CN113292891A

CN113292891A - Coating composition

Info

Publication number: CN113292891A
Application number: CN202110382510.XA
Authority: CN
Inventors: 埃里克·豪泽; 安雅·洛特尔特; 戈朗·巴尔加瓦; 马丁·文特; 罗贝·纳哈斯; 伊恩·哈维
Original assignee: Axalta Coating Systems GmbH
Current assignee: Axalta Coating Systems GmbH
Priority date: 2018-07-31
Filing date: 2019-07-31
Publication date: 2021-08-24

Abstract

A coating composition comprising (A) a binder component and (B) a pigment component. The (a) binder component comprises (a1) polyvinyl butyrate, (a2) a specific film-forming resin, (A3) an acid, (a4) an optional functionalized trialkoxysilane, and (a5) an optional polymeric phosphate ester. The (B) pigment component comprises (B1) calcium ion-exchanged silica, (B2) a corrosion inhibiting pigment, and (B3) polyalkylene oxide phosphate. The coating composition is formed by combining the aforementioned components. In one method, the coating composition is applied to a substrate.

Description

Coating composition

Cross Reference to Related Applications

The application is a divisional application of application with application date of 2019, 7 and 31, application number of 201980057274.5 and invention name of 'coating composition'.

The parent application claims priority to U.S. provisional application No. 62/712,682 filed on 31/7/2018, the contents of which are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to coating compositions. More specifically, the coating composition utilizes a binder component comprising polyvinyl butyral and a specific film forming resin, an acid, an optional functionalized trialkoxysilane, an optional phosphate ester; the pigment component comprises a calcium ion-exchanged silica, a corrosion inhibiting pigment, and a polyalkylene oxide phosphate ester.

Background

Coating systems that are deposited onto a substrate and cured, such as "color plus clear" coating systems and single coat coating systems, can be subject to damage from the environment. For example, corrosion of the coated metal substrate can occur when the substrate is exposed to oxygen and water present in the atmosphere. Therefore, a primer layer is typically used to protect the substrate from corrosion. The primer layer is typically applied directly to the bare or pretreated metal substrate. In some cases, particularly where a primer layer is applied to a bare metal substrate, the primer layer is deposited from a composition that includes a material that enhances the adhesion of the primer layer to the substrate, such as an acid (e.g., phosphoric acid). Such primers are sometimes referred to as etch primers, or wash primers.

As noted, in some cases, the metal substrate is pretreated prior to applying the primer layer (if such a primer layer is used). Such pre-treatments typically involve applying a phosphate conversion coating prior to applying a protective or decorative coating, followed by rinsing. Pretreatment is commonly used to passivate metal substrates and promote corrosion resistance.

Historically, corrosion-resistant coatings and metal pretreatments utilized chromium compounds and/or other toxic metals such as lead to achieve a desired level of corrosion resistance and adhesion to subsequently applied coatings. For example, metal pretreatment typically utilizes a phosphate conversion composition comprising a toxic metal such as nickel and a post-rinse comprising chromium. Furthermore, such compositions typically comprise a chromium compound. However, the use of chromium and/or other toxic metals may result in the generation of waste streams that pose environmental and disposal problems.

More recently, efforts have been made to reduce or eliminate the use of chromium and/or other toxic metals. Thus, compositions have been developed that include other materials added to inhibit corrosion. These materials include, for example, zinc phosphate particles, iron phosphate particles, zinc molybdate particles, calcium molybdate particles, and the like, and typically include particles to help resist corrosion. In some cases, these new compositions are inferior to their chromium-containing counterparts.

Thus, there remains an opportunity to develop improved chromium-free compositions that exhibit corrosion resistance characteristics that are the same as or better than similar chromium-containing compositions. Furthermore, it would be desirable to provide a method for treating metal substrates, including bare metal substrates, to improve the corrosion resistance of such substrates, wherein the method does not involve the use of chromium and/or other toxic metals.

Disclosure of Invention

In one embodiment, the present disclosure provides a coating composition comprising:

A. a binder component, the binder component comprising:

(1) polyvinyl butyral present in an amount of from about 30 to about 70 parts by weight based on 100 parts by weight of the binder component;

(2) a film-forming resin that is a glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) present in an amount of from about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component;

(3) an acid present in an amount of from about 10 parts by weight to about 30 parts by weight, based on 100 parts by weight of the binder component; and

(4) a functionalized trialkoxysilane present in an amount of from about 3 parts by weight to about 10 parts by weight based on 100 parts by weight of the binder component;

and

B. a pigment component comprising:

(1) calcium ion-exchanged silica present in an amount of from about 30 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component;

(2) a corrosion inhibiting pigment present in an amount of from about 40 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component; and

(3) a polyalkylene oxide phosphate present in an amount of from about 1 to about 7 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the coating composition consists essentially of (a) (1) to (a) (4) and (B) (1) to (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component. In yet another embodiment, the coating composition consists of (a) (1) to (a) (4) and (B) (1) to (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component. The present disclosure also provides a method of forming a coating composition comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (4), (B) (1), (B) (2), and (B) (3). The present disclosure also provides a method comprising the step of applying the coating composition to a metal substrate.

In another embodiment, the present disclosure provides a coating composition comprising:

A. a binder component, the binder component comprising:

(2) a film-forming resin that is poly [ (phenyl glycidyl ether) -co-formaldehyde ], present in an amount of about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component;

and

B. a pigment component comprising:

In yet another embodiment, the present disclosure provides a coating composition comprising:

A. a binder component, the binder component comprising:

(5) a polymeric phosphate ester present in an amount of about 3 parts by weight to about 10 parts by weight based on 100 parts by weight of the binder component;

and

B. a pigment component comprising:

In another embodiment, the coating composition consists essentially of (a) (1), (a) (2), (a) (3), and (a) (5), and (B) (1) through (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component. In yet another embodiment, the coating composition consists of (a) (1), (a) (2), (a) (3), and (a) (5), and (B) (1) to (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component. The present disclosure also provides a method of forming a coating composition comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3). The present disclosure also provides a method comprising the step of applying the coating composition to a metal substrate.

Detailed Description

The following detailed description is merely exemplary in nature and is not intended to limit the coating composition. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

Embodiments of the present disclosure generally relate to coating compositions and methods for making the same. For the sake of brevity, conventional techniques related to coating compositions may not be described in detail herein. In addition, various tasks and process steps described herein may be incorporated into a more comprehensive procedure or process having additional steps or functions not described in detail herein. In particular, various steps in the manufacture of coating compositions are well known, and thus, in the interest of brevity, many conventional steps will only be mentioned briefly herein or will be omitted entirely without providing the well known process details.

In certain embodiments, the present disclosure relates to coating compositions that are substantially free of chromium-containing materials. In other embodiments, the coating compositions of the present disclosure are completely free of such materials. As used herein, the term "substantially free" means that the material, if any, is present in the coating composition as an incidental impurity. In other words, the material does not affect the properties of the coating composition. In certain embodiments of the present disclosure, this means that the coating composition comprises less than 2 weight percent, 1 weight percent, 0.5 weight percent, 0.1 weight percent, or 0.05 weight percent of the chromium-containing material, or in some cases, comprises less than 0.05 weight percent of the chromium-containing material, wherein such weight percent is based on the total weight of the composition. As used herein, the term "completely free" means that the material is completely absent from the coating composition. Thus, the coating compositions of certain embodiments of the present disclosure do not include chromium-containing materials. As used herein, the term "chromium-containing material" refers to a material comprising hexavalent chromium. Non-limiting examples of such materials include chromic acid, chromium trioxide, chromic anhydride, dichromates such as ammonium dichromate, sodium dichromate, potassium dichromate, and calcium dichromate, barium dichromate, magnesium dichromate, zinc dichromate, cadmium dichromate, and strontium dichromate.

It is expressly contemplated that, in various non-limiting embodiments, the terms "wash primer composition" or "wash primer" may be used instead anywhere the term "coating composition" is used herein. In other words, the coating composition may alternatively be defined as a wash primer or a wash primer composition.

The coating compositions of certain embodiments of the present disclosure are substantially free of other undesirable materials, including toxic metals such as lead and nickel. In certain embodiments, the coating compositions of the present disclosure are completely free of such materials.

The present disclosure provides coating compositions comprising a binder component and a pigment component, each of which is described in detail below.

(A) The adhesive component:

(A1) polyvinyl butyral:

the binder component comprises polyvinyl butyral (i.e., PVB resin). Such resins can be prepared by reacting polyvinyl alcohol with butyraldehyde. Polyvinyl alcohols can be prepared by polymerization of vinyl acetate monomers and subsequent base-catalyzed methanolysis of the polyvinyl acetate obtained. The acetalization reaction of polyvinyl alcohol with butyraldehyde is not quantitative, and the resulting polyvinyl butyral may therefore contain a certain amount of hydroxyl groups. In addition, small amounts of acetyl groups may remain in the polymer chain. Commercially available polyvinyl butyral resins can be used. Such resins typically have an average degree of polymerization of 500 to 1000 and a degree of butyration of 57 to 70 mole percent. However, any PVB resin known in the art can be used. Specific examples of suitable polyvinyl butyral resins include those commercially available from Kuraray America, Inc. of New York, N.Y.

Series of polyvinyl butyral resins and commercially available from Eastman Chemical

A polyvinyl butyral resin.

