating system.

In accordance with the embodiment of the present disclosure, the coating system comprises a base coat and a top coat.

The base coat comprises: a. at least one odor absorbing material; b. at least one dispersing agent; c. a surfactant; d. a defoamer; e. a preservative; f. a thickening agent; g. a pH stabilizer; h. a porosity enhancing agent; i. a negative ion generator; j . optionally at least one first additive; k. optionally at least one second additive; and l. water.

The top coat comprises: a. at least one odor absorbing material; b. a rheology modifying agent; c. a porosity enhancing agent; d. at least one texturizing agent; e. a pH stabilizer; f. a defoamer; g. a surfactant; h. at least one dispersing agent; i. a biocide; j. a preservative; k. a thickening agent; l. a pigment; m. a negative ion generator; n. optionally a first binder; o. optionally a second binder; and p. water.

In accordance with an embodiment of the present disclosure, the base coat comprises: a. 1 mass% to 50 mass% of the odor absorbing material; b. 0. 1 mass% to 2 mass% of the dispersing agent; c. 0.05 mass% to 0.5 mass% of the surfactant; d. 0.05 mass% to 1 mass% of the defoamer; e. 0. 1 mass% to 2 mass% of the preservative; f. 0.05 mass% to 1 mass% of the thickening agent; g. 0.01 mass% to 0.5 mass% of the pH stabilizer; h. 1 mass% to 10 mass% of the porosity enhancing agent; i. 0. 1 mass% to 5 mass% of the negative ion generator; j . 0 mass% to 25 mass% of the first additive; k. 0 mass% to 40 mass% of the second additive; and

1. 10 mass% to 50 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In another embodiment of the present disclosure, the base coat comprises: a. 15 mass% to 35 mass% of the odor absorbing material; b. 0.5 mass% to 1 mass% of the dispersing agent; c. 0.3 mass% to 0.5 mass% of the surfactant; d. 0. 1 mass% to 0.5 mass% of the defoamer; e. 0. 1 mass% to 0.5 mass% of the preservative; f. 0.1 mass% to 1 mass% of the thickening agent; g. 0.05 mass% to 0.2 mass% of the pH stabilizer; h. 1 mass% to 8 mass% of the porosity enhancing agent; i. 0.3 mass% to 2 mass% of the negative ion generator; j . 0 mass% to 15 mass% of the first additive; k. 0 mass% to 40 mass% of the second additive; and

1. 20 mass% to 50 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In accordance with an embodiment of the present disclosure, the top coat comprises:

• 1 mass% to 50 mass% of the odor absorbing material;

• 0.1 mass% to 15 mass% of the rheology modifying agent;

• 0.01 mass% to 20 mass% of the porosity enhancing agent;

• 5 mass% to 25 mass% of the texturizing agent; • 0.01 mass% to 0.5 mass% of the pH stabilizer;

• 0.01 mass% to 1 mass% of the defoamer;

• 0.01 mass% to 1 mass% of the surfactant;

• 0.1 mass% to 2 mass% of the dispersing agent;

• 0.1 mass% to 1 mass% of the biocide;

• 0.1 mass% to 2 mass% of the preservative;

• 0.1 mass% to 1 mass% of the thickening agent;

• 1 mass% to 20 mass% of the pigment;

• 0.1 mass% to 5 mass% of the negative ion generator;

• 0 mass% to 10 mass% of the first binder;

• 0 mass% to 15 mass% of the second binder; and

• 10 mass% to 50 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In another embodiment of the present disclosure, the top coat comprises:

• 15 mass% to 35 mass% of the odor absorbing material;

• 0.1 mass% to 12 mass% of the rheology modifying agent;

• 0.05 mass% to 10 mass% of the porosity enhancing agent;

• 5 mass% to 25 mass% of the texturizing agent;

• 0.05 mass% to 0.2 mass% of the pH stabilizer;

• 0.1 mass% to 0.5 mass% of the defoamer;

• 0.1 mass% to 0.5 mass% of the surfactant;

• 0.1 mass% to 1 mass% of the dispersing agent;

• 0.1 mass% to 1 mass% of the biocide;

• 0.1 mass% to 1 mass% of the preservative;

• 0.1 mass% to 0.5 mass% of the thickening agent;

• 2 mass% to 15 mass% of the pigment;

• 0.1 mass% to 1 mass% of the negative ion generator;

• 0 mass% to 5 mass% of the first binder;

• 0 mass% to 10 mass% of the second binder; and

• 10 mass% to 40 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In accordance with the present disclosure, the odor absorbing material can be selected from the group consisting of copper metal adsorbed on the colloidal silica substrate (PREBONA® odor control TC), molecular sieves 4A powder, carbon charcoal mask powder and diatomaceous silica (Imerys Celite®, CelTiXTM, DiaFil™ 525).

Prebona® odor control TC is a colloidal dispersion of spherical amorphous silica in water. The surface of the silica particles is modified to reduce odor by effectively removing the odor molecules by catalytic conversion of odor causing molecules and converting it into the less odor causing molecules. Hence, the Prebona® odor control TC can be considered as a catalytic odor absorbing material. However, the other odor absorbing materials such as molecular sieves, charcoal and diatomaceous silica absorb odor by a reversible adsorption.

In accordance with the present disclosure, the dispersing agent can be at least one selected from the group consisting of sodium hexameta phosphate (SHMP-10% solution) and sodium salt of carboxylic acid (Indofil 850)).

In accordance with the present disclosure, the surfactant can be selected from the group consisting of a synthetic alcohol ethoxylate (Synperonic A9), polysorbate 20 (Tween 20), polyethylene glycol derivative (Triton X-100) and sodium dodecyl sulphate.

In accordance with the present disclosure, the defoamer can be selected from the group consisting of hydrocarbon oil-based defoamer (AM- 1512) and silicone oil based (BYK 022) defoamer.

In accordance with the present disclosure, the preservative can be selected from the group consisting of 2,4-Dichlorobenzyl alcohol (Protectol® DA S), nitrogenous heterocyclic compound (Loxanol® MI 6301) and a composition of chlormethyl-Zmethylisothiazolone and formaldehyde (Rocima 623).

In accordance with the present disclosure, the thickening agent can be selected from the group consisting of pseudoplastic hydroxyethyl cellulose (Tylose H YP2 200000), hydroxy propyl cellulose, carboxy methyl cellulose, alkali swellable emulsions (ASE) (Rheovis® AS) and hydrophobically modified alkali swellable emulsions (HASE) (Rheovis® HS).

In accordance with the present disclosure, the pH stabilizer is methylsiliconate (Silres BS 168). In accordance with the present disclosure, the porosity enhancing agent can be selected from the group consisting of polyester hollow fibers (Recron 3S polyester fibers), polyamide fibers and cellulose fibers.

In accordance with the present disclosure, the negative ion generator is tourmaline (crystalline boron silicate mineral).

In accordance with the present disclosure, the negative ion generator (tourmaline) generates negative ions in the odor absorbing coating system which neutralizes indoor toxic, harmful gases and bacteria (which are mostly positive ions) to form neutral coordination compounds. The tourmaline particles in the odor absorbing coating system releases negative ions for a long time, and neutralizes the positive electrostatic charge, to eliminate indoor static electricity.

In accordance with the present disclosure, the first additive can be at least one selected from the group consisting of a first binder, a rheology modifying agent, a plasticizer and a biocide.

In accordance with the present disclosure, the rheology modifying agent is Laponite RD 5% solution in water (lithium sodium magnesium silicate (Nao ? Sis Mgs 5 Lio.3 O20 (OH)4)).

In accordance with the present disclosure, the biocide can be selected from the group consisting of zinc omadine, isothiozolone and iodopropylene butylcarbamate (IPBC).

In accordance with the present disclosure, the second additive is at least one selected from the group consisting of a second binder, a texturizing agent, a plast retarder and a co-solvent.

In accordance with the present disclosure, the texturizing agent can be at least one selected from the group consisting of calcium magnesium carbonate (Dolomite (3mm)/ Dolomite Sand BSS 16/30 (0.59-1. 19mm)), calcium carbonate (VIMCRO CARB 1565) and silica sand of various large particle sizes.

In accordance with the present disclosure, the silica sand can be selected from the group consisting of white colored silica sand (100 microns to 500 microns), red colored silica sand and black colored silica sand.

In accordance with the present disclosure, the first binder and the second binder can be independently selected from the group consisting of powder form of ethylene vinyl acetate copolymer (Vinnapas 5010 N), vinyl acrylic resin (Visimer 4055) and liquid dispersion of ethylene vinyl acetate copolymer (Celvolit 1602).

In accordance with the present disclosure, the plasticizer is polycarboxylate ether.

In accordance with the present disclosure, the plast retarder is selected from the group consisting of gypsum setting retarder and citric acid.

In accordance with the present disclosure, the co-solvent is polyethylene glycol.

