Method and apparatus for producing an aqueous paint composition from a plurality of premixed compositions

Abstract

The present invention is directed to the provision of premixed aqueous compositions which are used to provide a paint composition of varying finish characteristics at the point of sale. Thus, the merchant distributing the paint composition made from the subject premixed compositions need only maintain inventory of four compositions. The particular compositions which are the subject of the invention exhibit stable characteristics during storage in their respective reservoirs. The compositions include a pigment composition, a dispersant thickening agent, a high resin content binder, and a low resin content binder. The compositions are combined in differing amounts to produce paint compositions being suitable for either interior or exterior use and having differing sheens, quality levels, and color bases.

1 . A premixed aqueous pigment composition useful for formulating a pigmented paint having a volume solids content of about 30% to about 70% and a Stormer viscosity of about 50 to about 250 KU, which premixed pigment composition contains other paint ingredients, which premixed pigment composition consists essentially of:
 (i) at least one pigment,   (ii) at least one dispersant,   (iii) at least one thickener, and   (iv) water;   
       wherein the dispersant(s) and the thickener(s) are stable when combined with the pigment(s) and with the other paint ingredients. 
     
     
         2 . The premixed pigment composition of  claim 1 , wherein the volume solids content is about 35% to about 50% and the Stormer viscosity is about 60 to about 150 KU. 
     
     
         3 . The premixed pigment composition of  claim 1 , wherein the dispersant comprises potassium tripolyphosphate. 
     
     
         4 . The premixed pigment composition of  claim 1 , wherein the thickener comprises a cellulosic. 
     
     
         5 . The premixed pigment composition of  claim 1 , further consisting essentially of at least one additive comprising a viscosity controlling agent, with the additive being present in an amount of 10% or less by weight, based on the total weight of the premixed pigment composition. 
     
     
         6 . A plurality of premixed compositions comprising two different, but stable premixed aqueous compositions useful for formulating a paint, which comprises:
 (a) the premixed pigment composition of  claim 1 ; and   (b) a resinous premixed binder composition having volume solids content of about 25% to about 70% or a Brookfield viscosity of less than about 100,000 centipoise at a shear rate of 1.25 reciprocal seconds, which premixed binder composition consists essentially of a water-borne resin containing binder having a Tg of about −430 degrees C. to about 70 degrees C. and water;   wherein the ingredients of the premixed compositions are stable when combined with each other and with the ingredients of the other premixed compositions in the plurality.   
     
     
         7 . The plurality of premixed aqueous compositions of  claim 6 , wherein the premixed binder composition has a volume solids content of about 30 to about 65% and a Brookfield viscosity of about 100 to about 50,000 centipoise at a shear rate of 1.25 reciprocal seconds, and consists essentially of a water-borne resin containing binder having a Tg of about −10 to about 60 degrees C. 
     
     
         8 . The plurality of premixed aqueous compositions of  claim 6 , wherein the premixed binder composition further consists essentially of at least one additive comprising a coalescent, the additive being present in an amount of less than about 10% by weight, based on the total weight of the premixed binder composition. 
     
     
         9 . A plurality of premixed compositions comprising three different, but stable, premixed aqueous compositions, useful for formulating a paint product, which plurality comprises:
 (a) the plurality of premixed compositions of  claim 6 ; and (b) a premixed low resin composition which consists essentially of:
 (i) at least calcined clay, ground limestone, and diatomaceous earth, 
 (ii) at least one thickener, 
 (iii) water, and 
 (iv) optionally a resin containing binder; 
   wherein the premixed low resin composition has a Stormer viscosity of about 50 to about 250 KU.   
     
     
         10 . The plurality of premixed aqueous compositions of  claim 9 , wherein the premixed low resin composition has a Stormer viscosity of about 60 to about 150 KU. 
     
     
         11 . The plurality of premixed aqueous compositions of  claim 9 , wherein the premixed binder composition further consists essentially of at least one additive comprising a coalescent, with the additive being present in an amount of less than about 20% by weight, based on the total weight of the premixed binder composition. 
     