In one embodiment, the PVB resin is present in an amount from about 30 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component. In various embodiments, the PVB resin is present in an amount from about 35 parts by weight to about 65 parts by weight, from about 40 parts by weight to about 60 parts by weight, from about 45 parts by weight to about 55 parts by weight, or from about 50 parts by weight to about 55 parts by weight, based on 100 parts by weight of the binder component. In other embodiments, the PVB resin is present in an amount of from about 30 parts by weight to about 70 parts by weight, such as from about 35 parts by weight to about 65 parts by weight, from about 40 parts by weight to about 60 parts by weight, from about 45 parts by weight to about 55 parts by weight, from about 50 parts by weight to about 55 parts by weight, from about 60 parts by weight to about 70 parts by weight, from about 60 parts by weight to about 65 parts by weight, from about 65 parts by weight to about 70 parts by weight, from about 61 parts by weight to about 69 parts by weight, from about 62 parts by weight to about 68 parts by weight, from about 63 parts by weight to about 67 parts by weight, from about 64 parts by weight to about 65 parts by weight, or from about 60 parts by weight, about 61 parts by weight, about 62 parts by weight, about 63 parts by weight, about 64 parts by weight, about 65 parts by weight, about 66 parts by weight, about 67 parts by weight, about 68 parts by weight, about 69 parts by weight, or about 70 parts by weight, based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(A2) Film-forming resin:

in addition to the PVB resin, the binder component also includes a film-forming resin. The film-forming resin may be a polymer selected from glycidyl-terminated poly (bisphenol a-co-epichlorohydrin), poly [ (phenyl glycidyl ether) -co-formaldehyde ], epoxy esters, phenolic resins, and combinations thereof. In one embodiment, the film-forming resin is glycidyl-terminated poly (bisphenol a-co-epichlorohydrin). In another embodiment, the film-forming resin is poly [ (phenyl glycidyl ether) -co-formaldehyde ]. In another embodiment, the film-forming resin is an epoxy ester. In another embodiment, the film-forming resin is a phenolic resin. In another embodiment, the film-forming resin is a combination of two or more of the foregoing resins.

The glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) can be any known in the art, such as Epon 1001 or Epon 1004. The poly [ (phenyl glycidyl ether) -co-formaldehyde ] can be any known in the art, such as DER 354, Epon 862, Epon 869, DEN431, and DEN 438-85. The epoxy ester may be any known in the art, such as Beckopox EM 460. The phenolic resin may also be any known in the art, such as Phenodur PR 263/70B. The film-forming resin is believed to increase haze solids and improve the manufacturability of the coating composition while not compromising the film properties provided by the PVB resin. The film-forming resin may also enhance the wet adhesion, chip resistance, corrosion resistance, and/or flexibility of the PVB resin.

Additional film-forming resins that may also be used in the coating compositions of the present disclosure include, but are not limited to, those used in automotive OEM coating compositions, automotive refinish coating compositions, industrial coating compositions, architectural coating compositions, coil coating compositions, aerospace coating compositions, and the like. In certain embodiments, the additional film-forming resin is or includes a thermosetting film-forming resin. As used herein, the term "thermoset" refers to a resin that "sets" irreversibly when cured or crosslinked, wherein the polymer chains of the polymeric components are linked together by covalent bonds. This property is generally associated with a crosslinking reaction of the composition components, which is usually caused, for example, by heat or radiation. The curing or crosslinking reaction may also be carried out at ambient conditions. Once cured or crosslinked, a thermoset resin will not melt upon application of heat and will not dissolve in a solvent. In other embodiments, the film-forming resin included in the coating compositions of the present disclosure includes a thermoplastic resin. As used herein, the term "thermoplastic" refers to a resin that comprises polymeric components that are not covalently linked so as to be capable of undergoing liquid flow upon heating and be soluble in a solvent.

Additional film-forming resins suitable for use in the coating compositions of the present disclosure include, for example, those formed from the reaction of a polymer having at least one type of reactive group with a curing agent having a reactive group that reacts with the reactive group of the polymer. As used herein, the term "polymer" is meant to include oligomers and includes, but is not limited to, both homopolymers and copolymers. The polymer may be, for example, acrylic, saturated or unsaturated polyester, polyurethane or polyether, polyethylene, cellulose, acrylate, silicon-based polymer, copolymers thereof, and mixtures thereof, and may contain reactive groups such as epoxy, carboxylic acid, hydroxyl, isocyanate, amide, carbamate, and carboxylate groups, and the like, including mixtures thereof.

The binder component may also include a curing agent. As used herein, the term "curing agent" refers to a material that promotes the "curing" of the coating composition components. As used herein, the term "cure" means that any crosslinkable components of the coating composition are at least partially crosslinked. In certain embodiments, the cross-link density (i.e., degree of cross-linking) of the cross-linkable component is from 5 percent to 100 percent of complete cross-linking, such as from 35 percent to 85 percent of complete cross-linking. Those skilled in the art understand that the presence of cross-linking and the degree of cross-linking (i.e., cross-link density) can be determined by a variety of methods, such as Dynamic Mechanical Thermal Analysis (DMTA) using a Polymer Laboratories MK III DMTA analyzer. Any of a variety of curing agents known to those skilled in the art may be used. For example, aminoplast resins, phenolplast resins, polyisocyanates, blocked isocyanates, anhydrides, polyacids, polyols, polyamines, and combinations thereof may be used.

The film-forming resin is present in an amount of about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component. In various embodiments, the polymer is present in an amount of from about 15 parts by weight to about 35 parts by weight, from about 20 parts by weight to about 30 parts by weight, or from about 25 parts by weight to about 30 parts by weight, based on 100 parts by weight of the binder component. In other embodiments, the film-forming resin is present in an amount of about 10 to about 20, about 11 to about 19, about 12 to about 18, about 13 to about 17, about 14 to about 16, about 15 to about 16, about 12 to about 15, about 13 to about 17, or about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 13, about 18, about 19, or about 20 parts by weight based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(A3) Acid:

the binder component also includes an acid. The acid may be any known in the art and may be organic or inorganic or a combination thereof. In various embodiments, the acid is selected from tannic acid, gallic acid, phosphoric acid, phosphorous acid, citric acid, malonic acid, derivatives thereof, or mixtures thereof. Suitable derivatives include esters, amides, and/or metal complexes of the above acids. In another embodiment, the acid is phosphoric acid. In another embodiment, the acid is tannic acid. In another embodiment, the acid is a combination of phosphoric acid and tannic acid.

Regarding tannic acid, tannins are extracted from various plants and trees, and according to their chemical properties, tannins can be classified into (a) hydrolyzable tannins, (b) condensed tannins, and (c) mixed tannins containing both hydrolyzable tannins and condensed tannins. Tannins useful in the present disclosure include those comprising tannins extracted from naturally occurring plants and trees, and are commonly referred to as plant tannins. Suitable vegetable tannins include crude, common or hot water soluble condensed vegetable tannins such as quebracho, mimosa, mangrove, spruce, hemlock, garbien (gabien), acacia, catechu, urada (uranday), tea tree, larch, myrobalan, chestnut, tamarind, valonia, sumac, cinchona, oak, and the like. These vegetable tannins are not pure chemical compounds with known structures, but contain many components, including phenolic moieties such as catechol, pyrogallol, etc., condensed into complex polymeric structures. In certain embodiments, the acid is phosphoric acid, such as 100 percent orthophosphoric acid, superphosphoric acid, or an aqueous solution thereof, such as a 70 percent to 90 percent phosphoric acid solution. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

The acid is present in an amount of about 10 parts by weight to about 30 parts by weight, based on 100 parts by weight of the binder component. In various embodiments, the acid is present in an amount of about 15 parts by weight to about 25 parts by weight, or about 20 parts by weight to about 25 parts by weight, based on 100 parts by weight of the binder component. In other embodiments, the acid is present in an amount of about 10 to about 20, about 11 to about 19, about 12 to about 18, about 12 to about 15, about 13 to about 17, about 14 to about 16, about 15 to about 16, about 13 to about 17, or about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 17, about 18, about 19, or about 20 parts by weight based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(A4) Functionalized trialkoxysilane:

the binder component may also contain an optional functionalized trialkoxysilane commonly used as an adhesion promoter. The term "optionally" means that the functionalized trialkoxysilane may or may not be present. In various embodiments, the functionalized trialkoxysilane is present in an amount of about 0 parts by weight to about 10 parts by weight, based on 100 parts by weight of the binder component. If a functionalized trialkoxysilane is utilized, it is present in an amount greater than zero parts by weight up to about 10 parts by weight, based on 100 parts by weight of the binder component. In various embodiments, the functionalized trialkoxysilane is present in an amount of about 0.5 parts by weight, about 1 part by weight, about 1.5 parts by weight, about 2 parts by weight, about 2.5 parts by weight, about 3 parts by weight, about 3.5 parts by weight, about 4 parts by weight, about 4.5 parts by weight, about 5 parts by weight, about 5.5 parts by weight, about 6 parts by weight, about 6.5 parts by weight, about 7 parts by weight, about 7.5 parts by weight, about 8 parts by weight, about 8.5 parts by weight, about 9 parts by weight, about 9.5 parts by weight, or about 10 parts by weight, based on 100 parts by weight of the binder component. In other embodiments, the functionalized trialkoxysilane is present in an amount of about 3 to about 10, about 4 to about 9, about 5 to about 8, about 6 to about 7, about 4 to about 6, or about 3, about 4, about 5, about 6, about 7, about 8, about 9, or about 10 parts by weight based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

A number of non-limiting examples of suitable functionalized trialkoxysilanes include methyltrimethoxysilane, methyltriethoxysilane, methyltrimethoxysilane, methyltripropoxysilane, methyltributoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, gamma-methyl-acryloxypropyltrimethoxysilane, gamma-aminopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane, gamma-mercaptopropyltrimethoxysilane, chloromethyltrimethoxysilane, chloromethyltriethoxysilane, dimethyldiethoxysilane, gamma-chloropropylmethyldimethoxysilane, gamma-chloropropylmethyldiethoxysilane, tetramethoxysilane, tetraethoxysilane, tetra-n-propoxysilane, tetra-n-butoxysilane, glycidoxymethyltriethoxysilane, glycidylmethoxysilane, and the like, Alpha-glycidoxyethyltrimethoxysilane, alpha-glycidoxyethyltriethoxysilane, beta-glycidoxyethyltrimethoxysilane, beta-glycidoxyethyltriethoxysilane, alpha-glycidoxypropyltrimethoxysilane, alpha-glycidoxypropyltriethoxysilane, beta-glycidoxypropyltrimethoxysilane, beta-glycidoxypropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, gamma-glycidoxypropylmethyldimethoxysilane, gamma-glycidoxypropyldimethylethoxysilane, and combinations thereof. In one embodiment, the functionalized trialkoxysilane is gamma-glycidoxy-propyltrimethoxysilane.