In accordance with the present disclosure, the pigment can be selected from the group consisting of titanium dioxide (R902 plus), zinc oxide, zinc sulphide, and their composites with other inorganic compounds.

Titanium dioxide can be of two types, rutile and anatase form. These forms can be used in all inorganic and organic pigments to achieve various colors or shades.

In a first exemplary embodiment of the present disclosure, the base coat comprises:

• 5 mass% of copper metal adsorbed on the colloidal silica substrate, 5 mass% of molecular sieves 4 A powder, 5 mass% of carbon charcoal mask powder and 10 mass% of diatomaceous silica as the odor absorbing agents;

• 0.25 mass% of sodium hexameta phosphate and 0.5 mass% of sodium salt of carboxylic acid as the dispersing agents;

• 0.4 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.4 mass% of hydrocarbon oil-based defoamer;

• 0.3 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as the preservative;

• 0.5 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 0.15 mass% methylsiliconate as the pH stabilizer;

• 5 mass% of polyester hollow fibers as the porosity enhancing agent;

• 0.5 mass% of crystalline boron silicate mineral (tourmaline) as the negative ion generator;

• 5 mass% of lithium sodium magnesium silicate (Nao.v Si« Mgs 5 Lio.3 O20 (Of 1), .;) as the rheology modifying agent and 0.5 mass% of zinc omadine as the biocide; • 10 mass% of calcium magnesium carbonate and 17 mass% of calcium carbonate as the texturizing agents and 10 mass% of liquid dispersion ethylene vinyl acetate copolymer as the second binder; and

• 24.5 mass% of water. wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In a second exemplary embodiment of the present disclosure, the base coat comprises:

• 3.33 mass% of copper metal adsorbed on the colloidal silica substrate, 1.25 mass% of molecular sieves 4 A powder, 1.25 mass% of carbon charcoal mask powder and 12.5 mass% of diatomaceous silica as the odor absorbing agents;

• 0.42 mass% of sodium hexameta phosphate and 0.5 mass% of sodium salt of carboxylic acid as the dispersing agents;

• 0.4 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.4 mass% of hydrocarbon oil-based defoamer;

• 0.25 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as the preservative;

• 0.35 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 0.1 mass% methylsiliconate as the pH stabilizer;

• 6.67 mass% of polyester hollow fibers as the porosity enhancing agent;

• 1.67 mass% of crystalline boron silicate mineral (tourmaline) as the negative ion generator;

• 4.17 mass% of powder form of ethylene vinyl acetate copolymer as the first binder, 8.33 mass% of lithium sodium magnesium silicate (Nao.7 Sis Mgs 5 Lio .3 O20 (OHL) as the rheology modifying agent and 0.26 mass% of zinc omadine as the biocide;

• 15 mass% of calcium magnesium carbonate as the texturizing agent; and

• 43.15 mass% of water. wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In a third exemplary embodiment of the present disclosure, the base coat comprises: • 9.1 mass% of copper metal adsorbed on the colloidal silica substrate, 4.55 mass% of molecular sieves 4 A powder, 1 mass% of carbon charcoal mask powder and 18 mass% of diatomaceous silica as the odor absorbing agents;

• 0.25 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.15 mass% of hydrocarbon oil-based defoamer;

• 0.2 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as the preservative;

• 0.15 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 0.1 mass% methylsiliconate as the pH stabilizer;

• 2 mass% of polyester hollow fibers as the porosity enhancing agent;

• 0.5 mass% of polycarboxylate ether as the plasticizer;

• 18 mass% of liquid dispersion of ethylene vinyl acetate copolymer as the second binder and 0.4 mass% of gypsum setting retarder as the plast retarder and 1 mass% of polyethylene glycol as the co-solvent; and

• 43.35 mass% of water. wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In a first exemplary embodiment of the present disclosure, the top coat comprises:

• 4.17 mass% of copper metal adsorbed on the colloidal silica substrate, 4.17 mass% of molecular sieves 4A powder, 13.33 mass% of diatomaceous silica as the odor absorbing materials;

• 5 mass% of lithium sodium magnesium silicate

(Nao.v Sig Mgs.5 Lio.3 O2 (OH)4) as the rheology modifying agent;

• 8.33 mass% of polyester hollow fibers as the porosity enhancing agent;

• 8.33 mass% of calcium carbonate as the texturizing agent;

• 0.13 mass% of methylsiliconate as the pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as the surfactant; • 0.42 mass% of sodium salt of carboxylic acid as the dispersing agent;

• 0.42 mass% of zinc omadine as the biocide;

• 0.42 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 13.33 mass% of titanium dioxide as the pigment;

• 8.33 mass% of liquid dispersion of ethylene vinyl acetate copolymer as the second binder; and

• 32.21 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In a second exemplary embodiment of the present disclosure, the top coat comprises:

• 10 mass% of lithium sodium magnesium silicate

(Nao.v Sig Mgs 5 Lio.3 O20 (OH)4) as the rheology modifying agent;

• 8.33 mass% of polyester hollow fibers as the porosity enhancing agent;

• 7 mass% of calcium carbonate as the texturizing agent;

• 0.1 mass% of methylsiliconate as the pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.42 mass% of sodium salt of carboxylic acid as the dispersing agent;

• 0.42 mass% of zinc omadine as the biocide;

• 0.17 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as the preservative;

• 0.35 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 13.33 mass% of titanium dioxide as the pigment;

• 0.5 mass% of crystalline boron silicate mineral (tourmaline) as the negative ion generator; • 4.5 mass% of powder form of ethylene vinyl acetate copolymer dispersion as the first binder; and

• 32.55 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In a third exemplary embodiment of the present disclosure, the top coat comprises:

• 4.17 mass% of copper metal adsorbed on the colloidal silica substrate, 3 mass% of molecular sieves 4A powder, 13 mass% of diatomaceous silica as the odor absorbing materials;

• 5 mass% of lithium sodium magnesium silicate

(Nao.7 Sig Mgs 5 Lio O20 (OITb) as the rheology modifying agent;

• 6 mass% of polyester hollow fibers as the porosity enhancing agent;

• 5 mass% of calcium carbonate, 5 mass% of white colored silica sand, 8 mass% of red colored silica sand and 2 mass% of black silica sand as the texturizing agents;

• 0.13 mass% of methylsiliconate as the pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.42 mass% of sodium salt of carboxylic acid as the dispersing agent;

• 0.42 mass% of zinc omadine as the biocide;

• 0.4 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 5 mass% of titanium dioxide as the pigment;

• 32.72 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In a fourth exemplary embodiment of the present disclosure, the top coat comprises: • 10 mass% of copper metal adsorbed on the colloidal silica substrate, 5 mass% of molecular sieves 4A powder, 15 mass% of diatomaceous silica as the odor absorbing materials;

• 0.2 mass% of lithium sodium magnesium silicate Nao 7 Sig Mg_{5 5} Lio s O₂o (OH)₄) as the rheology modifying agent;

• 0.1 mass% of polyester hollow fibers as the porosity enhancing agent;

• 10 mass% of calcium magnesium carbonate as the texturizing agent;

• 0.1 mass% of methylsiliconate as the pH stabilizer;

• 0.35 mass% of hydrocarbon oil-based defoamer;

• 0.35 mass% of synthetic alcohol ethoxylated as the surfactant;

• 0.5 mass% of sodium salt of carboxylic acid as the dispersing agent;

• 0.5 mass% of zinc omadine as the biocide;

• 0.3 mass% of pseudoplastic hydroxyethyl cellulose as the thickening agent;

• 12 mass% of titanium dioxide as the pigment;

• 8 mass% of liquid dispersion of ethylene vinyl acetate copolymer as the second binder; and

• 36.9 mass% of water, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

The coating system of the present disclosure can be applied on the substrate by the conventional methods of paint application. The coating system of the present disclosure is a textured composition. The base coat and the top coat of the present disclosure individually can form a dry fdm thickness (DFT) of about 2 mm to 7 mm. Further, the coating system (base coat and top coat) of the present disclosure can form a dry film thickness (DFT) of about 2 mm to 7 mm. The coating system of the present disclosure showed excellent odor absorption and air cleaning and hence, provides a safe and healthy ambience for the occupiers. Additionally, it also addresses the air cleaning for SOx and NOx gases in parking areas of the buildings. As the coating system is porous in nature, the additional benefits of the acoustic performance and thermal managements are also optimized to make the coating system with best sustainability for the occupiers. Moreover, the coating system when applied does not cause any odor and thus, provides the best comforts for the occupiers to occupy the space just after painting.

In a second aspect, the present disclosure provides a process for the preparation of a base coat.