     
         12 . A premixed aqueous pigment composition having a volume solids content of about 30% to about 70%, a PVC of about 35% to about 100%, and a Stormer viscosity of about 50 to about 250 KU, useful for formulating a pigmented paint product containing other paint ingredients, which premixed aqueous composition consists essentially of:
 (i) at least one pigment,   (ii) at least one dispersant,   (iii) at least one thickener,   (iv) at least one film-forming or non-film-forming resin, and   (v) water; wherein the dispersant(s), the thickener(s), and the resin(s) are stable when combined with the pigment(s) and with the other premixed composition ingredients and wherein the premixed composition is stable and free from settling.   
     
     
         13 . The premixed composition of  claim 12 , wherein the volume solids content is about 35% to about 50%, the PVC is about 50 to about 100%, and the Stormer viscosity is about 60 to about 150 KU. 
     
     
         14 . The premixed composition of  claim 12 , wherein the pigment comprises titanium dioxide. 
     
     
         15 . The premixed composition of  claim 12 , wherein the dispersant comprises potassium tripolyphosphate. 
     
     
         16 . The premixed composition of  claim 12 , wherein the thickener comprises a cellulosic. 
     
     
         17 . The premixed composition of  claim 12 , wherein the resin comprises an acrylic resin. 
     
     
         18 . The premixed composition of  claim 12 , further consisting essentially of at least one additive comprising a viscosity controlling agent, with the additive being present in an amount of 10% or less by weight, based on the total weight of the premixed composition. 
     
     
         19 . A plurality of premixed compositions comprising two different, but stable premixed aqueous compositions useful for formulating a paint product, which plurality comprises:
 (a) the premixed pigment composition of  claim 12 ; and   (b) a premixed binder composition having volume solids content of about 25% to about 70% or a Brookfield viscosity of less than about 100,000 centipoise at a shear rate of 1.25 reciprocal seconds, which premixed binder composition consists essentially of a water-borne resin containing binder having a Tg of about −430 degrees C. to about 70 degrees C. and water;   wherein the ingredients of the premixed compositions are stable when combined with each other and with the ingredients of the other premixed compositions in the plurality.   
     
     
         20 . The plurality of premixed compositions of  claim 19 , wherein the binder premixed composition has a volume solids content of about 30 to about 65% and a Brookfield viscosity of about 100 to about 50,000 centipoise at a shear rate of 1.25 reciprocal seconds, and consists essentially of a water-borne resin containing binder having a Tg of about −10 to about 60 degrees C. 
     
     
         21 . The plurality of premixed compositions of  claim 19 , wherein the premixed binder composition further consists essentially of at least one additive comprising a viscosity controlling agent, the additive being present in an amount of 10% or less by weight, based on the total weight of the premixed binder composition. 
     
     
         22 . The plurality of premixed aqueous compositions of  claim 19 , wherein the premixed binder composition further consists essentially of at least one additive comprising a coalescent, with the additive being present in an amount of less than about 20% by weight, based on the total weight of the premixed binder composition. 
     
     
         23 . A plurality of premixed compositions comprising three different, but stable, premixed aqueous compositions, useful for formulating a paint product, which plurality comprises:
 (a) the plurality of premixed compositions of  claim 19 ; and   (b) a premixed aqueous low resin composition which consists essentially of:
 (i) at least calcined clay, ground limestone, and diatomaceous earth, 
 (ii) at least one thickener, 
 (iii) water, and 
 (iv) optionally a resin containing binder; 
   wherein the premixed low resin composition has a Stormer viscosity of about 50 to about 250 KU.   
     
     
         24 . The plurality of premixed aqueous compositions of  claim 23 , wherein the premixed low resin composition has a volume solids content of about 35% to about 65%, a PVC of about 40% to about 100% and a Stormer viscosity of about 60 to about 150 KU.