In other embodiments, the functionalized trialkoxysilane is a dipodal silanes. The biped silanes are adhesion promoters with an inherent hydrolytic stability of up to about 10,000 times that of conventional silanes. These products have a significant impact on substrate bonding and mechanical strength of many composite systems comprising epoxy, urethane, epoxy/urethane mixtures, polysulfides, cyanoacrylates and silicones, and can be used in aqueous, high solids and photosensitive chemicals. Functionalized podandsilane and combinations of unfunctionalized podsilanes with functionalized conventional silanes have a significant impact on substrate bonding and enable activity in many adhesive systems, particularly primer and water immersion applications.

A number of non-limiting embodiments are set forth below:

(A5) polymeric phosphate ester:

the binder component may also include a polymeric phosphate ester. The polymeric phosphate ester is not particularly limited and may be any known in the art. For example, the polymeric phosphate ester can have a weight average molecular weight of from about 1000g/mol to about 5000g/mol, from about 1500g/mol to about 4500g/mol, from about 2000g/mol to about 4000g/mol, from about 2500g/mol to about 3500g/mol, from about 3000g/mol to about 3500g/mol, or from about 3500g/mol to about 4000 g/mol. In other embodiments, the polymeric phosphate ester has a weight average molecular weight of about 3000g/mol, about 3100g/mol, about 3200g/mol, about 3300g/mol, about 3400g/mol, about 3500g/mol, about 3600g/mol, about 3700g/mol, about 3800g/mol, about 3900g/mol, or about 4000 g/mol. In other embodiments, the polymeric phosphate ester may have a number average molecular weight of from about 250g/mol to about 2500g/mol, from about 500g/mol to about 2000g/mol, from about 1000g/mol to about 1500g/mol, from about 1500g/mol to about 2000g/mol, or from about 1000g/mol, about 1100g/mol, about 1200g/mol, about 1300g/mol, about 1400g/mol, about 1500g/mol, about 1600g/mol, about 1700g/mol, about 1800g/mol, about 1900g/mol, or about 2000 g/mol. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In various embodiments, the polymeric phosphate is a complex alkyl/aryl phosphate of the free acid. In other embodiments, the polymeric phosphate ester is the reaction product of a styrene/allyl alcohol copolymer (SAA100 or SAA101), phosphoric acid, and tert-amylphenol. In one embodiment, the polymeric phosphate ester is commercially available as Lubrizol 2062.

The polymeric phosphate ester may be present in an amount of about 3 parts by weight to about 10 parts by weight, based on 100 parts by weight of the binder component. In other embodiments, the polymeric phosphate ester is present in an amount of about 4 parts by weight to about 9 parts by weight, about 5 parts by weight to about 8 parts by weight, about 6 parts by weight to about 7 parts by weight, or about 3 parts by weight, about 4 parts by weight, about 5 parts by weight, about 6 parts by weight, about 7 parts by weight, about 8 parts by weight, about 9 parts by weight, or about 10 parts by weight, based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(B) The pigment component:

(B1) calcium ion-exchanged silica:

referring back to the pigment component, the pigment component comprises calcium ion exchanged silica. Any grade of calcium ion-exchanged silica may be utilized. The calcium ion-exchanged silica may be any known in the art, including but not limited to silica available from w.r&As of

AC3 and/or

C303 commercially available calcium ion-exchanged silica. Another suitable calcium ion-exchanged silica is available from PPG Industries as

And (4) carrying out commercial purchase. Still other suitable options include, but are not limited to, Sylomask SMK55 from Fuji Silysia, Wayncor 205 from WPC Technologies, LM-30 from Lingwe, and Heubach's Heucosil CTF.

The calcium ion-exchanged silica is present in an amount of about 15 parts by weight to about 100 parts by weight based on 100 parts by weight of the binder component. In various embodiments, the calcium ion-exchanged silica is present in an amount of from about 20 to about 95, from about 25 to about 90, from about 30 to about 85, from about 35 to about 80, from about 40 to about 75, from about 45 to about 70, from about 50 to about 65, or from about 55 to about 60 parts by weight based on 100 parts by weight of the binder component. In other embodiments, the calcium ion-exchanged silica is present in an amount of from about 30 to about 40, from about 31 to about 39, from about 32 to about 38, from about 33 to about 37, from about 34 to about 36, from about 35 to about 36, or from about 35 to about 36 parts by weight, based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(B2) Corrosion inhibiting pigments:

the pigment component may also contain an optional corrosion inhibiting pigment. Any corrosion inhibiting pigment known in the art, such as zinc phosphate, may be utilized. In other embodiments, a di-orthophosphate may be used, in which one of the cations is represented by zinc. For example, these may include Zn-Al, Zn-Ca, and also Zn-K, Zn-Fe, Zn-Ca-Sr, or Ba-Ca and Sr-Ca combinations. The phosphate anion can be combined with another corrosion-inhibiting effective anion such as silicate, molybdate, or borate. The modified phosphate pigment may be modified by an organic corrosion inhibitor. The modified phosphate pigment may be exemplified by the following compounds: aluminum phosphate (III) zinc (II), alkaline zinc phosphate, zinc phosphomolybdate, zinc calcium phosphomolybdate, and zinc borophosphate. Additionally, strontium phosphosilicates, barium phosphosilicates, strontium calcium phosphosilicates (Ca Sr Zn phosphosilicates), and combinations thereof. Also usable are gold salts of zinc 5-nitroisophthalate, calcium cyanurate, dinonylnaphthalenesulfonic acidA salt, and combinations thereof. Further examples are iron phosphate, colloidal silica, synthetic amorphous silica, and simpler molybdates such as calcium molybdate, zinc molybdate, barium molybdate and strontium molybdate. Suitable amorphous silicas are available under the trade name w.r.grace and Company

And (4) obtaining.

The optional corrosion inhibiting pigment may be present in an amount of about 0 parts by weight to about 100 parts by weight based on 100 parts by weight of the binder component. The term "optional" means that the corrosion inhibiting pigment may or may not be present. In various embodiments, the corrosion inhibiting pigment is present in an amount of from about 0 parts by weight to about 100 parts by weight, based on 100 parts by weight of the binder component. If a corrosion inhibiting pigment is utilized, it is present in an amount greater than zero parts by weight up to about 100 parts by weight based on 100 parts by weight of the binder component. In various embodiments, the corrosion inhibiting pigment is present in an amount of about 5 to about 95, about 10 to about 90, about 15 to about 85, about 20 to about 80, about 25 to about 75, about 30 to about 70, about 35 to about 65, about 40 to about 60, about 45 to about 55, or about 45 to about 50 parts by weight based on 100 parts by weight of the binder component. In other embodiments, the corrosion-inhibiting pigment is present in an amount of about 40 to about 50, about 41 to about 49, about 42 to about 48, about 43 to about 47, about 44 to about 46, or about 44 to about 45, or about 40, about 41, about 42, about 43, about 44, about 45, about 46, about 47, about 48, about 49, or about 50 parts by weight based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

(B3) Poly(s) are polymerizedAlkylene oxide phosphate ester:

the pigment component may also comprise polyalkylene oxide phosphate esters. The polyalkylene oxide phosphate ester may be further defined as a polyethylene oxide phosphate ester, a polypropylene oxide phosphate ester, a polybutylene oxide phosphate ester, or any combination of ethylene oxide, propylene oxide, and/or butylene oxide in a block copolymer structure or a mixed-block copolymer structure. In various embodiments, the polyalkylene oxide phosphate is present in an amount of from about 1 to about 7 parts by weight, based on 100 parts by weight of the binder component. For example, the polyalkylene oxide phosphate ester may be present in an amount of about 2 parts by weight to about 6 parts by weight, about 3 parts by weight to about 5 parts by weight, about 4 parts by weight to about 5 parts by weight, or about 1 part by weight, about 2 parts by weight, about 3 parts by weight, about 4 parts by weight, about 5 parts by weight, about 6 parts by weight, or about 7 parts by weight, based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In various embodiments, the polyalkylene oxide phosphate is a polyethylene oxide capped with one or more phosphate groups at any point in the polymer chain. In other embodiments, polyalkylene oxide phosphate esters are combined with MPEG (e.g., MPEG 400) and/or polyethylene oxide having methyl groups at both ends of the polyethylene oxide. Further, it is contemplated that the polyalkylene oxide phosphate ester may be combined with a nonionic surfactant. For example, the surfactant may have a high cloud point and an HLB of about 13. The surfactant may be Surfynol 465.