In an embodiment of the present disclosure, the process for the preparation of the base coat comprises the following steps:

(i) mixing predetermined amounts of water, a first odor absorbing material, at least one dispersing agent, a preservative, a first portion of a surfactant, a first portion of a defoamer and optionally at least one first additive selected from the group consisting of a first binder, a biocide, a plasticizer and a rheology modifying agent under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;

(ii) adding predetermined amounts of a thickening agent and a pH stabilizer to the first mixture at a second predetermined stirring speed for a second predetermined time period to obtain a second mixture; and

(iii) adding predetermined amounts of at least one second odor absorbing material, a porosity enhancing agent, a negative ion generator, optionally a second portion of the surfactant and optionally a second portion of the defoamer and optionally at least one second additive selected from the group consisting of a second binder, at least one texturizing agent, a plast retarder and a co-solvent to the second mixture at a third predetermined stirring speed for a third predetermined time period to obtain the base coat.

In an embodiment of the present disclosure, a predetermined amount of water is added at a predetermined stirring speed in the range of 300 rpm to 700 rpm to obtain a desired viscosity or consistency of the base coat. In an exemplary embodiment of the present disclosure, the predetermined stirring speed is 500 rpm.

The first predetermined stirring speed is in the range of 200 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the first predetermined stirring speed is 300 rpm. The first predetermined time period is in the range of 10 minutes to 60 min. In an exemplary embodiment of the present disclosure, the first predetermined time period is 15 min.

The second predetermined stirring speed is in the range of 200 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the second predetermined stirring speed is 500 rpm.

The second predetermined time period is in the range of 10 minutes to 60 min. In an exemplary embodiment of the present disclosure, the second predetermined time period is 15 minutes.

The third predetermined stirring speed is in the range of 800 rpm to 1500 rpm. In an exemplary embodiment of the present disclosure, the third predetermined stirring speed is 1000 rpm.

The third predetermined time period is in the range of 20 minutes to 60 minutes. In an exemplary embodiment of the present disclosure, the third predetermined time period is 30 minutes.

In an embodiment of the present disclosure, the ingredients are added keeping a predetermined time interval before and after addition of each ingredient. The predetermined time interval is in the range of 2 minutes to 30 minutes. In an exemplary embodiment of the present disclosure, the predetermined time interval is 5 minutes.

In an embodiment of the present disclosure, the base coat is added to gypsum in a mass ratio in the range of 1:3 to 1:5. In an exemplary embodiment of the present disclosure, the base coat is added to gypsum in a mass ratio of 1 :4.

The base coat of the present disclosure is used along with gypsum powder as odor absorption base coat which can be top coated with the smooth topcoat of the present disclosure to have very good aesthetics with the similar odor absorption performance as the coating system of the present disclosure.

In an embodiment of the present disclosure, the predetermined amounts of

• the odor absorbing material is in the range of 1 mass% to 50 mass%;

• the dispersing agent is in the range of 0.1 mass% to 2 mass%;

• the surfactant is in the range of 0.05 mass% to 0.5 mass%; • the defoamer is in the range of 0.05 mass% to 1 mass%;

• the preservative is in the range of 0.1 mass% to 2 mass%;

• the thickening agent is in the range of 0.05 mass% to 1 mass%;

• the pH stabilizer is in the range of 0.01 mass% to 0.5 mass%;

• the porosity enhancing agent is in the range of 1 mass% to 10 mass%;

• the negative ion generator is in the range of 0. 1 mass% to 5 mass%;

• the first additive is in the range of 0 mass% to 25 mass%;

• the second additive is in the range of 0 mass% to 40 mass%; and

• water is in the range of 10 mass% to 50 mass%, wherein the mass% of each ingredient is with respect to the total mass of the base coat.

In a third aspect, the present disclosure provides a process for the preparation of a top coat.

In an embodiment of the present disclosure, the process for the preparation of the top coat comprises the following steps:

(i) mixing predetermined amounts of water, a first odor absorbing material, a dispersing agent, a first portion of a surfactant, a first portion of a defoamer, a biocide, a preservative, a rheology modifying agent and optionally a first binder under stirring at a fourth predetermined stirring speed for a fourth predetermined time period to obtain a first mixture;

(ii) adding predetermined amounts of a thickening agent and a pH stabilizer to the first mixture at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a second mixture; and

(iii) adding predetermined amounts of a pigment, at least one second odor absorbing material, a porosity enhancing agent, at least one texturizing agent, a second portion of the defoamer, a second portion of the surfactant, a negative ion generator and optionally, a second binder to the second mixture at a sixth predetermined stirring speed for a sixth predetermined time period to obtain the top coat.

In an embodiment of the present disclosure, a predetermined amount of water is added at a predetermined stirring speed in the range of 300 rpm to 700 rpm to obtain a desired viscosity or consistency of the top coat. In an exemplary embodiment of the present disclosure, the predetermined stirring speed is 500 rpm.

The fourth predetermined stirring speed is in the range of 200 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the fourth predetermined stirring speed is 300 rpm.

The fourth predetermined time period is in the range of 10 minutes to 60 minutes. In an exemplary embodiment of the present disclosure, the fifth predetermined time period is 15 min.

The fifth predetermined stirring speed is in the range of 400 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the fifth predetermined stirring speed is 500 rpm.

The fifth predetermined time period is in the range of 10 minutes to 60 minutes. In an exemplary embodiment of the present disclosure, the fifth predetermined time period is 15 min.

The sixth predetermined stirring speed is in the range of 800 rpm to 1500 rpm. In an exemplary embodiment of the present disclosure, the sixth predetermined stirring speed is 1000 rpm.

The sixth predetermined time period is in the range of 20 minutes to 60 minutes. In an exemplary embodiment of the present disclosure, the sixth predetermined time period is 30.

In an embodiment of the present disclosure, the ingredients can be added keeping a predetermined time interval before and after addition of each ingredient. The predetermined time interval is in the range of 2 minutes to 30 minutes. In an exemplary embodiment of the present disclosure, the predetermined time interval is 5 minutes.

In an embodiment of the present disclosure, the predetermined amounts of

• the odor absorbing material is in the range of 15 mass% to 35 mass%;

• the rheology modifying agent is in the range of 0. 1 mass% to 12 mass%;

• the porosity enhancing agent is in the range of 0.05 mass% to 10 mass%;

• the texturizing agent is in the range of 5 mass% to 25 mass%;

• the pH stabilizer is in the range of 0.05 mass% to 0.2 mass%; • the defoamer is in the range of 0. 1 mass% to 0.5 mass%;

• the surfactant is in the range of 0. 1 mass% to 0.5 mass%;

• the dispersing agent is in the range of 0. 1 mass% to 1 mass%;

• the biocide is in the range of 0.3 mass% to 0.8 mass%;

• the preservative is in the range of 0. 15 mass% to 1 mass%;

• the thickening agent is in the range of 0.2 mass% to 0.5 mass%;

• the pigment is in the range of 2 mass% to 15 mass%;

• the negative ion generator is in the range of 0. 1 mass% to 1 mass%;

• the first binder is in the range of 0 mass% to 5 mass%;

• the second binder in the range of 0 mass% to 10 mass%; and

• water is in the range of 10 mass% to 40 mass%, wherein the mass% of each ingredient is with respect to the total mass of the top coat.

In an embodiment of the present disclosure, the first odor absorbing material and the second odor absorbing material are independently at least one selected from the group consisting of copper metal adsorbed on the colloidal silica substrate, molecular sieves 4A powder, carbon charcoal mask powder and diatomaceous silica; and the dispersing agent is selected from the group consisting of sodium hexameta phosphate and sodium salt of carboxylic acid.

In an embodiment of the present disclosure, the preservative is selected from the group consisting of 2,4-Dichlorobenzyl alcohol, nitrogenous heterocyclic compound and a composition of chloromethyl -/methylisothiazolone and formaldehyde; the surfactant is at least one selected from the group consisting of a synthetic alcohol ethoxylate, polysorbate 20 (Tween 20), polyethylene glycol derivative and sodium dodecyl sulphate and the defoamer is at least one selected from the group consisting of hydrocarbon oil-based defoamer and silicone oil based defoamer.

In an embodiment of the present disclosure, the thickening agent is selected from the group consisting of pseudoplastic hydroxyethyl cellulose, hydroxy propyl cellulose, carboxy methyl cellulose, alkali swellable emulsions (ASE) and hydrophobically modified alkali swellable emulsions (HASE) and the pH stabilizer is methylsiliconate.

In an embodiment of the present disclosure, the porosity enhancing agent is selected from the group consisting of polyester hollow fibers, polyamide fibers and cellulose fibers and the negative ion generator is tourmaline (crystalline boron silicate mineral). In an embodiment of the present disclosure, the biocide is selected from the group consisting of zinc omadine, isothiozolone and iodopropylene butylcarbamate (IPBC); the rheology modifying agent is lithium sodium magnesium silicate (Na0.7 Si8 Mg5.5 Li0.3 020 (OH)4); the first binder and the second binder are independently selected from the group consisting of powder form of ethylene vinyl acetate copolymer, vinyl acrylic resin and liquid dispersion of ethylene vinyl acetate copolymer; the plasticizer is polycarboxylate ether; and the texturizing agent is at least one selected from the group consisting of calcium magnesium carbonate, calcium carbonate and silica sand.