The other components:

in addition to the above components, the coating composition may also comprise one or more additional components. Alternatively, the coating composition may be free of one of these additional components described below. These additional components may be any known in the art of coating compositions. For example, the one or more additional components may be selected from the group consisting of color pigments, extender pigments, adhesion promoters, solvents, dispersants, etchants, rheology and flow additives, silicones, anti-settling agents, thickeners, dyes, surfactants, flow control agents, thixotropic agents, fillers, anti-gassing agents, organic co-solvents, catalysts, antioxidants, and other conventional adjuvants, and combinations thereof.

In one embodiment, the coating composition comprises a solvent component comprising one or more solvents. Any solvent known in the art may be used, including, but not limited to, propylene glycol methyl ether, n-butanol, isobutanol, xylene, aromatic hydrocarbons, and combinations thereof. In various embodiments, the total amount of solvent is present in an amount of from about 25 to about 95, from about 30 to about 85, from about 35 to about 80, from about 40 to about 75, from about 45 to about 70, from about 50 to about 65, from about 55 to about 60, or from about 70 to about 90 parts by weight per 100 parts by weight of the coating composition. In other embodiments, a separate solvent, such as any one or more of the foregoing options, may be present in any one or more of the foregoing amounts or in an amount of, for example, from about 0.5 to about 30, from about 0.5 to about 1, from about 1 to about 30, from about 1 to about 5, from about 5 to about 10, from about 10 to about 15, from about 15 to about 20, from about 20 to about 25, or from about 25 to about 30 parts by weight per 100 parts by weight of the coating composition. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In various embodiments, the coating composition comprises one or more adhesion promoting properties. In other embodiments, the coating composition comprises one or more colored pigments. Any colored pigment known in the art may be used, including, but not limited to, carbon black, red iron oxide, titanium dioxide, yellow iron oxide, and combinations thereof. For the purposes of this disclosure, these colored pigments are distinct from the calcium ion-exchanged silica described above and the optional corrosion inhibiting pigments described above. In various embodiments, the colored pigment is present in an amount of from about 4.5 to about 45, from about 9 to about 40.5, from about 13.5 to about 36, from about 18 to about 31.5, or from about 22.5 to about 27 parts by weight per 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In other embodiments, the coating composition comprises one or more extender pigments. Any extender pigment known in the art may be used, including but not limited to amorphous silica, talc, and combinations thereof. For the purposes of this disclosure, these extender pigments are distinct from the colored pigments described above, the calcium ion-exchanged silica, and the optional corrosion inhibiting pigments described above. In various embodiments, the extender pigment is present in an amount of from about 4.5 to about 45, from about 9 to about 40.5, from about 13.5 to about 36, from about 18 to about 31.5, or from about 22.5 to about 27 parts by weight per 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In other embodiments, the coating composition comprises one or more dispersants. Any dispersant known in the art may be used, including but not limited to Efka FA 4600. In various embodiments, the dispersant is present in an amount of about 1 to about 10, about 2 to about 9, about 3 to about 8, about 4 to about 7, or about 5 to about 6 parts by weight per 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In various embodiments, the coating composition may be divided into two parts, e.g., part a and part B. These portions may be combined prior to application of the coating composition, for example, up to about 8 hours prior to application. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In certain embodiments, the coating compositions of the present disclosure are formulated as a one-component composition, wherein the curing agent is mixed with additional composition components to form a storage stable composition. In other embodiments, the compositions of the present disclosure may be formulated as a two-component composition, wherein the curing agent is added to a preformed mixture of the other composition components immediately prior to application. It is to be understood that a curing agent is not required herein.

In a further embodiment, the solvent component is present in an amount of from about 70 parts by weight to about 90 parts by weight per 100 parts by weight of the coating composition. In another embodiment, the polyvinyl butyral is present in an amount from about 55 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component. In another embodiment, the film-forming resin is present in an amount of about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component. In yet another embodiment, the acid is present in an amount of about 15 parts by weight to about 25 parts by weight, based on 100 parts by weight of the binder component. In another embodiment, the functionalized trialkoxysilane is present in an amount of about 3 parts by weight to about 7 parts by weight based on 100 parts by weight of the binder component. In yet another embodiment, the calcium ion-exchanged silica is present in an amount of about 20 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component. In yet another embodiment, the corrosion inhibiting pigment is present in an amount of about 40 parts by weight to about 60 parts by weight based on 100 parts by weight of the binder component. In a further embodiment, the coating composition comprises an extender pigment present in an amount of from about 20 parts by weight to about 30 parts by weight based on 100 parts by weight of the binder component. In another embodiment, the coating composition comprises a colored pigment present in an amount of about 25 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component. In yet another embodiment, the coating composition includes a dispersant present in an amount of about 1 part by weight to about 5 parts by weight based on 100 parts by weight of the binder component. In yet another embodiment, the polyvinyl butyral is present in an amount of about 55 to about 65 parts by weight based on 100 parts by weight of the binder component, the film forming resin is present in an amount of about 10 to about 40 parts by weight based on 100 parts by weight of the binder component, the acid is present in an amount of about 15 to about 25 parts by weight based on 100 parts by weight of the binder component, the functionalized trialkoxysilane is present in an amount of about 3 to about 7 parts by weight based on 100 parts by weight of the binder component, the calcium ion exchanged silica is present in an amount of about 20 to about 40 parts by weight based on 100 parts by weight of the binder component, and the corrosion inhibiting pigment is present in an amount of about 40 to about 60 parts by weight based on 100 parts by weight of the binder component. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In certain embodiments, the coating compositions of the present disclosure are in the form of liquid coating compositions, examples of which include water-based coating compositions and solvent-based coating compositions. Regardless of form, the coating compositions of the present disclosure may be used alone or in combination with an electrocoat, basecoat, or topcoat. The coating composition may be described as an etch primer and/or a metal substrate pretreatment coating composition. The coating composition may be deposited on a substrate to prepare a surface for application of a protective or decorative coating system. Metal substrates that can be coated with such compositions include, for example, substrates comprising steel (including electrogalvanized steel, cold rolled steel, hot dip galvanized steel, etc.), aluminum alloys, zinc-aluminum alloys, and aluminized steel. Substrates that may be coated with such compositions may also comprise more than one metal or metal alloy, as the substrate may be a combination of two or more metal substrates assembled together, such as hot-dip galvanized steel assembled with an aluminum substrate.

The coating compositions of the present disclosure may be applied to bare metal. By "bare" is meant virgin material that has not been treated with any pretreatment composition (e.g., such as conventional phosphating baths, toxic metal rinses, etc.). In addition, the bare metal substrate coated with the coating composition can be a cut edge of the substrate that is otherwise treated and/or coated on the remainder of its surface.

Prior to application of the coating composition, the metal substrate may be first cleaned to remove grease, dirt, or other foreign matter. Conventional cleaning procedures and materials may be used. These materials may include, for example, solvent-based or alkaline cleaners, such as those commercially available. Examples include Axalta' S3900S cleaner, 3901S cleaner, 3909S cleaner, 3919S cleaner, V-3921S cleaner, and 3939S cleaner. Such a detergent may be applied after and/or before the water rinse.

The metal surface may then be rinsed with an acidic aqueous solution after rinsing with an alkaline cleaner and prior to contact with the metal substrate coating composition. Examples of suitable rinse solutions include weakly acidic or strongly acidic cleaners, such as Cromax of Axalta^TM225S aluminum metal detergent and 5717S metal conditioner.

The coating compositions of the present disclosure can be prepared by any of a variety of methods. For example, any one or more of the components may be mixed with any one or more additional components. All orders of addition are expressly contemplated herein for use in the various non-limiting embodiments herein. The components of any one or more combinations may be subjected to high shear stress conditions, for example by shaking the blend on a high speed shaker, until a homogeneous solution or dispersion is formed. Any mode of applying stress may be used if desired.

The coating compositions of the present disclosure can be applied to a substrate by any known application technique, such as dipping or immersion, spraying, intermittent spraying, dipping followed by spraying, spraying followed by dipping, brushing, or by roll coating. Typical spray techniques and equipment for air spraying and electrostatic spraying, either manual or automated, may be used. While the coating compositions of the present disclosure can be applied to a variety of substrates including elastomeric substrates and the like, such as wood, glass, cloth, plastic, foam, in many cases, the substrates include metal.

In the coating compositions of certain embodiments of the present disclosure, after the composition is applied to a substrate, a film is formed on the substrate surface by driving the solvent, i.e., the organic solvent and/or water, out of the film by heating or by air drying for a period of time. Suitable drying conditions will depend on the particular composition and/or application, but in some cases a drying time of about 1 minute to about 5 minutes at a temperature of about 50 ° f to about 250 ° f, i.e., about 10 ℃ to about 121 ℃, will be sufficient. More than one coating may be applied if desired. The previously applied coating is typically flashed, i.e., exposed to ambient conditions, between coatings for 5 minutes to 30 minutes. In certain embodiments, the coating has a thickness of 0.05 mils to 3 mils, such as about 0.5 mils to about 1.5 mils. The coating composition may then be heated. In the curing operation, the solvent is driven off and the crosslinkable components of the composition (if any) are crosslinked. The heating and curing operation is sometimes conducted at a temperature in the range of about 160 ° f to about 350 ° f (i.e., about 71 ℃ to about 177 ℃). Lower or higher temperatures may be used. In various non-limiting embodiments, all values and ranges of values, including and between those described above, are expressly contemplated for use herein.

In various embodiments, the coating composition is top-coated with a protective or decorative coating system, such as a single coat top coat, or a combination of a pigmented basecoat composition and a clearcoat composition (i.e., a color plus clearcoat system). Accordingly, the present disclosure also relates to multi-component composite coatings comprising at least one coating layer deposited from the coating composition of the present disclosure.

In various embodiments, the coating composition is further defined as an automotive OEM coating composition, an automotive refinish coating composition, an industrial coating composition, an architectural coating composition, a coil coating composition, an aerospace coating composition, or the like.