In an embodiment of the present disclosure, the co-solvent is polyethylene glycol; the plast retarder is selected from the group consisting of gypsum setting retarder and citric acid; and the plasticizer is polycarboxylate ether.

In an embodiment of the present disclosure, the pigment is at least one selected from the group consisting of titanium dioxide, zinc oxide and zinc sulphide.

In an embodiment of the present disclosure, the pigment is titanium dioxide.

The process for the preparation of the base coat and the top coat in accordance with the present disclosure is simple, economic and is convenient for industrial scale-up.

The coating system of the present disclosure is prepared by applying a base coat on a substrate followed by curing for predetermined time period and then applying a top coat.

The coating system of the present disclosure can be used in interior and/or exterior applications with the following key benefits:

• Odor absorption performance: the coating system performs as very good odor absorption solution for the following malodors;

- household malodors,

- toilet and urinal odors,

- odors due to microbial growth, and

- cigarette smoke and the associated odor.

• Removal of toxic chemicals (air cleaning): the coating system has an air purifying property by removing the typical toxic substances present in the indoor air such as formaldehyde, ammonia, H₂S and other chemicals typically used in household and SOx and NOx

• Acoustic Performance: the coating system when applied on the walls / celling / other paintable areas indoor, it performs as acoustic system preventing the objectionable noise and thus, providing good ambience for the living.

• Thermal insulation: the coating system when applied on the walls/ celling/ other paintable areas indoor, it acts as a thermal barrier and thus, provides the ambience with conducive temperature conditions which prevents the loss of energy (by saving the electricity of air conditioners/coolers).

• Attractive Aesthetics : the coating system when applied as a two layer coating (base coat and a top coat), it provides all the performances including acoustic performance, thermal insulation, odor absorption along with the attractive texture finish with possibility of various permutations as required for colors and finish.

• The base coat is for achieving high thickness and the top coat is for imparting aesthetic look.

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

The present disclosure is further described in light of the following experiments which are set forth for illustration purposes only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.

EXPERIMENTAL DETAILS:

Experiment 1(A): Process for the preparation of a base coat in accordance with the present disclosure General procedure: The predetermined amounts of water, a first odor absorbing material, at least one dispersing agent, a preservative, a first portion of a surfactant, a first portion of a defoamer and optionally at least one first additive selected from the group consisting of a first binder, a biocide, a plasticizer and a rheology modifying agent were mixed under stirring at 5 300 rpm for 15 minutes to obtain a first mixture. Predetermined amounts of a thickening agent and a pH stabilizer were added to the first mixture at 500 rpm for 15 minutes to obtain a second mixture. The predetermined amounts of a second odor absorbing material, a porosity enhancing agent, a negative ion generating agent, optionally a second portion of the surfactant, optionally a second portion of the defoamer and optionally at least one second 10 additive selected from the group consisting of a second binder, at least one texturizing agent, a plast retarder and a co-solvent were added to the second mixture at 1000 rpm for 30 minutes to obtain the base coat. The ingredients were added keeping 5 minutes time interval before and after addition of each ingredient.

Further, the predetermined amount of water was added at a stirring speed of 500 rpm to 15 obtain desired degree of dispersion and consistency of the base coat.

The base coats were prepared in Examples Bl to B3 by following the general procedure as above. The predetermined amounts of the specific ingredients of the base coat are as given in table 1.

Table 1: Predetermined amounts of the ingredients used in examples B1-B3

Experiment 1 (B): Process for preparation of a top coat in accordance with the present disclosure

General procedure: The predetermined amounts of water, a first odor absorbing material, a dispersing agent, a first portion of a surfactant, a first portion of a defoamer, a biocide, a preservative, a rheology modifying agent and optionally a first binder were mixed under stirring at 300 rpm for 15 minutes to obtain a first mixture. Predetermined amounts of a thickening agent and a pH stabilizer were added to the first mixture at 500 rpm for 15 minutes to obtain a second mixture. Predetermined amounts of a pigment, at least one second odor absorbing material, a porosity enhancing agent, at least one texturizing agent, a second portion of the defoamer, a second portion of the surfactant, a negative ion generator, optionally a second binder and a co-solvent were added to the second mixture at 1000 rpm for 30 minutes to obtain the top coat. The ingredients were added keeping 5 minutes time interval before and after addition of each ingredient. Further, the predetermined amount of water was added at a stirring speed of 500 rpm to obtain desired degree of dispersion and consistency of the top coat. The top coats were prepared in Examples T1 to T4 by following the general procedure as above. The predetermined amounts of the specific ingredients of the top coat are as given in table 2.

Table 2: Predetermined amounts of the ingredients used in examples T1-T4

For the sake of brevity, multiple number of experiments are not included in the specification. However, the other ingredients having similar functionality can be used in the preparation of the coating system of the present disclosure and the coating system will give similar results.

Experiment 1(C): Method of applying a coating system (base coat and top coat) in accordance with the present disclosure

A substrate such as cement composite panel was first coated with the base coat as prepared in Experiment 1(A) followed by curing for 12 hours and then was coated by applying the top coat as prepared in Experiment 1(B) to obtain the substrate coated with the coating system of the present disclosure. Experiment 2: Characterization study of the base coat and the top coat in accordance with the present disclosure

(I) Surface porosity analysis of a base coat and a top coat

The base coat (Bl) and the top coat (Tl) prepared in accordance with the present disclosure are subjected to characterization studies in order to study the surface porosity properties by using optical microscopy and SEM (scanning electron microscope).

(a) Study of surface porosity by using optical microscope

The optical micrographs of the base coat Bl (Figure 1A), and the top coat Tl (Figure 1C) indicated that the base coat and the top coat were highly porous having a pore size in the range of 0. 1 to 1.5 mm. Higher porosity in turn improved the odor absorption. (b) SEM

The SEM micrographs of the base coat (Bl) (Figure IB) indicated that the base coat showed porosity and fibers, which play a role in odor absorption. High porosity is responsible for the higher odor absorption. Further, the aesthetics and the finish of the base coats, the top coats and the coating system in accordance with the present disclosure were also studied. Figure 2A to Figure 2E indicate the images of (A) a basecoat Bl, (B) a topcoat (white) Tl, (C) a colored textured topcoat T3, (D) a basecoat (B3) with gypsum and (E) a base coat (B3) with gypsum and coated with topcoat T4 in accordance with the present disclosure .

Figure 2 shows the relative final finish which is obtained with the basecoats and topcoats in accordance with the present disclosure. Figure 2 (A) to (E) show that the various aesthetic finishing such as colored textured finish, smooth finish and the like, are obtained by using the coating system or an individual coating. (II) Physico-chemical properties analysis of a base coat and a top coat in accordance with the present disclosure

The base coats Bl - B3 and the top coats Tl- T4 were evaluated for their physico-chemical properties. Table 3 below shows the properties of the base coats and the top coats with appropriate values. Table 3: Physicochemical properties of the base coats and the top coats in accordance with the present disclosure

From Table 3, it is observed that the physicochemical properties of the basecoats and topcoats are equivalent to the commercially used coating system. Further, the rheological properties show good ease of application. Experiment 3: Performance analysis of the base coat, the top coat and a coating system prepared in accordance with the present disclosure

(A) Antibacterial and antifungal performance study

(i) Antibacterial or in-can preservation study

The base coat (Bl) and the top coat (Tl) as prepared in Experiment 1 were evaluated by ASTM D2574 for the anti-microbial performance namely in-can preservation (relates to the ability of the composition to sustain the microbial attack during storage in the can). ASTM D2574 is the standard antimicrobial test method for evaluating the resistance of emulsion paints in a can or container to microbial growth. The base coat and the top coat were challenged/exposed to Pseudomonas aeruginosa for 7 days and observed for the growth, wherein Pseudomonas aeruginosa was introduced in the closed container containing the basecoat (Bl) and the top coat (Tl), separately to ascertain the microbial strength of the composition to survive under this condition. Results of the test were interpreted as PASS i.e. if no growth was observed on the base coat/top coat and FAIL i.e. if growth was observed on the base coat/top coat.

The following Table 4 shows the microbiological status of the base coat and the top coat before and after the test/challenge as per ASTM D2574.

Table 4: Antimicrobial Test Results (as per ASTM D2574):

The results of Table 4, showed that the base coat and the top coat after 7 days of challenge/inoculation with the test organism i.e. Pseudomonas aeruginosa did not show any visible growth on the nutrient agar/cetrimide agar, indicating that the base coat and the top coat in accordance with the present disclosure had good In-can preservative performance.

(i) Anti-fungal performance study The base coats and the top coats as prepared in Experiment 1 were evaluated by ASTM 3274 for anti-fungal performance (relates to the ability of the composition to sustain the fungal growth on the dried film). The ASTM 3274 Method details a standardized rating system designed to evaluate the degree of fungal resistance of surface coatings (e.g. paint films). The base coat and the top coat were tested for evaluating the degree of surface disfigurement of coats by fungal growth. The test is carried out in a closed chamber as per ASTM 3274. The known fungal spores were exposed on precoated test panels for specified time period (minutes) and observed for the spread of the fungal growth in terms of disfigurement of the test panels was observed and recorded in terms of the rating 0 to 10, 0 for poor performance and 10 for best performance.