The present disclosure also relates to substrates, such as metal substrates, at least partially coated with the coating compositions of the present disclosure. In many cases, when the coating composition of the present disclosure is deposited on and cured at least a portion of one metal substrate selected from the group consisting of cold rolled steel, electrogalvanized steel, and aluminum, a substrate exhibiting corrosion resistance characteristics greater than the corrosion resistance characteristics exhibited by the same substrate when at least partially coated with the comparative coating composition under the same conditions is prepared.

As used herein, the term "corrosion resistance properties" refers to corrosion protection measurements on metal substrates using the test described in ASTM B117 (salt spray test). In this test, the coated substrate was scribed with a knife to expose the bare metal substrate. The scribed substrate is placed in a test chamber where an aqueous salt solution is continuously sprayed onto the substrate. The chamber was maintained at a constant temperature. The coated substrate is exposed to a salt spray environment for a specified period of time, such as 500 hours or 1000 hours. After exposure, the coated substrate was removed from the test chamber and evaluated for corrosion along the scribe line. Corrosion is measured by "scribe creep," which is defined as the total distance in millimeters that the corrosion travels through the scribe.

When it is stated that a substrate "exhibits greater corrosion resistance properties than another substrate, this means that the substrate exhibits less scratch creep (corrosion travels through fewer millimeters of scratches) than the other substrate. As used herein, the term "same conditions" means that the coating composition (i) is deposited on a substrate at the same or similar film thickness as compared to the composition being compared, and (ii) is cured or dried under the same or similar curing conditions, e.g., curing temperature, humidity, and time, as compared to the composition being compared.

In many cases, when the coating composition of the present disclosure is deposited on and cured on at least a portion of a metal substrate selected from the group consisting of cold rolled steel, electrogalvanized steel, and aluminum, a substrate is prepared that exhibits corrosion resistance properties similar to, or in some cases greater than, the corrosion resistance properties exhibited by the same substrate when at least partially coated with a conventional chromium-containing corrosion-resistant composition under the same conditions.

In this application, when it is stated that a substrate "exhibits corrosion resistance properties similar to" another substrate, this means that the substrate exhibits a scratch creep as measured by ASTM B117 as described above that is no more than 10% greater than the substrate being compared. As used herein, the term "conventional chromium-containing corrosion resistant composition" refers to commercially available coating compositions.

A first additional embodiment:

in further embodiments, as described below, it is expressly contemplated that any one or more of the components, method steps, amounts, ranges, etc. may be as described below or may be any of those described above. For example, one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) in any of the embodiments described below, or numerical amounts or ranges thereof, may replace, respectively, any one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) described above in any one or more of the above embodiments.

Further, for all of the embodiments below, it is expressly contemplated that all values and ranges of values, including and between those described below, may be used in the various non-limiting embodiments herein.

Further, it is expressly contemplated that the phrases including, consisting essentially of … …, and consisting of … … can be applied to any one or more of the embodiments above or below. Generally, the phrase consisting essentially of … … describes embodiments that are free of, or contain less than 10 weight percent, 5 weight percent, 4 weight percent, 3 weight percent, 2 weight percent, 1 weight percent, 0.5 weight percent, or 0.1 weight percent (based on the total amount of binder component, pigment component, or coating composition as a whole) of one or more binder components not considered herein, polymers not considered herein, acids not considered herein, silanes or silicones not considered herein, silicas not considered herein, pigments not considered herein, phosphate esters not considered herein, chromium compounds, polyalkylene oxide polymers or copolymers not considered herein, or the like. Furthermore, any optional compound described herein may be excluded from any one or more embodiments that utilize wording to include, consist essentially of … …. It is contemplated that the coating composition may comprise, consist essentially of, or consist of (a) a binder component and (B) a pigment component.

It is also contemplated that the coating composition can include, consist essentially of, or consist of (a) a binder component and (B) a pigment component and any other optional components described herein.

It is also contemplated that the coating composition may comprise, consist essentially of, or consist of (a) a binder component and (B) a color component and any other optional components described herein, wherein (a) and (B) may themselves comprise, consist of, and consist of (a1), (a2), (A3), and/or (A4), and/or (A5), and (B1), (B2), and (B3), respectively, consist essentially of (a1), (a 7378), (A3), and/or (A4), and/or (A5), and (B1), (B2), and (B3), respectively, or consist of (a1), (a2), (A3), and/or (a 355), and/or (a 585), and/or (B3623), and (B3623), respectively, and (B3), and/or consist of (a1), (a2), (A3), and/or (a 585), and/or (A5), and/or (B5), respectively, and any other optional components described herein (B2) And (B3).

A. a binder component, the binder component comprising:

and

B. a pigment component comprising:

(3) a polyalkylene oxide phosphate present in an amount of from about 1 to 7 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the coating composition consists essentially of (a) (1) to (a) (4) and (B) (1) to (B) (3). In another embodiment, the coating composition consists essentially of (a) (1) to (a) (4) and (B) (1) to (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component.

In yet another embodiment, the coating composition consists of (a) (1) to (a) (4) and (B) (1) to (B) (3). In yet another embodiment, the coating composition consists of (a) (1) to (a) (4) and (B) (1) to (B) (3), for example, wherein (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component, and/or (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight based on 100 parts by weight of the binder component.

The present disclosure also provides a method of forming a coating composition comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (4), (B) (1), (B) (2), and (B) (3).

In one embodiment, the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the acid is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the acid is phosphoric acid.

In another embodiment, the functionalized trialkoxysilane is present in an amount of about 4 parts by weight to about 6 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane.

In another embodiment, the calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the corrosion inhibiting pigment is present in an amount of about 45 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn.

In another embodiment, the polyalkylene oxide phosphate is present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the polyalkylene oxide phosphate is polyethylene oxide capped with phosphate groups.

In another embodiment, the polyalkylene oxide phosphate ester, which is a polyethylene oxide capped with a phosphate group, is mixed with additional components, which are a polyethylene oxide capped with a methyl group at one or both ends and an acetylenic diol modified with polyethylene oxide side chains.

In another embodiment, the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, which is present in an amount of about 12 parts by weight to about 15 parts by weight, based on 100 parts by weight of the binder component; the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane present in an amount of from about 3 parts by weight to about 10 parts by weight, based on 100 parts by weight of the binder component; calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 45 parts by weight to about 50 parts by weight, based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the polyvinyl butyral is present in an amount of about 63 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 16 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, which is present in an amount of about 14 parts by weight based on 100 parts by weight of the binder component; the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane present in an amount of about 5 parts by weight based on 100 parts by weight of the binder component; the calcium ion-exchanged silica is present in an amount of about 33 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 46 parts by weight based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of about 2 parts by weight, based on 100 parts by weight of the binder component.

A second additional embodiment:

in further embodiments, as described below, it is expressly contemplated that any one or more of the components, method steps, amounts, ranges, etc. may be as described below or may be any of those described above. For example, one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) in any of the embodiments described below, or numerical amounts or ranges thereof, may replace, respectively, any one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) described above in any one or more of the above embodiments. Moreover, it is expressly contemplated that the term comprising, consisting essentially of … …, and consisting of … … can apply to any one or more of the following embodiments.

In another embodiment, a coating composition comprises:

A. a binder component, the binder component comprising:

and

B. a pigment component comprising:

In another embodiment, the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the acid is phosphoric acid.

In another embodiment, the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, which is present in an amount of about 12 parts by weight to about 15 parts by weight, based on 100 parts by weight of the binder component; the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane present in an amount of from about 4 to about 6 parts by weight based on 100 parts by weight of the binder component; calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 45 parts by weight to about 50 parts by weight, based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the polyvinyl butyral is present in an amount of about 64 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 15 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, which is present in an amount of about 14 parts by weight based on 100 parts by weight of the binder component; the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane present in an amount of about 5 parts by weight based on 100 parts by weight of the binder component; the calcium ion-exchanged silica is present in an amount of about 34 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 47 parts by weight based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of about 2 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the present disclosure provides a method of forming a coating composition comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (4), (B) (1), (B) (2), and (B) (3).

In another embodiment, the present disclosure provides a method comprising the step of applying a coating composition to a metal substrate.

A third additional embodiment:

in further embodiments, as described below, it is expressly contemplated that any one or more of the components, method steps, amounts, ranges, etc. may be as described below or may be any of those described above. For example, one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) in any of the embodiments described below, or numerical amounts or ranges thereof may replace, respectively, any one or more of (a1), (a2), (A3), (a4), (a5), (B1), (B2), and/or (B3) described above in any one or more of the embodiments described above. Further, it is expressly contemplated that the term comprising, consisting essentially of … …, and consisting of … … can be used in any one or more of the following embodiments.

In another embodiment, a coating composition comprises:

A. a binder component, the binder component comprising:

and

B. a pigment component comprising:

In another embodiment, the acid is phosphoric acid.

In another embodiment, the polymeric phosphate ester is present in an amount of about 4 parts by weight to about 8 parts by weight based on 100 parts by weight of the binder component.

In another embodiment, the polymeric phosphate ester is the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol.