The following Table 5 shows the anti-fungal performance rating of the base coat and the top coat as per ASTM 3274.

Table 5: Antifungal Test Results (as per ASTM 3274):

*Scale 0 (poor performance) to 10 (best performance).

The results of Table 5 showed the performance ratings in the scale from 0-10, 0 being the poor performance and 10 being the best performance. From the Table 5, it is observed that the coating system (Bl and Tl) of the present disclosure showed a rating of ‘ 10’ which indicated that it has best anti-fungal performance and is comparable to the commercially available paints. It was observed that the results of the antifungal test were comparable to the commercially available luxury emulsion paint.

(B) Odor absorption performance study

The base coats and the top coats prepared in experiment 1 were evaluated for odor absorption performance by following experiments. For experiments, the coating system of the present disclosure (base coat and top coat) was applied on the cement composite panels of one sq. ft. size and was tested in the respective chambers made of acrylic sheets. The experimental panels were comparatively testes with the standard system.

(i) Toxic gases absorption performance

5 - Gas Chromatography analysis for the toxic gases absorption

Gas chromatography is a quantification technique used in analytical chemistry for separating and analyzing compounds that can be vaporized without decomposition. This GCMS technique was used to determine the remaining amount of a toxic gas after the absorption by the coating system of the present disclosure.

10 The base coat (B2), topcoat (T2) and the coating system (basecoat B2 + topcoat T2) were applied separately using a 2 mm (Wet film thickness) mold on release paper and allowed for 7 days air dry curing. Once the samples were dried they were cut into strips. The strips were cut into approximately 1 cm x 0.7 cm size and total weight was kept constant at 3.907 grams for the basecoat, the top coat and the coating system each and these sets were analyzed for 15 malodor absorption by spectroscopy.

The odor absorption capability of coating system was studied by using thermo fisher Trace 1300 series GC equipped with ISQ MS and Triplus RSH Headspace. A known amount of sample (as prepared above) was placed in 20 ml of Headspace vial. A toxic/ malodor gas (representative model compounds enlisted in Table 6) of known concentration was poured in 20 it. Vial was sealed with aluminium lid and PTFE (Polytetrafluoroethylene) septa using crimper. It was incubated at a temperature closer to boiling point of representative model compound in a precision oven for 10 minutes. It was allowed to cool down at a room temperature for two hours. After two hours the residual amount of model compound was determined by using below conditions as shown in Table 6. The test results are shown in 25 Table 7.

Table 6: Test conditions for various toxic gas absorption performances by GCMS method ene

- High-performance liquid chromatography (HPLC) analysis for formaldehyde absorption

The odor reduction capability of the coating system specifically by the formaldehyde 5 absorption was studied by using Agilent 1260 infinity Liquid chromatography. A known amount of sample (required to make up the concentration of formaldehyde at 4 ppm) was placed in 20 ml of Headspace vial. Formaldehyde of 4 ppm concentration was added in it. Vial was sealed with aluminium lid and PTFE septa using crimper. Vial was kept at room temperature for 2 hours. After 2 hours 10 ml of air sample was drawn from headspace vial 10 and purge into 10 ml of 2,4-Dinitrophenylhydrazine (DNpH) solution. This solution was kept at room temperature for 2 hours and then analyzed by using HPLC. The test results are shown in Table 7 below.

Table 7: Results of GCMC analysis for the base coat (B2), the top coat (T2) and the coating system of the present disclosure

* (control: commercial putty top coated by flat emulsion paint conventionally used for interior walls was used as a control for the comparative evaluation of odor absorption performance).

From Table 7, it is observed that the coating system (B2 + T2) of the present disclosure efficiently reduces the amount of malodor gaseous compounds. The coating system (B2 + T2) as well as the base coat and the top coat individually in accordance with the present disclosure when compared to the control, showed very good absorption of model compound representative of the respective malodors when compared to the control as shown in Table 7.

(ii) Olfactory measurement Dynamic Olfactometry Instrumental sensory measurements were carried out by employing the human nose in conjunction with an instrument, called olfactometer, which dilutes the odour sample with odour-free air, according to precise ratios, in order to determine odour concentrations.

Garlic paste test and cigarette smoke test in a closed chamber were carried out for the initial screening of the coating system of various base coats and the top coats prepared in accordance with the present disclosure. Two Acrylic Air tight chambers (made up of transparent acrylic sheets) (as shown in Figure 3) were taken which can hold 4 test panels (Isq. ft. each). This set up was prepared in duplicate, one for the garlic paste test and the other one for the cigarette smoke. The chamber had a manual opening in the upper wall which had a nob attached with it. The nob was opened after regular intervals to check the odor comparison.

For the garlic paste test, 10 grams of garlic ginger paste was kept in the petri dish in the acrylic chambers and for the cigarette smoke test 1 gm of cigarette was taken in the chambers having four panels (experimental panels in one chamber and control panel in another chamber) and was burnt simultaneously and after 15 minutes of burning completed, the testers were asked to smell the chambers and rate for the degree of smell perceived. The rating was on the scale of 0 to 10 (0=highest smell and 10=no smell).

Base coat (Bl and B2) was first applied on the four panels separately followed by the application of the top coat Tl. Standard Commercial Putty 1 mm thick + 2 distemper coats were applied on the other panels as control. The panels coated with the coating system (Bl + Tl), (B2 + Tl) and the control were dried for 48 hours and then put inside the chamber for cigarette smoke test.

Odor was assessed by volunteers. The volunteers were asked to sniff the chambers from the small manual opening after 4 hours and asked to provide the ratings. Ratings were given by volunteers/operators on the scale of 1 to 10, wherein Rating 1 was malodor maximum intensity and Rating 10 was lowest intensity of malodor. Table 8 (A) and Table 8 (B) showed the results of the odor assessment for the garlic paste test and the cigarette smoke test by the volunteers. Table 8 (A): Garlic paste odor absorption assessment for the coating system (Bl, B2 and Tl) and control

The results of Table 8(A) indicated that the coating system (Bl + Tl) and (B2+T1) of the present disclosure showed better garlic paste odor removal than the panel coated with the control system. The improved performance was also correlated with the amount of porosity (due to use of hollow fibers - recron) in the coating film.

Table 8 (B): Cigarette smoke odor absorption assessment for the coating system (Bl and B2 and Tl) and control

The results of Table 8 (B) indicated that the coating system (Bl + Tl) of the present disclosure showed better smoke removal than the panel coated with the control system. The improved performance was also correlated with the amount of porosity (due to use of hollow fibers - recron) in the coating film.

(iv) Gray wolf VOC meter analysis

Measurement of malodors such as ammonia, NOx, H₂S, CO in ppm levels and TVOC in ppb levels were carried out by using Gray wolf VOC meter instrument.

2 kg each of Basecoat (B2) & Top Coat (T2) were prepared as per the compositions shown in table 1 and table 2, respectively. Four sets of cementitious composite panels were prepared by applying the basecoat followed by topcoat (the coating system). These panels were allowed to be cured for 7 days at room temperature. Another four sets of cementitious composite panels were applied with commercially available standard putty with two top coats of commercial flat paint above it (control) and were kept for curing for 7 days.

The four sets of experimental panels as prepared above were kept in an air tight chamber equipped with the gray wolf gas monitoring equipment. The known amount of toxic malodor gases (H₂S, ammonia, NO, SO₂ and NO₂) were purged separately inside the closed chamber at 1 lit/minute for 5 minutes and then purging of the malodor was stopped. The concentration of the gases was measured with respect to time, after 30 minutes; the profile of concentration with respect to time was plotted and depicted as the quantitative odor absorption performance. Similar procedure was followed for the standard putty + flat paint (control) and the concentration of malodor with respect to time was analyzed. All parameters such as chamber size, amount of the malodor purged, temperature and humidity were kept constant in both the cases for control and experimental coating system. After the instrument recorded the data, it was graphically plotted for gases namely H₂S, ammonia, NO, SO₂ and NO₂ as shown below in the Figure 4 (A)-(E).

The results of Figure 4 (A)-(E) showed that the coating system (basecoat B2 and topcoat T2) of the present disclosure performed best with respect to the malodor gas absorptions namely H₂S, ammonia and NOx, SOx. Figure 4 (F) showed H₂S reduction performance for 6 month old coating system (base coat B2 + top coat T2) which indicated that the coating system (base coat B2 + top coat T2) had significant odor reduction of 61.53%. This confirmed about the sustainability of the formulated coating system that it can continue to perform even after 6 months. The results of Figure 4 (G) showed that the coating system (basecoat B2 and topcoat T2) of the present disclosure reduced H₂S in comparison with various commercially available products for odor absorption.

Further, the addition of the basecoat of the present disclosure in gypsum powder was evaluated for the odor absorption performance. For evaluating, the base coat (B3) was added to gypsum powder in a mass ratio of 1:4 (base coat B3 to gypsum) to obtain a mixture. The mixture was used for preparation of a cementitious composite, followed by applying a top coat (T4) to obtain a coated panel. The coated panel was evaluated for odor absorption performance for toxic malodor gases (H₂S and NO₂) by using Gray wolf VOC meter analysis as described above. Figure 7 (A) showed H₂S reduction performance of the coating system (basecoat B3 and topcoat T4) of the present disclosure in comparison with the control (standard putty + flat paint). Figure 7 (B) showed NO₂ reduction performance of the coating system (basecoat B3 and topcoat T4) of the present disclosure in comparison with the control (standard putty + flat paint). The results of Figure 7 (A) and 7 (B) showed reduction in the concentration of H₂S and NO₂ as compared with the control, indicating the effective performance of the coating system (basecoat B3 and topcoat T4) of the present disclosure.

(C) Thermal insulation performance study

The base coat (Bl prepared in accordance with the present disclosure was evaluated for the thermal insulation or heat management performance. For this study, cementitious fiber wood panels were painted with the basecoat (Bl) and control (commercial wall Putty + flat paint system). 2 mm thick texture paint was applied for both (Bl) and control. The panels were cured for 7 days and kept under heat source (IR lamp). The surface temperature difference was measured by non-contact thermometer after same time interval. The base coat (Bl) showed less increase in surface temperature when kept under heat source in comparison to the control (commercial wall Putty + flat paint system) after same time. The panel applied with basecoat Bl, showed 86.9 °C (Figure 5A) after 4 minutes whereas panel applied with control showed 92. 1°C (Figure 5B) after 4minutes.

The results of the study demonstrated that the base coat of the present disclosure, showed the thermal insulation performance (in the range of 5 °C to 10 °C) and hence it can contribute to the heat management along with the odor absorption.

(D) Acoustic performance study

Acoustic Performance of the base coat (Bl) and the top coat (Tl) in accordance with the present disclosure was studied using by measuring sound transmission loss. The panels were applied with the base coat (Bl) by using 5 mm square mould (to maintain the thickness of 5 mm) and the coating system [Basecoat (Bl) + Top coat (Tl)] by using 2 mm square mould (to maintain the thickness of 2 mm). Panels were then dried for 48 hours and were packed and tested for the measurement of Acoustic Performance by using ASTM method (sound impedance method), wherein the panels were kept in a cylindrical device where from one side the sound source is exposed and from the other side the sound measurement was done. Figures 6 (A) and Figure 6 (B) shows the images of the panel coated with the base coat and the panel coated with the coating system.

The results of the acoustic study showed sound transmission loss of 48.1dB for the base coat (Bl) and sound transmission loss of 57.2dB for the coating system (Bl + Tl), indicating the acoustic performances of the coating systems of the present disclosure.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of;

- a coating system that:

• is odorless;

• has odor absorbing property;

• removes toxic chemicals;

• has thermal insulation property;

• has air cleaning property for sulphur oxide (SOx) and nitric oxide (NOx); • has good acoustic performance;

• creates safe and healthy ambience; and

• has attractive aesthetics such as texture and finish; and

- processes for the preparation of a base coat and a top coat that are

• simple, economic and environment friendly.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired object or results.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A coating system comprising a base coat and a top coat, wherein said base coat comprises: a. at least one odor absorbing material; b. at least one dispersing agent; c. a surfactant; d. a defoamer; e. a preservative; f. a thickening agent; g. a pH stabilizer; h. a porosity enhancing agent; i. a negative ion generator; j . optionally at least one first additive; k. optionally at least one second additive; and l. water, and said top coat comprises: a. at least one odor absorbing material; b. a rheology modifying agent; c. a porosity enhancing agent; d. at least one texturizing agent; e. a pH stabilizer; f. a defoamer; g. a surfactant; h. at least one dispersing agent; i. a biocide; j. a preservative; k. a thickening agent; l. a pigment; m. a negative ion generator; n. optionally a first binder; o. optionally a second binder; and p. water. The coating system as claimed in claim 1, wherein said base coat comprises: a. 1 mass% to 50 mass% of said odor absorbing material; b. 0.1 mass% to 2 mass% of said dispersing agent; c. 0.05 mass% to 0.5 mass% of said surfactant; d. 0.05 mass% to 1 mass% of said defoamer; e. 0. 1 mass% to 2 mass% of said preservative; f. 0.05 mass% to 1 mass% of said thickening agent; g. 0.01 mass% to 0.5 mass% of said pH stabilizer; h. 1 mass% to 10 mass% said porosity enhancing agent; i. 0.1 mass% to 5 mass% of said negative ion generator; j . 0 mass% to 25 mass% of said first additive; k. 0 mass% to 40 mass% of said second additive; and

1. 10 mass% to 50 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said base coat. The coating system as claimed in claim 1, wherein said base coat comprises: a. 15 mass% to 35 mass% of said odor absorbing material; b. 0.5 mass% to 1 mass% of said dispersing agent; c. 0.3 mass% to 0.5 mass% of said surfactant; d. 0. 1 mass% to 0.5 mass% of said defoamer; e. 0. 1 mass% to 0.5 mass% of said preservative; f. 0.1 mass% to 1 mass% of said thickening agent; g. 0.05 mass% to 0.2 mass% of said pH stabilizer; h. 1 mass% to 8 mass% of said porosity enhancing agent; i. 0.3 mass% to 2 mass% of said negative ion generator; j . 0 mass% to 15 mass% of said first additive; k. 0 mass% to 40 mass% of said second additive; and

1. 20 mass% to 50 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said base coat. The coating system as claimed in claim 1, wherein said top coat comprises: a. 1 mass% to 50 mass% of said odor absorbing material; b. 0.1 mass% to 15 mass% of said rheology modifying agent; c. 0.01 mass% to 20 mass% of said porosity enhancing agent; d. 5 mass% to 25 mass% of said texturizing agent; e. 0.01 mass% to 0.5 mass% of said pH stabilizer; f. 0.01 mass% to 1 mass% of said defoamer; g. 0.01 mass% to 1 mass% of said surfactant; h. 0. 1 mass% to 2 mass% of said dispersing agent; i. 0. 1 mass% to 1 mass% of said biocide; j . 0.1 mass% to 2 mass% of said preservative; k. 0. 1 mass% to 1 mass% of said thickening agent; l. 1 mass% to 20 mass% of said pigment; m. 0. 1 mass% to 5 mass% of said negative ion generator; n. 0 mass% to 10 mass% of said first binder; o. 0 mass% to 15 mass% of said second binder; and p. 10 mass% to 50 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat. The coating system as claimed in claim 1, wherein said top coat comprises: a. 15 mass% to 35 mass% of said odor absorbing material; b. 0. 1 mass% to 12 mass% of said rheology modifying agent; c. 0.05 mass% to 10 mass% of said porosity enhancing agent; d. 5 mass% to 25 mass% of said texturizing agent; e. 0.05 mass% to 0.2 mass% of said pH stabilizer; f. 0. 1 mass% to 0.5 mass% of said defoamer; g. 0. 1 mass% to 0.5 mass% of said surfactant; h. 0. 1 mass% to 1 mass% of said dispersing agent; i. 0.3 mass% to 0.8 mass% of said biocide; j. 0.15 mass% to 1 mass% of said preservative; k. 0.2 mass% to 0.5 mass% of said thickening agent; l. 2 mass% to 15 mass% of said pigment; m. 0. 1 mass% to 1 mass% of said negative ion generator; n. 0 mass% to 5 mass% of said first binder; o. 0 mass% to 10 mass% of said second binder; and p. 10 mass% to 40 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat.

6. The coating system as claimed in claims 1 to 5, wherein said odor absorbing material is at least one selected from the group consisting of copper metal adsorbed on the colloidal silica substrate, molecular sieves 4A powder, carbon charcoal mask powder and diatomaceous silica; and said dispersing agent is at least one selected from the group consisting of sodium hexameta phosphate and sodium salt of carboxylic acid.

7. The coating system as claimed in claims 1 to 5, wherein said surfactant is at least one selected from the group consisting of a synthetic alcohol ethoxylate, polysorbate 20, polyethylene glycol derivative and sodium dodecyl sulphate and said defoamer is selected from the group consisting of hydrocarbon oil -based defoamer and silicone oil based defoamer.

8. The coating system as claimed in claims 1 to 5, wherein said preservative is selected from the group consisting of 2,4-Dichlorobenzyl alcohol, nitrogenous heterocyclic compound and a composition of chloromethyl-Zmethylisothiazolone and formaldehyde.

9. The coating system as claimed in claim 8, wherein said preservative is a composition of chloromethyl -/methylisothiazolone and formaldehyde.