In another embodiment, the coating composition consists essentially of (A) (1), (A) (2), (A) (3), (A) (5), (B) (1), (B) (2), and (B) (3). In another embodiment, the coating composition consists essentially of (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3), for example, wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

In another embodiment, the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, the acid being present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component; a polymeric phosphate ester that is the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol, the polymeric phosphate ester being present in an amount of from about 5 parts by weight to about 7 parts by weight based on 100 parts by weight of the binder component; calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 45 parts by weight to about 50 parts by weight, based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the polyvinyl butyral is present in an amount of about 62 parts by weight based on 100 parts by weight of the binder component; the film-forming resin is present in an amount of about 16 parts by weight based on 100 parts by weight of the binder component; the acid is phosphoric acid, which is present in an amount of about 14 parts by weight based on 100 parts by weight of the binder component; the polymeric phosphate ester is the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol, the polymeric phosphate ester being present in an amount of about 6 parts by weight based on 100 parts by weight of the binder component; the calcium ion-exchanged silica is present in an amount of about 33 parts by weight based on 100 parts by weight of the binder component; the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, present in an amount of about 46 parts by weight based on 100 parts by weight of the binder component; and a polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, the polyalkylene oxide phosphate being present in an amount of about 2 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the coating composition consists of (A) (1), (A) (2), (A) (3), (A) (5), (B) (1), (B) (2), and (B) (3). In another embodiment, the coating composition consists of (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3), for example, wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight, based on 100 parts by weight of the binder component.

In another embodiment, the present disclosure provides a method of forming a coating composition comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3).

Evaluation of physical Properties:

it is also contemplated that any one or more of the following standardized tests, or equivalents thereof as understood by one skilled in the art, may be used to evaluate one or more physical properties of the coating composition alone or after application to a substrate.

DIN EN ISO 9227: corrosion test in Artificial atmosphere-Salt fog test (neutral Salt fog for Cold Rolled Steel (CRS) and Zinc plated Steel (ASTM B117); acetate fog for aluminum alloys) (Corroson tests in organic coatings-Salt spray tests (neutral Salt spray (ASTM B117) for Cold Rolled Steel (CRS) and silver sprayed Steel; acetic acid Salt spray for aluminum alloys))

VDA 233-: cyclic corrosion testing of materials and components in automotive construction (Cyclic corrosion testing of materials and components in automotive construction)

DIN EN ISO 4623-1: color Paints and varnishes-Determination of filiform Corrosion resistance-Part 1: Steel substrate (ISO 4623-1:2000) (Paints and varnishes-Determination of resistance to filiform corrosion-Part 1: Steel substrate (ISO 4623-1:2000))

DIN EN ISO 4623-2: determination of filiform corrosion resistance-part 2: aluminum substrate (Determination of resistance to filiform corrosion-Part 2: Aluminum substrates)

DIN EN ISO 4628-10: paints and varnishes-assessment of degradation of the coating-indication of the number and size of defects, and of the strength of uniform change in appearance-part 10: assessment of the degree of filiform corrosion (Paints and stains-Evaluation of grading of coatings-design of quality and size of defects, and of sensitivity of uniformity changes in appearance-Part 10: Assessment of grading of viscosity)

DIN EN ISO 6270-2: determination of moisture resistance (Determination of resistance to humidity)

ASTM D714-02: standard Test Method for Evaluating the Degree of Blistering of Paints (Standard Test Method for Evaluating the Degree of Blistering of Paints)

DIN EN ISO 2409: cross-cut test (Adhesion) (Cross-cut test (Adhesion))Examples

Six coating compositions were evaluated herein. The first two coating compositions are comparative compositions. Comparative composition 1 is a chromium-containing composition. Comparative composition 2 is a chromium-free composition. The next four coating compositions are inventive coating compositions. These compositions are inventive composition 1, inventive composition 2, inventive composition 3, inventive composition 4 and inventive composition 5. Each of the seven compositions is shown below.

Comparative composition 1:

the adhesive component:

the pigment component:

phenolic resins are curable resins that are used as binders for shop primers and wash primers. Which has excellent pigment wetting characteristics.

Anionic surfactants work after ionization. When added to water, anionic surfactants ionize and have a negative charge. A negatively charged surfactant is associated with the positively charged particles. It was a blend of 35.5% anionic surfactant, 27.5% 1-butanol, 1% sodium bisulfite and 36% water. Anionic surfactants are used as anti-settling agents for non-aqueous coatings. As modern anti-settling agents, they act by adsorption phenomena on the pigment surface and effectively prevent the pigment from settling and forming hard, difficult to stir deposits even in low viscosity coatings (such as, for example, dip coatings and wash primers). It is effective over a wide range of polarities. In addition, the uniform electrostatic charge imparted by the anionic surfactant prevents reagglomeration, thereby counteracting any premature settling of the pigment.

Comparative composition 2:

the adhesive component:

the pigment component:

a glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) type resin (MW range 450 to 600) was used in comparative composition 2. It is a standard epoxy resin of the solid type derived from bisphenol a and epichlorohydrin. In particular, it has excellent adhesion, chemical resistance, heat resistance, and the like.

Anionic surfactants work after ionization. When added to water, anionic surfactants ionize and have a negative charge. A negatively charged surfactant is associated with the positively charged particles. It is a mixture of 35.5% anionic surfactant, 27.5% 1-butanol, 1% sodium bisulfite and 36% water. Anionic surfactants are used as anti-settling agents for non-aqueous coatings. As modern anti-settling agents, they act by adsorption phenomena on the pigment surface and are effective in preventing the pigment from settling and forming hard, difficult to stir deposits even in low viscosity coatings (such as, for example, dip coatings and wash primers). It is effective over a wide range of polarities. In addition, the uniform electrostatic charge imparted by the anionic surfactant prevents reagglomeration, thereby counteracting any premature settling of the pigment.

Inventive composition 1:

the adhesive component:

the pigment component:

PVB (polyvinyl alcohol content 12 wt% to 16 wt%, polyvinyl acetate 1 wt% to 4 wt%, average MW in the range of 50,000g/mol to 60,000g/mol) is used in inventive composition 1. The degree of acetalization in PVB determines its water resistance, solubility in organic solvents, and compatibility with other formulation components such as plasticizers and other resins. PVB can begin to crosslink with resins such as epoxies and phenolics. The crosslinking density depends primarily on the degree of acetalization and the number of OH groups available for the reaction. The water absorption of PVB decreases with increasing acetalization. The hydroxyl groups in the molecule determine the excellent adhesion and high toughness of the polymer to polar surfaces.

A poly [ (phenyl glycidyl ether) -co-formaldehyde ] resin (epoxy molar mass 169 g/eq to 175 g/eq) was used in inventive composition 1. The resin is a low viscosity multifunctional epoxy novolac resin with a typical epoxy functionality of 2.5. Which combines low viscosity and easy processability with good thermal stability, mechanical strength and chemical resistance.

The polyethylene oxide capped with a phosphate group has a molecular weight distribution of 440 to 800 and is capped at the other end with a methoxy group.

Inventive composition 2:

the adhesive component:

PVB (polyvinyl alcohol content 12 wt% to 16 wt%, polyvinyl acetate 1 wt% to 4 wt%, average MW in the range of 50,000g/mol to 60,000g/mol) is used in inventive composition 2. The degree of acetalization in PVB determines its water resistance, solubility in organic solvents, and compatibility with other formulation components such as plasticizers and other resins. PVB can begin to crosslink with resins such as epoxies and phenolics. The crosslinking density depends primarily on the degree of acetalization and the number of OH groups available for the reaction. The water absorption of PVB decreases with increasing acetalization. The hydroxyl groups in the molecule determine the excellent adhesion and high toughness of the polymer to polar surfaces.

A glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) type resin (MW range 450 to 600) was used in inventive composition 2. It is a standard epoxy resin of the solid type derived from bisphenol a and epichlorohydrin. In particular, it has excellent adhesion, chemical resistance, heat resistance, and the like.

The polymeric phosphate ester used was the reaction product of a styrene/allyl alcohol 2.33/1 copolymer having a weight average molecular weight of about 1600 reacted with orthophosphoric acid and p-tert-amylphenol in a molar ratio of 1:3:3 to a weight average molecular weight of about 3500.

The pigment component:

inventive composition 3:

the adhesive component:

the pigment component:

PVB (polyvinyl alcohol content 12 wt% to 16 wt%, polyvinyl acetate 1 wt% to 4 wt%, average MW in the range of 50,000g/mol to 60,000g/mol) is used in inventive composition 3. The degree of acetalization in PVB determines its water resistance, solubility in organic solvents, and compatibility with other formulation components such as plasticizers and other resins. PVB can begin to crosslink with resins such as epoxies and phenolics. The crosslinking density depends primarily on the degree of acetalization and the number of OH groups available for the reaction. The water absorption of PVB decreases with increasing acetalization. The hydroxyl groups in the molecule determine the excellent adhesion and high toughness of the polymer to polar surfaces.

A glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) type resin (MW range 450 to 600) was used in inventive composition 3. It is a standard epoxy resin of the solid type derived from bisphenol a and epichlorohydrin. In particular, it has excellent adhesion, chemical resistance, heat resistance, and the like.

Inventive composition 4:

the adhesive component:

the pigment component:

PVB (polyvinyl alcohol content 12 wt% to 16 wt%, polyvinyl acetate 1 wt% to 4 wt%, average MW in the range of 50,000g/mol to 60,000g/mol) is used in inventive composition 4. The degree of acetalization in PVB determines its water resistance, solubility in organic solvents, and compatibility with other formulation components such as plasticizers and other resins. PVB can begin to crosslink with resins such as epoxies and phenolics. The crosslinking density depends primarily on the degree of acetalization and the number of OH groups available for the reaction. The water absorption of PVB decreases with increasing acetalization. The hydroxyl groups in the molecule determine the excellent adhesion and high toughness of the polymer to polar surfaces.

A glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) type resin (MW range 450 to 600) was used in inventive composition 4. It is a standard epoxy resin of the solid type derived from bisphenol a and epichlorohydrin. In particular, it has excellent adhesion, chemical resistance, heat resistance, and the like.