10. The coating system as claimed in claims 1 to 5, wherein said thickening agent is selected from the group consisting of pseudoplastic hydroxyethyl cellulose, hydroxy propyl cellulose, carboxy methyl cellulose, alkali swellable emulsions and hydrophobically modified alkali swellable emulsions (HASE).

11. The coating system as claimed in claim 10, wherein said thickening agent is pseudoplastic hydroxyethyl cellulose.

12. The coating system as claimed in claims 1 to 5, wherein said pH stabilizer is methylsiliconate.

13. The coating system as claimed in claims 1 to 5, wherein said porosity enhancing agent is selected from the group consisting of polyester hollow fibers, polyamide fibers and cellulose fibers; and said negative ion generator is tourmaline (crystalline boron silicate mineral).

14. The coating system as claimed in claim 13, wherein said porosity enhancing agent is polyester hollow fibers.

15. The coating system as claimed in claims 1 to 3, wherein said first additive is at least one selected from the group consisting of a first binder, a rheology modifying agent, a plasticizer and a biocide; said second additive is at least one selected from the group consisting of a texturizing agent, a second binder, a plast retarder and a co-solvent.

16. The coating system as claimed in any of the preceding claims, wherein said rheology modifying agent is lithium sodium magnesium silicate (Nao.7 Sig Mgs.s Lio 3 O20 (OI-D4); said biocide is at least one selected from zinc omadine, isothiozolone and iodopropylene butylcarbamate (IPBC); said texturizing agent is at least one selected from the group consisting of calcium magnesium carbonate, calcium carbonate and silica sand; and said pigment is at least one selected from the group consisting of titanium dioxide, zinc oxide and zinc sulphide.

17. The coating system as claimed in claim 16, wherein said biocide is zinc omadine.

18. The coating system as claimed in claim 16, wherein said pigment is titanium dioxide.

19. The coating system as claimed in any of the preceding claims, wherein said first binder and said second binder are independently selected from the group consisting of powder form of ethylene vinyl acetate copolymer, vinyl acrylic resin and liquid dispersion of ethylene vinyl acetate copolymer; said plasticizer is polycarboxylate ether; said plast retarder is selected from the group consisting of gypsum setting retarder and citric acid; and said co-solvent is polyethylene glycol. The coating system as claimed in any of the preceding claims, wherein said base coat comprises:

• 5 mass% of copper metal adsorbed on the colloidal silica substrate, 5 mass% of molecular sieves 4 A powder, 5 mass% of carbon charcoal mask powder and 10 mass% of diatomaceous silica as said odor absorbing agents;

• 0.25 mass% of sodium hexameta phosphate and 0.5 mass% of sodium salt of carboxylic acid as said dispersing agents;

• 0.4 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.4 mass% of hydrocarbon oil-based defoamer;

• 0.3 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as said preservative;

• 0.5 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 0.15 mass% methylsiliconate as said pH stabilizer;

• 5 mass% of polyester hollow fibers as said porosity enhancing agent;

• 0.5 mass% of crystalline boron silicate mineral (tourmaline) as said negative ion generator;

• 5 mass% of lithium sodium magnesium silicate (Nao.7 Sig Mgs 5 Lio s O20 (OHh) as said rheology modifying agent and 0.5 mass% of zinc omadine as said biocide;

• 10 mass% of calcium magnesium carbonate and 17 mass% of calcium carbonate as said texturizing agents and 10 mass% of liquid dispersion of ethylene vinyl acetate copolymer as said second binder; and

• 24.5 mass% of water. wherein said mass% of each ingredient is with respect to the total mass of said base coat. The coating system as claimed in any of the preceding claims, wherein said base coat comprises:

• 3.33 mass% of copper metal adsorbed on the colloidal silica substrate, 1.25 mass% of molecular sieves 4 A powder, 1.25 mass% of carbon charcoal mask powder and 12.5 mass% of diatomaceous silica as said odor absorbing agents; • 0.42 mass% of sodium hexameta phosphate and 0.5 mass% of sodium salt of carboxylic acid as said dispersing agents;

• 0.4 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.4 mass% of hydrocarbon oil-based defoamer;

• 0.25 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as said preservative;

• 0.35 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 0.1 mass% methylsiliconate as said pH stabilizer;

• 6.67 mass% of polyester hollow fibers as said porosity enhancing agent;

• 1.67 mass% of crystalline boron silicate mineral (tourmaline) as said negative ion generator;

• 4.17 mass% of powder form of ethylene vinyl acetate copolymer as said first binder, 8.33 mass% of lithium sodium magnesium silicate (Nao.7 Sig Mgs 5 Lio O20 (OHfi) as said rheology modifying agent and 0.26 mass% of zinc omadine as said biocide;

• 15 mass% of calcium magnesium carbonate as said texturizing agent; and

• 43.15 mass% of water. wherein said mass% of each ingredient is with respect to the total mass of said base coat.

22. The coating system as claimed in any of the preceding claims, wherein said base coat comprises:

• 9.1 mass% of copper metal adsorbed on the colloidal silica substrate, 4.55 mass% of molecular sieves 4 A powder, 1 mass% of carbon charcoal mask powder and 18 mass% of diatomaceous silica as said odor absorbing agents;

• 0.25 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.15 mass% of hydrocarbon oil-based defoamer;

• 0.2 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as said preservative;

• 0.15 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 0.1 mass% methylsiliconate as said pH stabilizer; • 2 mass% of polyester hollow fibers as said porosity enhancing agent;

• 0.5 mass% of polycarboxylate ether as said plasticizer;

• 18 mass% of liquid dispersion of ethylene vinyl acetate copolymer as said second binder and 0.4 mass% of gypsum setting retarder as said plast retarder and 1 mass% of polyethylene glycol as said co-solvent; and

• 43.35 mass% of water. wherein said mass% of each ingredient is with respect to the total mass of said base coat. The coating system as claimed in any of the preceding claims, wherein said top coat comprises:

• 4.17 mass% of copper metal adsorbed on the colloidal silica substrate, 4.17 mass% of molecular sieves 4A powder, 13.33 mass% of diatomaceous silica as said odor absorbing materials;

• 5 mass% of lithium sodium magnesium silicate

(T4ao.7 Sis Mgs s Lio O20 (OHfi) as said rheology modifying agent;

• 8.33 mass% of polyester hollow fibers as said porosity enhancing agent;

• 8.33 mass% of calcium carbonate as said texturizing agent;

• 0.13 mass% of methylsiliconate as said pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.42 mass% of sodium salt of carboxylic acid as said dispersing agent;

• 0.42 mass% of zinc omadine as said biocide;

• 0.42 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 13.33 mass% of titanium dioxide as said pigment;

• 8.33 mass% of liquid dispersion of ethylene vinyl acetate copolymer as said second binder; and

32.21 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat. The coating system as claimed in any of the preceding claims, wherein said top coat comprises:

• 10 mass% of lithium sodium magnesium silicate

(Nao.7 Sis Mgs 5 Lio .3 O20 (OHL) as said rheology modifying agent;

• 8.33 mass% of polyester hollow fibers as said porosity enhancing agent;

• 7 mass% of calcium carbonate as said texturizing agent;

• 0.1 mass% of methylsiliconate as said pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.42 mass% of sodium salt of carboxylic acid as said dispersing agent;

• 0.42 mass% of zinc omadine as said biocide;

• 0.17 mass% of a composition of chloromethyl-Zmethylisothiazolone and formaldehyde as said preservative;

• 13.33 mass% of titanium dioxide as said pigment;

• 4.5 mass% of powder form of ethylene vinyl acetate copolymer dispersion as said first binder; and

• 32.55 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat. The coating system as claimed in any of the preceding claims, wherein said top coat comprises: • 4.17 mass% of copper metal adsorbed on the colloidal silica substrate, 3 mass% of molecular sieves 4A powder, 13 mass% of diatomaceous silica as said odor absorbing materials;

• 5 mass% of lithium sodium magnesium silicate Nao 7 Sig Mg_{5 5} Lio s O₂o (OH)₄) as said rheology modifying agent;

• 6 mass% of polyester hollow fibers as said porosity enhancing agent;

• 5 mass% of calcium carbonate, 5 mass% of white colored silica sand, 8 mass% of red colored silica sand and 2 mass% of black silica sand as said texturizing agents;

• 0.13 mass% of methylsiliconate as said pH stabilizer;

• 0.33 mass% of hydrocarbon oil-based defoamer;

• 0.33 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.42 mass% of sodium salt of carboxylic acid as said dispersing agent;

• 0.42 mass% of zinc omadine as said biocide;

• 0.4 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 5 mass% of titanium dioxide as said pigment;

• 32.72 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat. The coating system as claimed in any of the preceding claims, wherein said top coat comprises:

• 10 mass% of copper metal adsorbed on the colloidal silica substrate, 5 mass% of molecular sieves 4A powder, 15 mass% of diatomaceous silica as said odor absorbing materials; • 0.2 mass% of lithium sodium magnesium silicate

(Nao.7 Sig Mgs 5 Lio s O20 (OHfi) as said rheology modifying agent;

• 0.1 mass% of polyester hollow fibers as said porosity enhancing agent;

• 10 mass% of calcium magnesium carbonate as said texturizing agent;

• 0.1 mass% of methylsiliconate as said pH stabilizer;

• 0.35 mass% of hydrocarbon oil-based defoamer;

• 0.35 mass% of synthetic alcohol ethoxylated as said surfactant;

• 0.5 mass% of sodium salt of carboxylic acid as said dispersing agent;

• 0.5 mass% of zinc omadine as said biocide;

• 0.3 mass% of pseudoplastic hydroxyethyl cellulose as said thickening agent;

• 12 mass% of titanium dioxide as said pigment;

• 8 mass% of liquid dispersion of ethylene vinyl acetate copolymer as said second binder; and

• 36.9 mass% of water, wherein said mass% of each ingredient is with respect to the total mass of said top coat. A process for the preparation of a base coat, wherein said process comprises the following steps:

(i) mixing predetermined amounts of water, a first odor absorbing material, at least one dispersing agent, a preservative, a first portion of a surfactant, a first portion of a defoamer and optionally at least one first additive selected from the group consisting of a first binder, a biocide and a rheology modifying agent under stirring at a first predetermined stirring speed for a first predetermined time period to obtain a first mixture;

(ii) adding predetermined amounts of a thickening agent and a pH stabilizer to said first mixture at a second predetermined stirring speed for a second predetermined time period to obtain a second mixture; and (iii) adding predetermined amounts of at least one second odor absorbing material, a porosity enhancing agent, a negative ion generator, optionally a second portion of said surfactant and optionally a second portion of said defoamer and optionally at least one second additive selected from the group consisting of a second binder, at least one texturizing agent, a plast retarder and a co-solvent to said second mixture at a third predetermined stirring speed for a third predetermined time period to obtain said base coat. A process for the preparation of a top coat, wherein said process comprises the following steps:

(ii) adding predetermined amounts of a thickening agent and a pH stabilizer to said first mixture at a fifth predetermined stirring speed for a fifth predetermined time period to obtain a second mixture; and

(iii) adding predetermined amounts of a pigment, at least one second odor absorbing material, a porosity enhancing agent, at least one texturizing agent, a second portion of said defoamer, a second portion of said surfactant, a negative ion generator and optionally a second binder to said second mixture at a sixth predetermined stirring speed for a sixth predetermined time period to obtain said top coat. The process as claimed in claims 27 and 28, wherein said first odor absorbing material and said second odor absorbing material are independently at least one selected from the group consisting of copper metal adsorbed on the colloidal silica substrate, molecular sieves 4A powder, carbon charcoal mask powder and diatomaceous silica; and said dispersing agent is selected from the group consisting of sodium hexameta phosphate and sodium salt of carboxylic acid. The process as claimed in claims 27 and 28, wherein said preservative is selected from the group consisting of 2,4-Dichlorobenzyl alcohol, nitrogenous heterocyclic compound and a composition of chloromethyl-Zmethylisothiazolone and formaldehyde; said surfactant is at least one selected from the group consisting of a synthetic alcohol ethoxylate, polysorbate 20, polyethylene glycol derivative and sodium dodecyl sulphate and said defoamer is at least one selected from the group consisting of hydrocarbon oil-based defoamer and silicone oil based defoamer. The process as claimed in claims 27 and 28, wherein said thickening agent is selected from the group consisting of pseudoplastic hydroxyethyl cellulose, hydroxy propyl cellulose, carboxy methyl cellulose, alkali swellable emulsions (ASE) and hydrophobically modified alkali swellable emulsions (HASE) and said pH stabilizer is methylsiliconate. The process as claimed in claims 27 and 28, wherein said porosity enhancing agent is selected from the group consisting of polyester hollow fibers, polyamide fibers and cellulose fibers and said negative ion generator is tourmaline (crystalline boron silicate mineral). The process as claimed in claims 27 and 28, wherein said biocide is selected from the group consisting of zinc omadine, isothiozolone and iodopropylene butylcarbamate (IPBC); said rheology modifying agent is lithium sodium magnesium silicate (Na0.7 Si8 Mg5.5 Li0.3 020 (014)4); said first binder and said second binder are independently selected from the group consisting of powder form of ethylene vinyl acetate copolymer, vinyl acrylic resin and liquid dispersion of ethylene vinyl acetate copolymer; said plasticizer is polycarboxylate ether; and said texturizing agent is at least one selected from the group consisting of calcium magnesium carbonate, calcium carbonate and silica sand. The process as claimed in claim 27, wherein said co-solvent is polyethylene glycol; said plast retarder is selected from the group consisting of gypsum setting retarder and citric acid; and said plasticizer is polycarboxylate ether. The process as claimed in claim 28, wherein said pigment is at least one selected from the group consisting of titanium dioxide, zinc oxide and zinc sulphide. process as claimed in claim 35 wherein said pigment is titanium dioxide. process as claimed in claims 27 and 28, wherein

• said first predetermined stirring speed and said second predetermined stirring speed are independently in the range of 200 rpm to 1000 rpm;

• said third predetermined stirring speed is in the range of 800 rpm to 1500 rpm;

• said fourth predetermined stirring speed is in the range of 200 rpm to 1000 rpm;

• said fifth predetermined stirring speed is in the range of 400 rpm to 1000 rpm; and

• said sixth predetermined stirring speed is in the range of 800 rpm to 1500 rpm. process as claimed in claims 27 and 28, wherein

• said first predetermined stirring speed and said fourth predetermined stirring speed are independently 300 rpm;

• said second predetermined stirring speed and said fifth predetermined stirring speed are independently 500 rpm; and

• said third predetermined stirring speed and said sixth predetermined stirring speed are independently 1000 rpm. process as claimed in claims 27 and 28, wherein

• said first predetermined time period and said second predetermined time period are independently in the range of 10 minutes to 60 minutes;

• said third predetermined time period is in the range of 20 minutes to 60 minutes;

• said fourth predetermined time period and said fifth predetermined time period are independently in the range of 10 minutes to 60 minutes; and

• said sixth predetermined time period is in the range of 20 minutes to 60 minutes. process as claimed in claims 27 and 28, wherein • said first predetermined time period and said second predetermined time period are independently 15 minutes;

• said third predetermined time period is 30 minutes;

• said fourth predetermined time period and said fifth predetermined time period are independently 15 minutes; and

• said sixth predetermined time period is 30 minutes. he process as claimed in claim 27, wherein said predetermined amounts of

• said odor absorbing material is in the range of 1 mass% to 50 mass%;

• said dispersing agent is in the range of 0. 1 mass% to 2 mass%;

• said surfactant is in the range of 0.05 mass% to 0.5 mass%;

• said defoamer is in the range of 0.05 mass% to 1 mass%;

• said preservative is in the range of 0. 1 mass% to 2 mass%;

• said thickening agent is in the range of 0.05 mass% to 1 mass%;

• said pH stabilizer is in the range of 0.01 mass% to 0.5 mass%;

• said porosity enhancing agent is in the range of 1 mass% to 10 mass%;

• said negative ion generator is in the range of 0. 1 mass% to 5 mass%;

• said first additive is in the range of 0 mass% to 25 mass%;

• said second additive is in the range of 0 mass% to 40 mass%; and

• water is in the range of 10 mass% to 50 mass%, wherein said mass% of each ingredient is with respect to the total mass of said base coat. he process as claimed in claim 28, wherein said predetermined amounts of

• said odor absorbing material is in the range of 15 mass% to 35 mass%;

• said rheology modifying agent is in the range of 0. 1 mass% to 12 mass%;

• said porosity enhancing agent is in the range of 0.05 mass% to 10 mass%;

• said texturizing agent is in the range of 5 mass% to 25 mass%;

• said pH stabilizer is in the range of 0.05 mass% to 0.2 mass%;

• said defoamer is in the range of 0.1 mass% to 0.5 mass%;

• said surfactant is in the range of 0. 1 mass% to 0.5 mass%;

• said dispersing agent is in the range of 0.1 mass% to 1 mass%; • said biocide is in the range of 0.3 mass% to 0.8 mass%;

• said preservative is in the range of 0. 15 mass% to 1 mass%;

• said thickening agent is in the range of 0.2 mass% to 0.5 mass%;

• said pigment is in the range of 2 mass% to 15 mass%; • said negative ion generator is in the range of 0. 1 mass% to 1 mass%;

• said first binder is in the range of 0 mass% to 5 mass%;

• said second binder in the range of 0 mass% to 10 mass%; and

• water is in the range of 10 mass% to 40 mass%, wherein said mass% of each ingredient is with respect to the total mass of said top coat. The process as claimed in claim 27, wherein said base coat is added to gypsum in a mass ratio in the range of 1:3 to 1:5. The process as claimed in claim 27, wherein said base coat is added to gypsum in a mass ratio of 1:4.