Inventive composition 5:

the adhesive component:

the pigment component:

PVB (polyvinyl alcohol content 12 wt% to 16 wt%, polyvinyl acetate 1 wt% to 4 wt%, average MW in the range of 50,000g/mol to 60,000g/mol) is used in inventive composition 5. The degree of acetalization in PVB determines its water resistance, solubility in organic solvents, and compatibility with other formulation components such as plasticizers and other resins. PVB can begin to crosslink with resins such as epoxies and phenolics. The crosslinking density depends primarily on the degree of acetalization and the number of OH groups available for the reaction. The water absorption of PVB decreases with increasing acetalization. The hydroxyl groups in the molecule determine the excellent adhesion and high toughness of the polymer to polar surfaces.

A glycidyl-terminated poly (bisphenol a-co-epichlorohydrin) type resin (MW range 450 to 600) was used in inventive composition 5. It is a standard epoxy resin of the solid type derived from bisphenol a and epichlorohydrin. In particular, it has excellent adhesion, chemical resistance, heat resistance, and the like.

Each of comparative compositions 1 and 2 and inventive compositions 1 to 5 were evaluated as described below.

The evaluation of the degree of foaming was carried out according to DIN EN ISO 4628-2, where 0 ═ no bubbles, 5 ═ dense/large bubbles, and wr ═ wrinkling.

The cross-hatched evaluation was carried out according to DIN EN ISO 2409, using a 2mm (60 μm to 120 μm) or 3mm (121 μm to 250 μm) grid in combination with 1X Tesa 4657 adhesive tape. Repeated measurements and a distance of 2cm from the panel edge were used.

The degree of delamination and corrosion around scribe lines or other artifacts was evaluated according to DIN EN ISO 4628-8 (applicable to VDA 233-. The length of the scratch is at least 12cm and the average of six measurements is reported. Starting at least 1cm from the edge of the scribe line and taking the same distance along the scribe line. Creep or delamination is reported as the average of the distance from the completely removed paint to the scribe line minus 0.2mm (the width of the scribe line) divided by 2. On steel, creep is a dark brown iron oxide precipitate near the score line, while delamination is a region of blank delamination. The latter being composed of OH^-Formation and pH increase. Direct evaluation is preferred because flash rust formation may hamper the evaluation. Only delamination of the primer from the metal was noted. No topcoat delamination was recorded.

A standard test method for evaluating the degree of blistering of coatings, ASTM D714-02, wherein standard procedures describing bubble size and density allow for severity comparisons to be made. Two characteristics of blistering were evaluated using this standard test method: size and frequency:

size: four grades of reference standards were selected on a scale from 10 to 0 to measure size, with no blister indicated by number 10. The bubble criteria No. 8 indicates the smallest size of bubbles that are easily seen by the naked eye. Foaming criteria No. 6, No. 4 and No. 2 indicate progressively larger sizes.

Frequency: the reference criteria for selecting four frequency levels at each size level are specified as follows: dense, D; moderately dense, MD; medium, M; small amount, F.

Evaluation of the degree of filiform corrosion was carried out in accordance with DIN EN ISO 4628-10. The process involves measuring the maximum distances, Ll and Lr (in mm), from the score line to the point to which filiform corrosion has developed, on the left and right sides respectively. Report the length L of the longest filament, which is the average of Ll and Lr; further, distances M1 and Mr (in mm) to which most of the filaments have developed from the scribe line were measured from the left and right sides, respectively. The most common filament length M is reported as the average of M1 and Mr. Finally, the length L of the longest filament and the most common filament length M are numerically rated as filiform corrosion, L5/M3 meaning that the length of the longest filament is 5mm and the most common filament length is 3 mm.

The results of these evaluations are listed in the following table. In the table, the designation (×) indicates that the inventive example performed better than both comparative example 1 and comparative example 2, (×) indicates that the inventive example performed better than comparative example 2 but performed worse than comparative example 1 containing chromium, and (×) indicates that the inventive example performed worse than both comparative example 1 and comparative example 2.

Table 1: DIN EN ISO 6270-2: determination of moisture resistance on Al 6014 alloy

Table 2: DIN EN ISO 6270-2: determination of moisture resistance on Al 5083 alloy

Table 3: DIN EN ISO 6270-2: determination of moisture resistance on Cold Rolled Steel (CRS)

Table 4: DIN EN ISO 6270-2: determination of moisture resistance on galvanized steel

Table 5: VDA 233-: cyclic corrosion testing on Cold Rolled Steel (CRS)

Table 6: VDA 233-: cyclic corrosion testing on galvanized steel

Table 7: DIN EN ISO 9227: corrosion testing in Artificial atmosphere-resistance to acetate fog on Al 5083 alloys

Table 8: DIN EN ISO 4623-2: determination of filiform corrosion resistance on Al 6014 alloy

In the following table, the designations (^#) The inventive examples performed as in comparative example 1 or better than comparative example 1.

Table 9: ASTM D714-02: standard test method for evaluating the degree of blistering of paint

Table 10: ASTM D714-02: standard test method for evaluating the degree of blistering of coatings

Table 11: VDA 233-: cyclic corrosion testing on Cold Rolled Steel (CRS)

Table 12: VDA 233-: cyclic corrosion test on Al 6014 alloy

Table 13: DIN EN ISO 9227: corrosion test in Artificial atmosphere-resistance to acetate fog on Al 6014 alloy

Table 14: DIN EN ISO 4623-2: determination of filiform corrosion resistance on Al 6014 alloy

Table 15: DIN EN ISO 4623-2: determination of filiform corrosion resistance on CRS

The data show that the comparative examples, both containing chromium and no chromium, have poor humidity performance on all substrates tested. The inventive examples performed better than the comparative examples, except on 5083 grade aluminum, and the chromium containing comparative examples performed slightly better than both the comparative examples and the inventive examples without chromium on 5083 grade aluminum. The poor humidity performance of conventional wash primers both containing chromium and no chromium is well known to those skilled in the art.

The data also show that the inventive examples outperform the two comparative examples on galvanized steel in the VDA cycle corrosion test. On CRS, all three invention examples were better than the chromium-free comparative example, and invention example 1 and invention example 2 were better than the chromium-containing comparative example.

The data further show that all three inventive examples outperform the chromium-free comparative example and are comparable to the chromium-containing comparative example in the filiform corrosion test. Inventive example 1 was slightly better than the chromium-containing comparative example.

The data also show that all three inventive examples are superior to the chromium-free comparative example, but inferior to the chromium-containing comparative example, in the acidified salt spray test.

The moisture resistance data show that invention example 4 shows better performance than comparative example 1 (containing chromium) on both Al 6014 and CRS. Inventive example 5 was slightly weaker in Al 6014 but comparable in CRS as compared to comparative example 1.

The data also show that inventive example outperforms comparative example 1 on CRS in the VDA cycle corrosion test. On Al 6014, the two inventive examples are slightly weaker than the chromium-containing comparative example.

The data also show that in the acidified salt spray test, both inventive examples are comparable to comparative example 1.

The data further show that in filiform corrosion testing on CRS, two inventive examples are better than comparative example 1. On Al 6014, the comparative example containing chromium is better than the two inventive examples.

In various additional non-limiting embodiments, it is contemplated that any one or more of the components in any one or more of the examples can be replaced with any one or more of the corresponding components set forth in the detailed description. Similarly, in still other non-limiting embodiments, the amounts of any one or more of the examples can be replaced with any one or more of the amounts of the corresponding components set forth in the detailed description. In other words, the examples are not necessarily strictly limited to those components and amounts explicitly set forth above, and may be modified by one of ordinary skill in the art.

All combinations of the foregoing components, amounts, ranges, values, method steps and the like used in the various non-limiting embodiments are expressly contemplated herein. More specifically, all combinations are expressly contemplated herein even if various components, amounts, ranges, values, method steps, etc., are not described in the same or adjacent paragraphs above. Moreover, in various non-limiting embodiments, all values and ranges of values, including and between those above, are expressly contemplated for use herein.

While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims.

The present application also relates to the following solutions.

1. A coating composition comprising:

A. a binder component, the binder component comprising:

(2) a film-forming resin that is a glycidyl-terminated poly (bisphenol a-co-epichlorohydrin), and that is present in an amount of from about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component;

and

B. a pigment component comprising:

2. The coating composition of item 1, wherein the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

3. The coating composition of item 1 or 2, wherein the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight, based on 100 parts by weight of the binder component.

4. The coating composition of any one of items 1 to 3, wherein the acid is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component.

5. The coating composition of item 4, wherein the acid is phosphoric acid.

6. The coating composition of any of items 1 to 5, wherein the functionalized trialkoxysilane is present in an amount of about 4 to about 6 parts by weight based on 100 parts by weight of the binder component.

7. The coating composition of item 6, wherein the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane.

8. The coating composition of any one of items 1 to 7, wherein the calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight, based on 100 parts by weight of the binder component.

9. The coating composition of any one of items 1 to 8, wherein the corrosion inhibiting pigment is present in an amount of about 45 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component.

10. The coating composition of item 9, wherein the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn.

11. The coating composition of any one of items 1 to 10, wherein the polyalkylene oxide phosphate is present in an amount of from about 2 to about 5 parts by weight, based on 100 parts by weight of the binder component.

12. The coating composition of item 11, wherein the polyalkylene oxide phosphate is polyethylene oxide capped with phosphate groups.

13. The coating composition of item 1 consisting essentially of (a) (1) to (a) (4) and (B) (1) to (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

14. The coating composition of item 13, wherein:

the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component;

the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight, based on 100 parts by weight of the binder component;

the acid is phosphoric acid and is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component;

the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane and is present in an amount of from about 3 parts by weight to about 10 parts by weight, based on 100 parts by weight of the binder component;

the calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component;

the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, and is present in an amount of about 45 parts by weight to about 50 parts by weight, based on 100 parts by weight of the binder component; and

the polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, and is present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

15. The coating composition of item 13, wherein:

the polyvinyl butyral is present in an amount of about 63 parts by weight based on 100 parts by weight of the binder component;

the film-forming resin is present in an amount of about 16 parts by weight based on 100 parts by weight of the binder component;

the acid is phosphoric acid and is present in an amount of about 14 parts by weight based on 100 parts by weight of the binder component;

the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane and is present in an amount of about 5 parts by weight based on 100 parts by weight of the binder component;

the calcium ion-exchanged silica is present in an amount of about 33 parts by weight based on 100 parts by weight of the binder component;

the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, and the corrosion inhibiting pigment is present in an amount of about 46 parts by weight based on 100 parts by weight of the binder component; and

the polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group, and the polyalkylene oxide phosphate is present in an amount of about 2 parts by weight, based on 100 parts by weight of the binder component.

16. The coating composition of item 1 consisting of (a) (1) to (a) (4) and (B) (1) to (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight, based on 100 parts by weight of the binder component.

17. The coating composition of item 16, wherein:

18. The coating composition of item 16, wherein:

19. A method of forming the coating composition of item 1, comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (4), (B) (1), (B) (2), and (B) (3).

20. A method comprising the step of applying the coating composition of item 1 to a metal substrate.

21. A coating composition comprising:

A. a binder component, the binder component comprising:

(2) a film-forming resin that is poly [ (phenyl glycidyl ether) -co-formaldehyde ], and is present in an amount of about 10 parts by weight to about 40 parts by weight, based on 100 parts by weight of the binder component;

and

B. a pigment component comprising:

22. The coating composition of item 21, wherein the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

23. The coating composition of clause 21 or 22, wherein the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight based on 100 parts by weight of the binder component.

24. The coating composition of any one of items 21 to 23, wherein the acid is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component.

25. The coating composition of item 24, wherein the acid is phosphoric acid.

26. The coating composition of any of items 21 to 26, wherein the functionalized trialkoxysilane is present in an amount of about 4 to about 6 parts by weight based on 100 parts by weight of the binder component.

27. The coating composition of item 26, wherein the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane.

28. The coating composition of any one of claims 21 to 27, wherein the calcium ion-exchanged silica is present in an amount of about 30 to about 35 parts by weight based on 100 parts by weight of the binder component.

29. The coating composition of any one of items 21 to 28, wherein the corrosion inhibiting pigment is present in an amount of about 45 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component.

30. The coating composition of item 29, wherein the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn.

31. The coating composition of any one of items 21 to 30, wherein the polyalkylene oxide phosphate is present in an amount of from about 2 to about 5 parts by weight, based on 100 parts by weight of the binder component.

32. The coating composition of item 31, wherein the polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group.

33. The coating composition of item 21, consisting essentially of (a) (1) to (a) (4) and (B) (1) to (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

34. The coating composition of item 33, wherein:

the functionalized trialkoxysilane is gamma-glycidoxypropyltrimethoxysilane and is present in an amount of from about 4 to about 6 parts by weight based on 100 parts by weight of the binder component;

35. The coating composition of item 33, wherein:

the polyvinyl butyral is present in an amount of about 64 parts by weight based on 100 parts by weight of the binder component;

the film-forming resin is present in an amount of about 15 parts by weight based on 100 parts by weight of the binder component;

the calcium ion-exchanged silica is present in an amount of about 34 parts by weight based on 100 parts by weight of the binder component;

the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn, and the corrosion inhibiting pigment is present in an amount of about 47 parts by weight based on 100 parts by weight of the binder component; and

36. The coating composition of item 21, consisting of (a) (1) to (a) (4) and (B) (1) to (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

37. The coating composition of item 36, wherein:

38. The coating composition of item 36, wherein:

39. A method of forming the coating composition of item 21, comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (4), (B) (1), (B) (2), and (B) (3).

40. A method comprising the step of applying the coating composition of item 21 to a metal substrate.

41. A coating composition comprising:

A. a binder component, the binder component comprising:

and

B. a pigment component comprising:

42. The coating composition of item 41, wherein the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

43. The coating composition of clauses 41 or 42, wherein the film-forming resin is present in an amount of about 13 to about 17 parts by weight based on 100 parts by weight of the binder component.

44. The coating composition of any one of items 41 to 43, wherein the acid is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component.

45. The coating composition of item 44, wherein the acid is phosphoric acid.

46. The coating composition of any one of items 41 to 45, wherein the polymeric phosphate ester is present in an amount of about 4 to about 8 parts by weight based on 100 parts by weight of the binder component.

47. The coating composition of item 46, wherein the polymeric phosphate ester is the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol.

48. The coating composition of any one of items 41 to 47, wherein the calcium ion-exchanged silica is present in an amount of about 30 to about 35 parts by weight based on 100 parts by weight of the binder component.

49. The coating composition of any one of items 41 to 48, wherein the corrosion inhibiting pigment is present in an amount of about 45 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component.

50. The coating composition of item 49, wherein the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn.

51. The coating composition of any one of items 41 to 50, wherein the polyalkylene oxide phosphate is present in an amount of from about 2 to about 5 parts by weight, based on 100 parts by weight of the binder component.

52. The coating composition of clause 51, wherein the polyalkylene oxide phosphate is polyethylene oxide capped with a phosphate group.

53. The coating composition of item 41, consisting essentially of (A) (1), (A) (2), (A) (3), (A) (5), (B) (1), (B) (2), and (B) (3), wherein based on 100 parts by weight of the binder component, (A1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (A2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

54. The coating composition of item 53, wherein:

the polymeric phosphate ester is a reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol, and is present in an amount of from about 5 parts by weight to about 7 parts by weight based on 100 parts by weight of the binder component;

55. The coating composition of item 53, wherein:

the polyvinyl butyral is present in an amount of about 62 parts by weight based on 100 parts by weight of the binder component;

said polymeric phosphate ester being the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol, and said polymeric phosphate ester being present in an amount of about 6 parts by weight based on 100 parts by weight of said binder component;

56. The coating composition of item 41, consisting of (A) (1), (A) (2), (A) (3), (A) (5), (B) (1), (B) (2), and (B) (3), wherein based on 100 parts by weight of the binder component, (A1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (A2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or based on 100 parts by weight of the binder component, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight.

57. The coating composition of item 56, wherein:

58. The coating composition of item 56, wherein:

59. A method of forming a coating composition according to item 41, comprising the step of combining (A) (1), (A) (2), (A) (3), (A) (5), (B) (1), (B) (2), and (B) (3).

60. A method comprising the step of applying the coating composition of item 41 to a metal substrate.

Claims

1. A coating composition comprising:

A. a binder component, the binder component comprising:

and

B. a pigment component comprising:

2. The coating composition of claim 1, wherein the polyvinyl butyral is present in an amount from about 60 parts by weight to about 65 parts by weight based on 100 parts by weight of the binder component.

3. The coating composition of claim 1, wherein the film-forming resin is present in an amount of about 13 parts by weight to about 17 parts by weight, based on 100 parts by weight of the binder component.

4. The coating composition of claim 1, wherein the acid is present in an amount of about 12 parts by weight to about 15 parts by weight based on 100 parts by weight of the binder component.

5. The coating composition of claim 4, wherein the acid is phosphoric acid.

6. The coating composition of claim 1, wherein the polymeric phosphate ester is present in an amount of about 4 parts by weight to about 8 parts by weight based on 100 parts by weight of the binder component.

7. The coating composition of claim 6, wherein the polymeric phosphate ester is the reaction product of a styrene/allyl alcohol copolymer, phosphoric acid, and tert-amylphenol.

8. The coating composition of claim 1, wherein the calcium ion-exchanged silica is present in an amount of about 30 parts by weight to about 35 parts by weight based on 100 parts by weight of the binder component.

9. The coating composition of claim 1, wherein the corrosion inhibiting pigment is present in an amount of about 45 parts by weight to about 50 parts by weight based on 100 parts by weight of the binder component.

10. The coating composition of claim 9, wherein the corrosion inhibiting pigment is phosphosilicate Ca Sr Zn.

11. The coating composition of claim 1, wherein the polyalkylene oxide phosphate is present in an amount of from about 2 parts by weight to about 5 parts by weight, based on 100 parts by weight of the binder component.

12. The coating composition of claim 11, wherein the polyalkylene oxide phosphate is polyethylene oxide capped with phosphate groups.

13. The coating composition of claim 1, consisting essentially of (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight, based on 100 parts by weight of the binder component.

14. The coating composition of claim 13, wherein:

15. The coating composition of claim 13, wherein:

16. The coating composition of claim 1, consisting of (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3), wherein based on 100 parts by weight of the binder component, (a1) is present in an amount of about 60 parts by weight to about 70 parts by weight, based on 100 parts by weight of the binder component, (a2) is present in an amount of about 10 parts by weight to about 20 parts by weight, and/or, (A3) is present in an amount of about 10 parts by weight to about 20 parts by weight, based on 100 parts by weight of the binder component.

17. The coating composition of claim 16, wherein:

18. The coating composition of claim 16, wherein:

19. A method of forming the coating composition of claim 1, comprising the step of combining (a) (1), (a) (2), (a) (3), (a) (5), (B) (1), (B) (2), and (B) (3).

20. A method comprising the step of applying the coating composition of claim 1 to a metal substrate.